Your Reliability Engineering Professional Development Site
A listing in reverse chronological order of these article series:
RCA Self-Assessment Tool. (linked version no longer available) The purpose of this tool is to allow individuals or groups to anonymously self-assess their current RCA system. How they wish to use the results is completely up to them!
All results are private and not retained anywhere. Therefore, if you wanted to keep your results, you would have to print them out and scan them back into your work station (or your past results are gone).
Almost all maintenance, reliability or asset management professionals have heard of reliability engineering. But what is reliability engineering? A quick google search will return the following definition “Reliability Engineering is engineering that emphasizes dependability in the lifecycle management of a product. Dependability, or reliability, describes the ability of a system or component to function under stated conditions for a specified period of time.”
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Computerized data gathering and information management systems are indispensable tools for business. Just remember the last power failure you experienced and you’ll understand. Technology continues to develop and become more complex. The array of available business applications is astounding and more are added daily.
This failure occurred on a turbine driven boiler feedwater pump (TDBFP) at a fossil fuel power plant. The pump in question is an outboard boiler feed pump. Plant is operating normally when unexpectedly pump shuts down and causes a forced outage.
What does the word statistics bring to mind when you hear it? Horrible high school classes that you sat through wondering why do I need this stuff? Complex math problems what were almost impossible to figure out? Or is it nonsense that is only used in political polls?
Statistics are used in every aspect of Reliability Engineering. So if you don’t have a good relationship with statistics, I highly recommend that you are starting investing time in building your knowledge in statistics. [Read more…]
Most of us wouldn’t argue that if you can measure it, you can improve it. Performance measures do indeed drive results, both good and bad. Knowing where you are now and what you want to achieve by some point in the future do help you to outline your path towards your objective. Once you know your path, you then need a way to make sure you are still on it. And once you’ve past way-points, you also need to know that what you’ve achieved so far, continues to be sustained.
This is a failed shaft that came out of a pump in a paper mill. The pump was only in service for about a month before it failed unexpectedly.
From the top view above, identify the type of failure pattern that you see from the fractured surface(s). If you need more info to make your assessment, just ask.
Materials management for maintenance purposes is often a big mess. When I visit operations (doesn’t matter what industry) I often hear complaints from maintainers that they cannot get the parts they need, when they need them. Sometimes, their supply chain (warehouse, inventory, and purchasing management) are indeed a mess, but more often than not maintenance planning is also a mess, and there is usually (almost always) a lack of integration between planning and supply chain.
We will create a reorder point analysis file from scratch with simple CMMS data as our starting point. Learn how to create a file which will update automatically each time CMMS data is updated.
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Where does ‘failure’ come from? Why do some things not go as we planned? When bad things happen, at that time, it can be chaotic and appear very complex. Often, in hindsight (when the urgency has faded), we find that good people made bad decisions at that time. Most of the time such failures were not complicated and we find that most likely, anyone else put in the same position, would have made the same decision. So why do things not always go as planned?
How many times has an asset been installed or commissioned, only to have it fail in a few days or months when it should have lasted even longer? If you look at the study by Nowlan & Heap, they have found that only 11% of failures are age related, so when is happening with these assets? The answer… comes down to poor installation practices.
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From demonstrating compliance and ensuring safety to maintaining assets and increasing productivity, food manufacturing maintenance managers have their work cut out for them. Thankfully, computerized maintenance management software (CMMS) can streamline processes and improve maintenance operations for the food manufacturing industry. Read on to learn how food manufacturing CMMS software can significantly benefit your organization.
[Read more…]Like the human body, our plant and mobile equipment will break down if it’s not looked after. If we exercise and push ourselves harder, we gain strength. Unlike our biological bodies that can self-repair, our physical plants and mobile equipment do NOT strengthen if we overload them. Yes, they will tolerate some abuse but not for long. Machinery, unlike biological organisms, can not recover from damage on its own. It needs a bit of basic care. Basic care is all about taking care of our physical assets so they continue to do what we need them to do. Take care of their fluids (e.g.: oils, coolants), keep them from running hot (e.g.: clean heat transfer surfaces like cooling fins), and keep them free of contaminants that damage their insides (e.g.: keep moisture and dirt out). In the “Uptime Pyramid of Excellence,” the pinnacle is “Choosing Excellence”. That choice implies an active application of all of the model’s components. It’s a journey, not a destination.
Trick question, it’s neither!
When we hear people use the term ‘error’ it is normally associated with being the cause of some type of bad outcome. We hear it all the time with airline accidents where they conclude ‘pilot error’.
‘Error’ is neither the cause nor the undesirable outcome! Let’s see why.
Is the only type of error a ‘human error’? I struggled to think of an ‘error’ that is not a human error, so I asked if others could think of something else. I would like to thank Dr. Peter Elias who commented that errors can occur in biologic processes, such as RNA and DNA replication or messaging. He also cited non-human animals make errors all the time as well.
