Your Reliability Engineering Professional Development Site
If managers knew what the overall power of a well supported Root Cause Analysis (RCA) effort meant for their bottom-line, they would be breaking down doors to implement the process.
Unfortunately, this is often not the case, so this paper is an attempt to educate such individuals about the characteristics of an effective RCA methodology. The paper focuses on the three aspects of RCA we believe leadership teams need to understand the most. [Read more…]
Failures during product testing and use are a fact of life. Even with the most robust design we can develop an overly aggressive reliability test or find users that dish out punishing treatment, causing product failures. And for designs that are less robust, standard reliability tests and normal users will cause failures, occasionally or frequently depending on the design robustness.
When a product fails, its related to failure of individual components and/or joints between components. When a component or joint fails, it’s because their materials degraded to the point that the component or joint could no longer perform as required.
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We live in turbulent times. Transformational times. But what are the possible implications for the production industries and for process plant reliability engineering?
In 2020, Deloitte (Deloitte Touche Tohmatsu Limited) attempted to address the first part of this question by examining four (4) possible scenarios for the future of Europe’s chemical process industry. The results of their study (refer Figure 1) are relevant for many industries and suggest that “proactive transformation” will be required for a profitable and sustainable future (i.e., Scenario 1).
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For industrial operations struggling to get budgeted monthly operating results, we have a new book about building a “success system” in your company. If you want to ensure your monthly production targets and operating costs are always hit, read Industrial and Manufacturing Wellness.
Developed from the Plant Wellness Way, the Industrial and Manufacturing Wellness Enterprise Asset Management methodology gives you a systematic, structured approach to build a holistic, lifecycle business system that consistently gets you the best possible monthly production successes.
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Hot on the heels of my two articles (part 1 and part 2) about Data being unfit for purpose is another article by my colleague, Paul Daoust, just published in Canadian Business Quarterly.
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Dr. Davison has more than 30 years’ experience in environmental management, integrated water cycle management and risk assessment. Davison has more than 30 years’ experience in environmental management, integrated water cycle management and risk assessment. She is the Principal Risk Analyst and founding Director of Risk Edge® Pty Ltd. and co-founder and R&D Manager, D2K Information Pty Ltd. She received her PhD in Environmental Biochemistry and Microbiology from Macquarie University. Her most recent book is entitled: The Application of ISO 31000 to Drinking Water Quality Risk Management: A Practical Approach. It is published by Edge Pty Ltd, Sydney Australia.
[Read more…]A version of this article was previously published in the December 2015 edition of Quality Progress magazine.
Last summer while visiting my hometown, I ran into Sam, an old friend who works in a senior technical position for a very large organization. In the course of our conversation, Sam told me about a recent discussion he had with his division’s manager about the possibility of moving up in the company. He was trying to find out if his boss would recommend him for a promotion to a particular supervisory level position that had just opened. His manager’s reply was provocative. He said, “Sam, you’re excellent at your job. I don’t know what we’d do without you. But before I could recommend you for a team leader position, you’re going to have to work on your soft skills.”
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The 20th century was a time of great technological change that forever transformed how we live and work – changes that necessitated the birth and development of the field of Process Safety Management. The early years saw the evolution of mechanization into assembly lines and true industrialization. Lack of access to South American nitrate during World War I, led to the creation of the synthetic chemical industry. World War II fostered increased industrial growth and sophistication. By the 1960s, we were building computers and beginning our race to the moon. Industries grew becoming increasingly sophisticated and reliant on automated systems. The 1970s brought the creation of the US EPA and OSHA. The 1980s witnessed one of the greatest tragedies in the last century – an estimated 4,000 people died in the 1984 Bhopal accident. Since then, the process safety community has evolved in its approaches and methodologies to better manage risks.
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Do you need design margin in your product? A composite frac plug may need margin as a mitigation against uncertainty in material properties. Long service life products used in offshore wells are sometimes designed with structural margin as a mitigation against changing downhole conditions. But can margin be used for other parameters?
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The foundations of systems thinking and facilitation apply to business cases because the analysis requires a group to establish the nature of separate and inter-related components. This article discusses five ways to effectively facilitate business cases by conducting pre-session exchanges, asking powerful questions, using exercises that engage, anticipating disruption, and controlling the tempo.
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Safety is often directly correlated with system or component reliability. Is that really the case?
Find out what the experts and their data really says.
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Adopting the business strategy of intentionally tightening process and work quality standards will drive operating profits higher. You get most operating profits when process and work quality variables are sitting on their optimal cost points. The Taguchi Loss Functions of your operation show the connection between your operating costs and your process and work quality.
Keywords: Taguchi Loss Function, quality verses cost, Quality Cost Function
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What does the future hold for project management? Remote and flexible work arrangements were trends prior to COVID-19. The pandemic greatly accelerated the trends and a lot of it will be permanent well after the virus is tamed. Remote work arrangement means any work you do that dose not require commuting into an office. A flexible work arrangement are alternate arrangements or schedules from the traditional working day and week. Employees may choose a different work schedule to meet personal or family needs
This paper discusses the risks these changes will have on project management for future work. It does not present new technologies and the risks they will impose on projects. This is a subject for another paper.
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I’ve driven this route at least 3,000 times in the last 12 years. If you asked me if I would ever see a Tupperware-bowl-full of cut honeydew melon…or a pair of sneakers and an orange sitting atop a highway barrier, I would have said “𝘯𝘰.”
[Read more…]I recently came across a report from European Gas Pipeline Incident Data Group (EGIG) titled “Safety Performance Determines The Acceptability of Cross Country Gas Transmission Systems”. The paper presents incident data contributed by six European gas transmission operators over a 30-year period of 1970-2001.
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