Emerging stronger from crisis – that’s our current challenge. We know we can do it. What doesn’t kill us makes us stronger. Our businesses can emerge stronger too, but that won’t happen without leadership and choice.

Capital asset-intensive industries that have had a chance to pause have been wise if they used the opportunity to catch up on deferred maintenance and review their proactive maintenance programs for effectiveness. They will emerge stronger. Better maintained equipment will run better, longer, and last longer, producing more and doing so with lower levels of risk.

The 4 Physical Failure Mechanisms of Component Failure: The Basics (Part I)

This article is directed at those ‘first responders’ who arrive immediately at the failure scene. These are the people who have to ensure the area is safe, preserve the scene for investigators and contribute to a plan to expedite a quick, safe return to production norms.

Many do not understand how valuable failed parts are to the metallurgical/forensic investigators. Broken parts are to metallurgists’, like the murder weapon is to a forensic crime investigator.

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by James Kovacevic Leave a Comment

The 9 Indicators of an Effective Lubrication Program

Understanding the Key Components of an Effective Lubrication Program

Lubrication is often overlooked in organizations. Why it is overlooked, I am unsure. Maybe it is because it is considered to be a basic job, given to the apprentice, or it is just too simple to not to do it correctly.

However, with a focus on lubrication, many failure mechanisms can be reduced and the equipment life prolonged. But implementing an effective and world-class lubrication program is not simple. It requires a dedicated focus to implement and sustain. Below is my list of what I look for when evaluating a lubrication program.
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by James Reyes-Picknell Leave a Comment

Uptime Insights – 9 – Teamwork for results

There’s an old saying that, “two heads are better than one”. Teamwork has been proven time and again to produce superior results. It is the basis for many successful methods like RCM-R, PMR/O, RCFA, Total Productive Maintenance (TPM) and various quality improvement programs like Six Sigma. The various methods that help us while Choosing Excellence depend on a foundation of teamwork. Beyond facilitated teamwork, self-organized teams are even more effective.

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by Robert (Bob) J. Latino 1 Comment

Name that Failure Pattern (3)…

Can you identify and name this fracture pattern?

How can you tell it is that fracture pattern?

Where are the origin(s) of the failure on the fractured surface?

How can you tell where the origin(s) are?

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by James Kovacevic Leave a Comment

A Review of Proper Grease Gun Use

Preventing Contamination During Lubrication

I can remember the first time I was told to grease a bearing. I ask the millwright “How do I know when there is enough grease?”. He responded, ” When you see it come out of the sides of the bearing”… How many of you had this same experience?

During this brief instruction, there was no mention of selecting the right grease, preventing contamination, etc. So, with this experience in mind, I wanted to provide what I believe are best practices when using a grease gun. Why do I think there needs to be a review of how to grease with a grease gun? I still see manual lubrication performed with no regard for best practices, and lubrication is still a major contributor to equipment failures.
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by Alex Williams Leave a Comment

Selecting CMMS Systems: Considerations for Small and Medium-Sized Enterprises

CMMS systems were developed and became available around 1965. Traditionally, CMMS software was reserved for big companies that needed to automate and organize large, complex maintenance operations. Only the largest manufacturing firms were able to use maintenance software back then, but things have changed dramatically since those days.

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by Bryan Christiansen 1 Comment

How Can CMMS Supplement Fault Tree Analysis

Fault tree analysis (FTA) is used to establish a potential chain or path of equipment failures using Boolean logic to generate a graphical relationship of events leading to part or system failure. It is a deductive approach that is useful for different systems or facilities at the product design or operational stages. FTA fosters reliability of systems by: [Read more…]

by James Reyes-Picknell Leave a Comment

Uptime Insights – 8 – Asset Reliability

You can wait for something to break, then fix it, or you can be proactive and manage the failure before it causes you problems. Being proactive is all about managing failures and their consequences before they occur. The failure itself, in some cases, is unavoidable, but how you manage consequences is entirely within your control.

How Does Your Root Cause Analysis (RCA) Effort Measure Up?

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).

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by James Kovacevic Leave a Comment

What is Reliability Engineering?

An Overview of the Reliability Engineering Discipline

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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Uptime Insights – 7 – Support Systems, EAM, CMMS

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.

Name That Failure Pattern (2)…

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.

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by James Kovacevic 1 Comment

The Role of Statistics in Reliability Engineering

This Isn’t Your High School Statistics Course

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…]

by James Reyes-Picknell Leave a Comment

Uptime Insights – 6 – KPIs and Performance Management

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.

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