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Who Should You Align With?

Who Should You Align With?

With over twenty years in the Manufacturing Reliability Consulting business, I have been approached at least a dozen times to align or partner with other companies who sell services and or equipment that don’t compete with the services I provide. While our community consists of thousands of individual companies around the globe, if you’ve worked in our world for more than five years and attended two to three of the major conferences each year, you’ll notice many of the same faces but often wearing a different shirt.

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The Failure Mode Effect Analysis

The Failure Mode Effect Analysis

Should You use a Top Down or Bottom Up Approach?

A Failure Mode Effect Analysis (FMEA) or a Failure Mode Effect Criticality Analysis (FMECA) are great tools to help develop an effective maintenance strategy.  These tools enable organizations to dive down to the failure mode level and develop preventive, predictive, or other tactics to prevent or mitigate failures.
However, there is a struggle that takes place with FMEAs of how much is enough detail and what is too much or too little. This often comes with experience and the level of risk an organization is willing to accept. The more detail, the more time, resources and effort the FMEA will take, even if the consequences are minimal.
Determining the level of detail can be determined based on the type of FMEA, and whether it is a Top-Down FMEA or a Bottom-Up FMEA.

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Air Mover and Air Amplifier Problems.

Air Mover and Air Amplifier Problems.

Air Mover And Air Amplifier problems! Touted as great maintenance savers and a very efficient means of moving large volumes of air, they can in fact be extremely energy hungry. Based on using a small amount of compressed air to draw through a large amount of entrained air they can cause huge energy waste if an air compressor is run in order for the air mover to operate. It is wasteful to install an air mover on a plant air system unless the air compressor is always running well under peak demand.

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Are you Informed, or Data Distracted? You need AIM

Are you Informed, or Data Distracted? You need AIM

Asset Information is far more than just data, and it must be managed. We want to be informed, not distracted by our data. Our goal is to make “evidence-based decisions”. The “evidence” of what is going on can be very useful if it is accurate, timely, complete, and fit for its intended purpose. Increasingly, we are turning to our computers for that evidence. But do we find it? Or do we end up searching through data looking for that “needle in the haystack”? Do we spend our time making informed decisions, or seeking information from an increasingly large and confusing array of disorganized, out-of-date, inaccurate, and incomplete data? Data must be fit for purpose. 

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Micro-management: Macro Risk?

Micro-management: Macro Risk?

Guest Post by Malcolm Peart (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

Micromanagement is rarely praised but is sometimes very necessary.  When new operations commence and procedures are being developed, or there is a high degree of complexity, it is essential to get things right and ‘micromanagement’ comes into its own.  Training new people can require micromanagement until they get up to speed, understand an organisation’s processes and procedures, and develop any necessary experience.  Also, if there is a need for greater control over an operation requiring accurate performance metrics then micromanagement will be the order of the day.

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Thoroughly Modern Maintenance

Thoroughly Modern Maintenance

Efficiency of 99.995% … in 1915

The Street Railway Journal, later renamed the Electric Railway Journal was published from 1884 until 1931.  The first 1884 volume described the reason for the journal’s existence, to serve the streetcar industry better than journals focusing on heavy rail. In 1884 it was most common for horses to pull street cars on fixed rails.  The importance of animal power was reflected in the articles about managing animals and many advertisements for grooming machines, traces, harnesses, and cures for horse colic.  A rarer method of motive power was a steam engine that drove an underground tow cable.  The second 1884 volume reported several experiments in using electric motors to power the cable instead of steam. 

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Failure Analysis – Mitigation

Failure Analysis – Mitigation

Failure Simulation has confirmed all root causes in the Storm Packer failure analysis. The focus is now on mitigations that prevent them from occurring again. 

Mitigations are controls that prevent failures or reduce their probability of occurring. Ideally, an OEM implements mitigations to the product through Design for Reliability (DfR) activities before commercialization. Some mitigations may be best practices in product design. Others may be best practices for installation or maintenance processes. Some have been acquired through FRACAS programs. However, all will be based on institutional knowledge.

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Is the Human Being Really an ‘Asset’?

Is the Human Being Really an ‘Asset’?

We often hear our organizations referring to their workforce as their greatest ‘asset’. But are they really?

Let’s first define ‘asset’ from a financial perspective:

“In financial accounting, an asset is an economic resource. Anything tangible or intangible that can be owned or controlled to produce value and that is held by a company to produce positive economic value is an asset. Simply stated, assets represent value of ownership that can be converted into cash (although cash itself is also considered an asset)”

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Understanding Soft Foot and How to Correct It

Ensure Your Precision Alignment Program Is On The Right Foot.

Imagine (or maybe you don’t have to) that you take out your brand new Easy-Laser system, and proceed to perform a shaft alignment.  However, it seems that no matter what you do, you can’t get a great alignment.  What is going on?  The foundation looks good, new shims were used, the asset is clean, and there is no pipe strain.  After some discussion with others, they mention a term in which you are unfamiliar with, soft foot.
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Proactive Maintenance is More Covid, How “Covid” is Yours?

Proactive Maintenance is More Covid, How “Covid” is Yours?

Proactive maintenance requires fewer people and is more suited to physical distancing, yet cost-savings measures are driving more reactive work and workplace crowding than necessary. Proactive maintenance is more “Covid”. You have laid-off workers, contractors, and reduced spending on maintenance and parts. In fact, Covid-19 presented you with a great savings opportunity! Have you done anything to make sure those costs stay down though? Short term maintenance cost savings are easy to achieve. but they bite hard later! [Read more…]

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Speaking Up is Hard (Especially) for Risk Managers

Speaking Up is Hard (Especially) for Risk Managers

Guest Post by Andrew Sheves (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

In David McKee’s book for children ‘Not Now Bernard’, a young boy tries to warn his parents about a monster in the yard, but they’re too busy to pay attention. All they say is ‘not now Bernard’ and ignore him. In the end, the monster eats Bernard and moves into the house, but his parents are still too busy to notice.

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MTBF versus Useful Life

MTBF versus Useful Life

There’s a big difference between MTBF and Useful Life. The two values are often misunderstood and misapplied when assigning Preventive Maintenance task intervals. In this video, I’ll explain which one is used to assign intervals for Scheduled Replacement and Scheduled Restoration tasks. We’ll also discuss Operating Context and how that can affect Manufacturer Recommended Maintenance. This is an “edutainment” video. If you’d like to skip the fun stuff (although I don’t know why you’d want to ☺️), I’ve time stamped the Reliability Moments below. Enjoy!

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