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A state variable is a parameter that is categorized into a countable number of defined states. Examples would include transmission gear states, PRNDL positions, ignition switch states, and others. Sometimes continuous variable, like pedal positions, may be binned into discrete states to be displayed as a histogram. State change timing is unpredictable since vehicle operation is highly variable. A way to deal with this data is Markov Analysis.
We have promoted this definition for Design of Experiments for a long time. This video provides the background of what each phrase is important. [Read more…]
Imagine being able to easily share information across sites or even organizations. Or how about utilizing a risk management framework that is recognized and agreed upon by all in the organization. Benchmarking made easy? Standards enable this. [Read more…]
General Electric (GE) for many years was the go-to company for competitiveness, efficiency, and innovation. General Electric’s tagline was ‘Imagination at work.’
GE more recently has had a number of troubles. GE’s profitability tanked. GE is selling many of its assets and divisions. GE was also taken off the Dow after 110 years. [Read more…]
Rotating shafts under bending stress. It is common to transmit motion using rotating shafts. The shafts are mounted in bearings and turned by force through a drive arrangement. The shafts usually also carry a load. These loads cause bending and the shaft reacts by producing counter stresses within itself. Provided the reactive stresses are within the shaft’s strength range it will take the load. But if the stresses are greater than what the shaft can take it will bend. Even if the stresses are below the load limit but fluctuate, it is possible that the shaft will break from fatigue. The point of highest stress can be found by looking at the arrangement of the shaft supports and loads and calculating the forces and stresses.
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I was presenting at the Aerospace Conference earlier this year, where something astounding happened. I was talking to the audience about ‘organizational culture’ and my experiences working with a small satellite manufacturer to help them improve their product’s reliability.
At the end of my talk, I was asked the following questions (which I have done my best to remember verbatim):
How do you accommodate the young engineers of today, who will only stay at one organization for a couple of years before moving on? Research has shown they typically leave within three years – so why should we invest time and effort into them?
If you are a team leader or manager that is searching for the answer to this question, I have some potentially bad news for you:
It is not them … it is you. [Read more…]
I just returned from a great conference in Stuttgart called “Reliability Days.” I presented on some new concepts and techniques with regard to assessing and improving reliability culture in the product development process. Enjoy the presentation.
-Adam
When testing, it is good to know your options. The Advanced tools of Design of Experiments are good to consider. What are they, why should you consider them, and when should they be used. Those are the topics we will discuss in this video. [Read more…]
One of the best things about my job is from time to time I get to work with some fantastic young people who have a passion for the Maintenance and Reliability business and have made the decision to pursue a career in this business. I really enjoy being a mentor, guiding the ambitious and offering advice on where to find information, articles and real, workable solutions. [Read more…]
Imagine if every day you had to relearn a process or use a different CMMS. Chances are you would get virtually nothing accomplished, leaving your plant operating poorly. Now we all know that we having to relearn a process every day or using a new CMMS is not practical nor is it rooted in reality (not to be confused with the Rooted in Reliability podcast). But this type of thing happens more often than you may think. [Read more…]
This story is about risk at the enterprise program/project level. It is an example of centering your design around a high-tech solution to a problem when a low risk proven technology would have more than sufficed. Technical expertise ego got in the way of a practical low-cost approach resulting in unplanned schedule and cost growth. [Read more…]
Orifice plate meter flow measurement. An orifice meter is a circular piece of metal plate placed between flanges in a pipe. In it is a square-edged round hole machined 0.5 to 0.8 pipe diameter in size. Pressure tapping points are placed either side of the plate at specified distances. The orifice causes a flow restriction and produces a pressure drop from one side of the hole to the other. The amount of pressure difference is proportional to the flow of fluid through the hole. The flow is calculated from the pressure difference and flow areas using accurate mathematical formulas. [Read more…]
I was recently talking with my colleague Fred Schenkelberg from FMS Reliability (this conversation can be heard here), about a plane that he had never heard of. Most of the world hasn’t heard of it. And there is a reason you probably haven’t either. The plane in question is a case study on how to design something to fail.
How do you know if YOU need robustness? It is a combination of testing and analysis. Can you afford it? How do you decide? This video helps set the stage for this decision. [Read more…]
I recently had a very interesting discussion with a craftsman at a large automotive manufacturer. During this discussion, he outlined a few of the issues he saw in his plant, and why they weren’t able to overcome them.
The craftsman indicated that he had been reading my previous posts and that it all made sense. In fact, he stated, ” it is common sense, but we don’t have that here”.
