The Plant and Equipment Wellness Way was designed to quickly create Operational Excellence success. You can only get the Plant Wellness Way from LRS Operational Excellence Consultants.
[Read more…]The Plant Wellness Way DifferenceÂ
on Maintenance Reliability
A listing in reverse chronological order of these article series:
- Usman Mustafa Syed — Aasan Asset Management series
- Arun Gowtham — AI & Predictive Maintenance series
- Miguel Pengel — Asset Management in the Mining Industry series
- Bryan Christiansen — CMMS and Reliability series
- James Reyes-Picknell — Conscious Asset series
- Alex Williams — EAM & CMMS series
- Nancy Regan — Everday RCM series
- Karl Burnett — History of Maintenance Management series
- Mike Sondalini — Life Cycle Asset Management series
- James Kovacevic — Maintenance and Reliability series
- Mike Sondalini — Maintenance Management series
- Mike Sondalini — Plant Maintenance series
- Andrew Kelleher — Process Plant Reliability Engineering series
- George Williams and Joe Anderson — The ReliabilityXperience series
- Doug Plucknette — RCM Blitz series
- Robert Kalwarowsky — Rob's Reliability Project series
- Gina Tabasso — The Intelligent Transformer Blog series
- Tor Idhammar — The People Side of Maintenance series
- André-Michel Ferrari — The Reliability Mindset series
Knowledge: Cornerstone of Human Capital
Article first posted at Conscious Reliability by James Reyes-Picknell, Jesus Sifonte, and team.
Managing assets to make them deliver the products and services we need now and in the future is the essential purpose of Asset Management. However, Asset Management is more about obtaining value from assets than what you do to the assets. It is about utilizing assets to deliver value to your organization while attaining corporate goals. Human capital is an essential element of the whole asset management process from strategy to operation.
[Read more…]Building Credibility: The Cornerstone of Professional Success
Credibility, often described as the currency of trust, is a quality that sets the foundation for professional success. It’s the attribute that influences how others perceive your competence, reliability, and integrity. Whether you’re an individual striving to advance your career or a business aiming to gain the trust of your clients, credibility is your guiding star. In this blog, we’ll delve into the methods of developing and enhancing credibility to help you stand out in your professional journey.
[Read more…]Getting Life Distributions from “Reliability” Handbooks? Be Careful!
The need for life distributions
Maintenance and Reliability practitioners often need to find quick methods to estimate life distributions in order to get some urgent answers to a customer. The tempting solution and easy way out to this is to refer to a handbook or publication out there. Also known as “Reliability Data” handbooks. These publications would have “ready to go” life distributions. However, this can come with multiple pitfalls listed as follows.
[Read more…]Dangers of Inventing Your Own KPIs to Measure Production Performance
A certain Operations Manager started inventing production KPIs in order to measure reliability from a production perspective. So he got together his colleagues and they came up with this formula.
Reliability = Good Production / (Net Production Hours + Nominal Speed)
When asked to define ‘good production’, I was told that it was the saleable production remaining after losses such as speed losses, first time quality, downtime, change overs, etc. were taken off.
After 3 years of running TPM (Total Productive Maintenance) across 3 factories, they made the following observations. The mean time between failure (MTBF) of equipment in all 3 factories increased. The production volumes increased. However the Reliability remained flat. How can this be? Something is not right. Is the above formula incorrect?
Is there a better way to calculate Reliability from a production perspective?
[Read more…]Should RCM Templates be used
Maybe. Great care must be taken if any kind of template of failure mode library is used to complete an RCM analysis.
[Read more…]Introduction to Barringer Process Reliability
Barringer Process Reliability – Your factory performance on a single page!
Barringer Process Reliability (BPR) was developed by Paul H. Barringer, a fellow reliability engineer “extraordinaire” and an outstanding mentor for myself and countless others in this field of practice. BPR highlights operational issues. Not addressed and mitigated, those could have significant revenue impacts. A BPR analysis uses the Weibull probability plot which happens to be a very well-known tool in the field of Reliability Engineering. On one side of a sheet of paper only, the BPR plot can tell the true “story” on the operation.
[Read more…]RCM – 10 Myths Debunked
Article first posted at Conscious Reliability by James Reyes-Picknell, Jesus Sifonte, and team.
What do you know about Reliability Centered Maintenance?
James Reyes-Picknell
Despite its well-documented successes, Reliability Centered Maintenance (RCM) has always drawn a lot of discussion and controversy. Much of it is because of a lack of understanding and “myths” generated to discredit RCM as a viable business solution. Here we attempt to fill in some of those gaps in understanding and debunk some of the myths.
[Read more…]Tips on Maintenance Job Priority RatingÂ
To help select which work orders to do first in situations of resource shortage many CMMS provide calculations for maintenance work order priority. Deciding maintenance work priority is a risk decision. The presence of risk totally changes the way to allocate maintenance job priority if you want to compare situations equally1. When you work with risk you cannot use a linear priority scale. Using linear priority ranking gives the wrong order of importance for doing maintenance work.
[Read more…]How to calculate optimal maintenance intervals
In a previous article we covered how to perform a detailed Weibull Analysis in Excel. The outputs from a Weibull analysis are important because we can use them for a variety of Reliability calculations such as when to most economically maintain assets.
A common mistake we see made is Reliability Engineers determining the optimal maintenance interval as the MTBF. This is incorrect as it assumes that you will have failed approximately 50-60% of the components before you have maintenance performed on them. (Sounds ridiculous when you say it that way right!?)
[Read more…]Physics of Failure Analysis for Roller Bearing FailuresÂ
A tutorial explaining the Physics of Failure method applied to regularly failing roller bearings in a dewatering press. After three years of exhaustive efforts to solve the cause of the bearing failures it was decided to test Physics of Failure Analysis with the aim of finding a lasting answer.
Exemplary Maintenance Leadership
The Backbone of High-Quality Operations
In the world of industrial and manufacturing enterprises, where precision and reliability are paramount, maintenance leadership stands as the unsung hero. Behind the scenes, these individuals and teams are the custodians of high-quality operations, ensuring that machinery hums with efficiency, downtime is minimized, and standards are not just met but exceeded. Let’s take a closer look at the essence of exemplary maintenance leadership and why it’s the cornerstone of a well-oiled operation.
[Read more…]Should RCM be Applied to all Assets?
Really? I don’t know any organization that has the time, money, and other resources to do so.
[Read more…]Ten Books About One Failure Mode
Failure of Ship Hulls Due to Rot
British oak forests provided the wood to build the fleets that fought the Seven Years’ War, American Revolutionary War, French Revolution, and the Napoleonic Wars. New trees had to mature for 80-120 years for shipbuilding. By the early 1800s, three-quarters of British oak forests had been harvested to fight a half century of naval wars. Additionally, a scourge of dry rot reduced the service life of Britain’s main battle ships from the historical 25 years to less than 7 years. Britain had a severe national security problem – the Timber Crisis.
[Read more…]When Will my Equipment Reach its End-of-Life State? – It Depends…
End-of-life definition
Operators need to estimate when in the future their equipment will attain their end-of-life state. Obsolescence is another word for equipment end-of life. Once they reach this stage, equipment replacement often leads to significant budgetary expenditures. In addition, if the operation has a large number of a particular equipment types, they could all reach their end-of life at the same time leading to even greater financial impact. In industry jargon, this is known as the “Tsunami” effect. Operators need to aware and prepared in order to avoid this “wave” of consequences. Managing future cash inflow and outflows happens to be crucial financial exercise in any organization. Therefore, end-of-life management in an important financial accounting exercise. However, estimating end of life this is not always as straightforward as it seems.
