Articles

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3 Ways to Improve your Reliability Program

A Few Simple Ideas to Improve Your Reliability Program

Spending too much on reliability and not getting the results you expect? Just getting started and not sure where to focus your reliability program? Or, just looking for ways to improve your program?

There is not one way to build an effective reliability program. The variations in industries, expectations, technology, and the many constraints shape each program. Here are three suggestions you can apply to any program at any time. These are not quick-fix solutions, nor will you see immediate results, yet each will significantly improve your reliability program and help you achieve the results you and your customers expect. [Read more…]

by Ray Harkins Leave a Comment

Risk Management Models

Turning Uncertainty into Informed Action

Co-authored by Mike Vella

At its core, risk management exists to protect us. It aims to reduce both the likelihood and the consequences of adverse events, whether those events affect safety, quality, cost, equipment, or project schedules.

Good risk management is not reactive. It is proactive. It assumes that future events can be influenced and, to some degree, controlled. That belief alone fundamentally changes how organizations plan, design, and operate.

[Read more…]

by Semion Gengrinovich Leave a Comment

Continuous Improvement

Coordinating multiple improvement programs effectively within an organization requires a structured approach that ensures alignment, communication, and collaboration across various teams and departments. Here are some key strategies and techniques to achieve this:

1. Establish Clear Objectives and Common Purpose

– Align Teams Around a Common Purpose: Ensure that all teams understand and are committed to the overarching goals of the organization. This shared sense of purpose helps keep everyone focused and motivated.

[Read more…]

by Mike Sondalini 1 Comment

Developing Enterprise Asset Management, Maintenance and Reliability KPIs

Developing Maintenance KPIs, Reliability KPIs, And Enterprise Asset Management KPIs Of Value For Good Decision Making

When developing maintenance KPIs, or any performance measure, you will have no real ‘grass-roots’ support, nor lasting success, until people are involved in setting their own measures and key performance indicators.

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I’ve been tasked with developing maintenance KPIs and equipment reliability KPIs.
I would be thankful if you guide me to a proven list of maintenance and reliability KPI’s. We would like to measure performance on individual plant and corporate levels.
We have 120 plants for various products: metals, chemicals, petrochemicals, fertilizers.
We are not currently using unified measures, i.e. every plant is going in its own direction, and we now are looking to unify maintenance and reliability across the corporation by introducing a reliability solution to create a scientific maintenance strategy. Part of our strategy is to introduce specific KPIs which have to be achieved by all plants.

[Read more…]

by James Reyes-Picknell Leave a Comment

Is Perfection Getting in Your Way?

Perfection is difficult to achieve. It takes a lot of work and that delays progress. In operational environments that can lead to lost or deferred opportunities, and leave money on the table.

[Read more…]

by Greg Hutchins Leave a Comment

Risks in the Electric Vehicle World

Safety and sustainability are the major considerations within the growing electric vehicle industry, there is lots of excitement and lots of challenges in the fast-moving electric vehicle industry and both descriptions quickly work their way into the conversation.

Gasoline- and diesel-powered cars are familiar, quick to refuel, and can travel long distances between fill-ups, all of which can’t (yet) necessarily be said about electric cars.
EVs, however, bring with them a whole unique set of positives, from an inherently exhilarating drive feel to a significantly less harmful impact on the environment.
The current knocks against EVs will be resolved in time as more people adopt the technology.

The electric car has gone mainstream with sleeker, more affordable options to choose from. Because electric car models are newer than their gas-powered counterparts, many consumers are unaware of their options aside from the many recently announced carmakers’ electric vehicles. In this article, we will focus purely on the pros and cons of all-electric cars.

[Read more…]

by Nancy Regan Leave a Comment

When to apply Reliability Centered Maintenance (RCM)

The Surprising Answer!

True or False? Can RCM Be Applied at Any Stage in an Asset’s Lifecycle.

In this video, I tackle a common question: Can Reliability Centered Maintenance (RCM) be applied at any point in an asset’s lifecycle? The answer is True! While it’s best to start RCM as early as possible—ideally at the design stage—many successful RCM programs around the world have been implemented long after systems were fielded.

Because RCM is a zero-based process, applying it to legacy equipment offers a chance to reevaluate years of tradition and habits, ensuring that the most safe and cost-effective Failure Management Strategies are in place. RCM’s flexibility means it can deliver great results at any point in an asset’s lifecycle.

I’m Nancy Regan, and I hope you enjoy this quick dive into the versatility of RCM. Thank you for watching!

[Read more…]

by Joe Anderson Leave a Comment

Defect Elimination: The Cornerstone of Equipment Reliability

In the pursuit of operational excellence and equipment reliability, defect elimination stands as a powerful and proactive strategy. It focuses on identifying and addressing the root causes of failures and inefficiencies, rather than repeatedly treating the symptoms. By targeting the sources of defects, organizations can significantly reduce downtime, extend asset lifespans, and improve overall productivity.

What is Defect Elimination?

