A quality item lasts longer, runs better and looks good when others fade. To change the way you think about quality takes a lot of experience with using poorer options. When you are sitting down with your head in your hands wondering what can be done to get costs down, to get production up and how you are going to hit the key performance indicators, remember the importance of quality equipment, quality systems, quality training and your quality mindset!

Keywords: quality control [Read more…]

by James Kovacevic Leave a Comment

The Next Step in Your Failure Data

Improve your failure data to improve the speed and accuracy of your failure & reliability analysis.

Part 5 of 7

A few years into your reliability journey, you start to struggle to make the improvements you were able to when you first started.

Why is this? You were able to systematically eliminate all of the low hanging fruit using the existing data in your CMMS. But now you have to dig deeper to realize the improvements and that requires better data. [Read more…]

by James Reyes-Picknell Leave a Comment

Rapid Proactive Maintenance Program – PM Program – Part 3

In the first installment of this series, we described the basics behind proactive maintenance and some of the considerations users need to make.

The second installment described RCM programs – the “gold standard” if you like for program development. This third installment describes what you can do if you realize you need a program but have nothing. It would also work if you’ve got a PM program but you are unhappy with the results you are getting. Chances are that something is missing or not being done often enough.

We’ve often encountered maintenance programs that are lacking. They need a stronger proactive component and they need it quickly to get things under control.

This guideline is intended to help to get things under control. [Read more…]

by Mike Sondalini Leave a Comment

Shaft Sealing with a Packed Gland

What you will learn from this article:

How shaft packing works.
What to consider when selecting and using shaft packing.
Good installation practices.
Proper commissioning of shaft packing.

[Read more…]

by Fred Schenkelberg Leave a Comment

First Step in Analyzing Repairable Systems Data

Using the right plot enables your team to know what is working or need improvement.

Part 4 of 7

Your facility has data and maybe too much data. Using simple plotting may be the key to unlocking how well your maintenance program is performing.

Building on the concept of reliability growth modeling James Kovacevic described a convenient way to quickly visualize your repairable system failure data is with a mean cumulative function (MCF) plot. [Read more…]

by James Reyes-Picknell Leave a Comment

If You Want a Proactive Maintenance Program That Really Works, Then Reliability Centered Maintenance (RCM) Is The Way

This article is Part Two in my three part series about “PM” programs.

Reliability Centered Maintenance (RCM) is the world’s leading method for identifying maintenance and other activities required to sustain reliable performance of physical assets. If you want a proactive maintenance program that really works, then Reliability Centered Maintenance is the most thorough approach you can take to get there. [Read more…]

by Mike Sondalini Leave a Comment

A Brief Introduction to Process Chemical Corrosion

Chemical corrosion can destroy the containment materials in contact with a process.

Means exist to mitigate and even prevent chemical corrosion. This article focuses on several such methods.

Acceptable corrosion

At times chemical corrosion is acceptable and one need only allow for it by using thicker materials. An example is the storage of sulphuric acid in mild steel tanks at ambient conditions and concentrations [Read more…]

by James Kovacevic 4 Comments

Quantify the Improvements (or Gaps) In Your Reliability

Using a Crow-AMSAA [Reliability Growth Analysis (RGA)] to Quantify Your Reliability Improvements (or Losses)

Part 3 of 7

Imagine being able to predict the next time a failure will occur for a piece of equipment without a huge amount of work. Wouldn’t it be nice to know the approximate point in time that a failure will occur on a critical piece of equipment? It is possible, but I am not talking about using MTBF, as it is not a good measure (if you need to understand why, please visit http://www.NoMTBF.com). What I am talking about is a Crow-AMSAA analysis. [Read more…]

by James Reyes-Picknell Leave a Comment

Preventive Maintenance “PM” Programs – Part 1 – The Basics

Do you replace your car headlights at regular intervals of six months? Do you wait to replace your tires until they wear through? Do you check your car engine oil with some sort of oil analysis before replacing it? Each component and system in your car has a function that is prone to failure. Each of those has consequences – some with little importance and others with great importance. [Read more…]

by Mike Sondalini Leave a Comment

Tracking Large Rotating Equipment

What you will learn from this article.

The importance of using datum for aligning kilns.
How to set-up the necessary datum.
The effect of trunnion alignment on the behavior of the kiln.
How axial float is achieved by skewing the trunnions.

Rotary dryers, kilns, mills, and reactors turn on tyres and trunnions.

[Read more…]

by Fred Schenkelberg 5 Comments

The “What” & “Why” of Weibull Analysis

How to conduct a Weibull analysis and the questions the analysis will generate.

Part 2 of 7

Every failure is part of a puzzle. The equipment we are maintaining is trying to communicate with the use of each and every failure.

Often the message is not obvious.

There is the immediate failure. And, if we’re paying attention we can sort out the root cause of the failure along with replacing or repairing the damaged parts. Sometimes though the damage is caused by another issue with the system. [Read more…]

by Mike Sondalini Leave a Comment

Ultrasonic Level Detectors

Consider these Experiences when making a Selection

What you will learn from this article:

How ultrasonic level detectors work.
Issues to consider when reviewing their suitability for use. Issues to consider when selecting their location.
The importance of process and chemical compatibility.

[Read more…]

by James Kovacevic Leave a Comment

Using the Maintenance Data You Already Have

Leverage the existing data in your CMMS to make sustainable improvements to your maintenance program

Part 1 of 7

Let’s face it, your technicians have been entering data into the CMMS for years, but you haven’t been able to use it to make improvements. Is it because the data isn’t codified or it doesn’t have the right data points? Generally, this is how most maintenance managers will view their data, but it is incorrect. The CMMS does have data that you can use almost immediately. [Read more…]

by Mike Sondalini 2 Comments

The Cost of Maintenance Destroys Your Capital Investment Returns

The cost of maintenance destroys your capital investment returns.

When equipment is first selected the buyer has the choice to buy for quality and long trouble-free operating life or to buy based on least cost. The least cost choice will result in high maintenance and operating expense for the life of the equipment.

When net present value cost of maintenance for cheap equipment is calculated in today’s dollars investors will discover that a large part of their capital will never earn them income but will be spent on maintenance and repair.

Keywords: replacement asset value, internal rate of return, opportunity cost [Read more…]

by Mike Sondalini 4 Comments

Flange Bolting-up Practices

What readers will learn in this article:

Bolts and studs behave like springs when loads are applied.
Gaskets behave like springs when loads are applied
Introduced to the use of force diagrams to explain and analyze bolt and gasket behavior.
Bolt torque-up issues and considerations.
The effects of thread surface finish on friction.
Proper bolting practices, sequence, and methods.

[Read more…]