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Find all articles across all article series listed in reverse chronological order.
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.
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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On 10 August 2020 the US Midwest experienced a Derecho that brought widespread devastation to many areas. A Derecho is a widespread, long-lived, straight-line wind storm that is associated with a fast-moving group of severe thunderstorms known as a mesoscale convective system. Derechos can cause hurricane-force winds, tornadoes, heavy rains, and flash floods. As depicted below the 10 August 2020 Derecho spanned serval states over a 12 hour period.
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.
In previous articles, we discussed the advantages that Xbar charts have over Individuals charts in detecting process shifts. (See “How Should the Subgroup Size be Selected for an Xbar Chart (Part I)”) We saw that charts of Individuals are ineffective at quickly detecting small process shifts (and detecting these small process changes may be critical!).
Charts of averages (Xbar) are superior because averaging the subgroup data gives us greater certainty as to where the process is actually running at a point in time. Selecting an appropriate sample size on an Xbar chart allows us to align the statistical performance of the control chart with the desired practical process changes we’d like to detect. That is, the sensitivity (ability to detect change) may be adjusted based on the sample size utilized. [Read more…]
A high-pressure packer for use in 9 5/8”, thick-walled, P-110 casing is being developed for a well barrier application. It is based on a legacy configuration. Is it a candidate for simulation?
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?
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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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.
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…]
Have faith to seize on opportunities that come your way (but the risk is within us!)
Everyone has opportunities. But it is up to us to seize the opportunities that come our way!
There will be opportunities to build lives, to better ourselves, or to serve the community.
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.
In the last article, we learned how to compute and graphically interpret both main effects and interaction effects. Eventually, the statistically significant effects will be used to develop a predictive model. But how do we determine which effects are statistically significant?
Conceptually, we first develop an “error” distribution that represents the distribution of Insignificant Effects. If we have an idea of what the Insignificant Effects look like, we can determine which of the effects we compute look significant by comparison. [Read more…]
Software tools are a cornerstone of modern Reliability Engineering, enabling reliability practitioners to perform their analysis without getting bogged down in the details of the underlying mathematical processes. There are many software tools available for reliability engineering, some of which are tailored to this application, while others are more general statistical tools which can be adapted to the needs of reliability engineers. One thing these tools have in common is their graphical user interface (GUI). The GUI requires only a basic level of knowledge to operate, but with a few clicks of the correct buttons, the desired task can be achieved with relatively little mental effort. It is the user friendly GUI that draws reliability engineers to select such applications as their tools of choice for performing reliability engineering analyses.
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).