Defect elimination is the systematic process of identifying, analyzing, and removing defects that lead to equipment failure or suboptimal performance.These defects can take many forms, including design flaws, operational errors, poor maintenance practices, or even environmental conditions. The goal is to ensure that equipment operates as intended, reliably and efficiently, with minimal intervention.

[Read more…]

by Hemant Urdhwareshe Leave a Comment

Weibull Analysis of Right-Censored Data with a Free Software

Dear friends, we are happy to release our103rd technical video! In this video, Hemant Urdhwareshe explains and illustrates procedure to perform Weibull Analysis of right Censored data (or suspensions) using a free open-source software ‘Reliability Analytics Toolkit’. Hemant is a Fellow of ASQ and is certified by ASQ as CRE, Six Sigma Master Black Belt, CQE and CMQ/OE. This will help viewers to understand how to perform Weibull Analysis of incomplete right censored data without investing in expensive software.

[Read more…]

by Kerina Epperly Leave a Comment

The Curious Case of “Normal” Bearing Failure

When Poor Habits Become the Norm

Opening Scene

Imagine an intricate and lengthy production line, where every minute of inactivity costs thousands of dollars. The constant buzz of motors and conveyors conceals a profound tension: production goals are approaching, supervisors are vigilant, and the pressure remains unyielding.

In a constrained environment with a limited maintenance budget and sparse spare parts, your inexperienced and stretched-thin team constantly reacts to urgent breakdowns, prioritizing speed over thoroughness. Shortcuts become necessary for survival, leading to misaligned work and temporary fixes. While immediate repairs may succeed, small defects accumulate, resulting in entrenched bad habits and hidden failures. Eventually, a critical breakdown occurs, revealing the underlying issues, marking the start of a necessary investigation. [Read more…]

by JD Solomon 2 Comments

Systems Thinking Improves Reliability and Dependability (15 ways to do it)

Organizations can systematically enhance reliability and dependability by integrating key approaches into the development, deployment, and maintenance processes of their products and systems. Systems thinking rules! Despite subtle differences in terminology, regular assessments and updates should be conducted to address emerging challenges and technological advancements. This article provides a brief description and demonstration of several key approaches for enhancing reliability and dependability.

Reliability and Dependability Are Often Used Interchangeably

When it comes to choosing the right word to describe a product or service, the terms “reliability” and “dependability” are often used interchangeably. However, there are subtle differences between the two that can impact how they are perceived in practice and by consumers.

[Read more…]

by Semion Gengrinovich Leave a Comment

Reliability Allocation

In the realm of complex electromechanical systems, reliability allocation is a critical process that demands a delicate balance between safety, cost, and performance. As engineers, we are tasked with creating systems that not only meet functional requirements but also operate safely, efficiently, and cost-effectively over their intended lifespan. This article explores key strategies for optimal reliability allocation, emphasizing the importance of safety while considering economic factors and system performance.

[Read more…]

by Fred Schenkelberg Leave a Comment

5 Clues Using MTBF is Not Helping

Have you ever heard the claim that “We use MTBF, as it’s working just fine”?

They may be profitable and successful in the marketplace. Is MTBF serving them well?

Probably not.

One way help the folks claiming MTBF is alright is to illustrate using a better reliability metric may provide an improvement over using MTBF. Asking a few questions may find the inevitable chink in the MTBF armor.

Any early failures due to supplier or assembly error?
Any test design to check for how long the system will last?
Ever notice maintenance seems to improve or degrade system performance?
Did you fix the time frame for the calculation of MTBF?
Do you plot and track the month to month changes in MTBF?

[Read more…]

by Greg Hutchins Leave a Comment

The Ghost Company

All truth passes through three stages. First, it is ridiculed. Second, it is violently opposed. Third, it is accepted as being self-evident.
Arthur Schopenhauer – Philosopher

I’ve seen the Future Of Work. And, I don’t like it. Why? In Portland, Oregon, a retail store sells kombucha, a slightly alcoholic green or black tea. Great location. Great storefront. Sure money-maker!

[Read more…]

by Mike Sondalini Leave a Comment

Equipment Reliability 101

Learn Vital Equipment Reliability Basics for Equipment Reliability Management Success

Learning how to run your industrial plant and equipment to get outstanding reliability requires an understanding of its failure mechanisms.

You can have tremendous equipment reliability if you use the right maintenance strategies at the right times during the equipment life cycle to prevent the causes of failure.

Abstract:

Equipment Reliability Basics 101 for Reliability Management. When you understand the behaviour of equipment over its lifetime you will understand why proactive maintenance (as opposed to repairs) is critical. Our technologically based society depends on machinery and equipment to keep it operating. Knowing how equipment behaves during its operating life, and why it fails from time to time, means you can set up the right maintenance strategies to deliver lifetime reliability. Learn to apply the correct ways to use equipment failure curves to select your maintenance strategies. Change your maintenance and operating practices to control and eliminate failure and ensure you deliver outstanding equipment reliability.Keyword: Keywords: Equipment reliability management, reliability curves, equipment failure curves

[Read more…]