Articles

Find all articles across all article series listed in reverse chronological order.

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…]

by Nancy Regan Leave a Comment

The Best Definition of Reliability Centered Maintenance I Ever Heard

Storytime: What is Reliability Centered Maintenance (RCM)? This is the best definition of RCM I ever heard.

In this video, I share a story that has stuck with me throughout my 26-year journey with Reliability Centered Maintenance (RCM). It all started when I was working as a civilian employee at the US Navy’s Naval Warfare Center in Lakehurst, New Jersey. One evening, during a dinner with the British Royal Navy’s RCM team in Bath, England, Commander Andrew Matters shared a simple yet profound definition of RCM: “RCM is nothing more than common sense applied to physical assets.” That definition has guided my understanding of RCM ever since.

RCM might seem complex, but at its core, it’s grounded in practical, common-sense principles. In this video, I explain how RCM helps us identify safe and cost-effective maintenance tasks, manage failure modes, and build a strong reliability culture. When applied correctly, RCM has the power to transform organizations—and I’ve seen it happen firsthand.

What’s keeping you from carrying out a couple of RCM pilot projects? Why not see for yourself how RCM can make a difference for your equipment and your reliability team?

I’m Nancy Regan. Thank you for watching!

[Read more…]

by Hemant Urdhwareshe 1 Comment

Weibull Analysis with a Free Open Source Software

Dear friends, I am releasing this 102nd video after a long gap of more than three months! I went through some critical health issues since October-2024! Now that I have recovered fairly well, I have created this interesting video. In this video, I have explained how to perform Weibull Probability Plotting and life data analysis of complete data using ‘Reliability Analytics Toolkit’.

[Read more…]

by André-Michel Ferrari 2 Comments

Relia-nomics – When Reliability meets Economics

In an increasingly complex and interconnected world, ensuring that systems—from machinery to software, from power networks to consumer products—perform reliably across their intended lifetimes, is essential not only for safety and quality but also for economic viability. This intersection between ensuring dependable performance and managing costs is broadly studied under what is known as Reliability Engineering and Economics. Or Relia-nomics.

[Read more…]

by Chris Weir Leave a Comment

Why Human Factors Matter in Reliability and Maintainability

For reliability engineers, numbers can be our comfort zone. Predictions, modelling, analysis and results, work that is rigorous, data-driven, and essential for complex systems – but does it always tell the full story?

Recently completing Level 1 of the CIEHF Cross-Sector Learning Pathway has led me to consider system reliability in a different light. Technical performance alone does not guarantee success and to truly understand reliability, we must also account for the human component – the operators, maintainers, and decision-makers whose actions are inseparable from system outcomes.

[Read more…]

by JD Solomon 1 Comment

Why Fix Your Asset Management Program When Replacement Asset Values Are Missing

Asset management for facilities and infrastructure has fallen into the leadership realm of gearheads and data managers. The result is asset management programs that are years (or decades) and hundreds of thousands (or millions) of dollars into their programs and still cannot produce realistic replacement values for their assets.

Too Much Time in the Wrong Places?

Does it matter that we have spent most of our attention on asset management systems, GIS integrations, condition assessments, and preventive maintenance programs? You bet it does. And you may have put too much time in the wrong places. [Read more…]

by Semion Gengrinovich 2 Comments

Data Scientist vs. Reliability Engineer

In today’s data-driven business landscape, two roles have emerged as critical to improving company strategy through data analysis and system optimization: data scientists and reliability engineers. While these roles have distinct focuses, they share common skills and often work together to drive organizational success. This article will explore the similarities and differences between data scientists and reliability engineers, highlighting how their skills complement each other in day-to-day activities and contribute to data-driven decision-making.

[Read more…]