Blog - Accendo Reliability

The Importance of Documentation in Precision Maintenance

Why Proper Documentation Will Lead to Sustainable Improvements

Imagine being able to look back and see what settings the equipment was last ran at for a particular SKU. Or being able to look back at the last three alignment inspections and see that slowly the alignment is drifting. What could you do with this type of information? You could perform Root Cause Analysis to see why the alignment is drifting, or trend the drifting to know when it will be out of acceptable tolerances.

Having the right information is critical to making informed decisions and driving systematic improvements in the performance of the equipment. This information is typically captured in a report or work order and should be linked to the asset and easily searchable. However, most organizations that I have worked with do not record the right information, which would allow them to make informed decisions. This documentation is a critical piece in precision maintenance, so what is required for documentation? [Read more…]

by Greg Hutchins Leave a Comment

Schedule Risk is a Major Reason for Project Failures

Guest Post by John Ayers (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

Studies show most projects fail due to poor management of known risks. The known risks on a project are:

Scope.
Schedule.
Cost.
Quality.

How to minimize the schedule risk on a project is addressed in this paper. The approach to do this is based on my 30 years of project and project risk management experience and knowledge.

[Read more…]

by James Reyes-Picknell Leave a Comment

Maintenance and Reliability Maturity – 2

In part 1 of this 2 part series, “Maintenance and Reliability Maturity”, I point out that achieving the maximum value from your physical assets will require excellence in 2 main dimensions, efficiency, and effectiveness. Those are described more fully in our recent book, “Paying Your Way“. I also promised a Maintenance and Reliability Maturity Assessment tool. That tool is now available to you, our readers.

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by Larry George Leave a Comment

Help! They Lost the Data

What can we do without reliability function estimates? FMEA? FTA? RCA? RCM? Argue about MTBFs and availability? Weibull? Keep a low profile? Run Admirals’ tests? Look for a new, well-funded project far from the deliverable stage?

Ask for field data; there should be enough to estimate reliability and make reliability-based decisions, even if some data are missing. Field data might even be population data!

[Read more…]

by Steven Wachs Leave a Comment

Ten Ways to Improve Your Measurement Systems Assessments

Why Measurement Systems Assessment (MSA)?

Effective use of data to drive decision making requires adequate measurement systems. For example, when implementing statistical process control charts, we assume that a signal represents a significant change in the process and we react as such. However, inadequate measurement systems may result in inappropriate signals or even worse, charts that fail to detect important process changes. Thus, it is incumbent upon us to ensure that measurement systems are adequate for their intended use via proper assessments prior to their use. Only capable measurement systems should be utilized in data based methods such as Statistical Process Control, Design of Experiments, Inspection activities, etc. [Read more…]

by George Williams Leave a Comment

7 Steps of Clean, Inspect, & Lubricate

Through daily inspections, cleaning, and lubrication practices we can measure, prevent, and restore deterioration to our equipment. The expectation is that a team is put together made up of maintenance, operations, and leadership employees to roll out strategy beginning with one piece of equipment. They will implement the following 7 steps:

Initial Cleaning
Eliminate sources of dirt and hard to clean & inspect areas
Create and maintain cleaning, inspection and lubrication standards
General Inspection
Operator Inspection
Activities standardized
Team Development and Operator Driven Reliability

Recognizing Basic Gear Fatigue Failure Patterns

Lets start with a fresher on general Component Fatigue.

Fatigue occurs when a material is subjected to repeated loading and unloading.
When the loads are above a certain threshold, microscopic cracks will begin to form at a material’s surface.
Cracks always begin in high stressed areas of a material.
Eventually a crack will reach a critical size, and the structure will suddenly fracture.

[Read more…]

by Doug Plucknette Leave a Comment

Allowing Wrong To Become Normal

I’ve seen it twice this year and it concerns me. In twenty years of working with companies to improve manufacturing reliability I would like to believe that those of us who care are leaving a mark. It’s the days I’m about to describe that make you wonder.

I created RCM Blitz™ over twenty years ago as a tool that would help companies identify a complete maintenance strategy to improve and achieve the inherent designed reliability of their critical assets. Prior to entering the world of consulting, I had completed and implemented several RCM (Reliability Centered Maintenance) analyses on critical assets at Eastman Kodak company. With each analysis we completed, I gained knowledge and confidence that the process when adhered to and implemented, could improve the reliability of even our worst assets. In the same two years of proving the process I also learned something very important.

[Read more…]

by James Kovacevic Leave a Comment

Learn to Speak Finance

The Key To Gaining The Ear Of Your Executives

As a maintenance professional, you spend a lot of time explaining how a proper maintenance & reliability program will improve uptime, safety, etc. But why is it that there is a hard time gaining support for the improvement initiatives? Well, senior executives are focused on how the company is being a measure of performance from the shareholders, financial analysts, or owners. Most of these measures are financial in nature, and while there are others, the primary measures are financial. [Read more…]

by Alex Williams Leave a Comment

Maximizing the Potential of Your CMMS System

It’s no secret that equipment maintenance software offers many benefits to your organization. However, organizations frequently find that the software doesn’t deliver the end results they anticipated. This often happens because organizations don’t maximize CMMS potential. In other words—they’re not using their software to its fullest potential.

[Read more…]

by Greg Hutchins Leave a Comment

Short on Resources: Where to Apply Your Focus

Guest Post by Andrew Sheves (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

Effective execution is a matter of dealing with scarcity: a scarcity of time, a scarcity of resources, and scarcity of information (although too much information can also cause problems). Tools like a risk assessment help manage this scarcity by prioritizing things to allow you to better allocate resources on what’s most important.

[Read more…]

by James Reyes-Picknell Leave a Comment

Maintenance and Reliability Maturity – 1

Maintenance and reliability maturity provides an understanding of both how well we do maintenance and how good is our maintenance program. One delivers a major business result, the other is a big part of how you get there. Doing maintenance with precision and care, so the job is done once and done well by the right people and without delay is what maintenance organizations strive for. Some achieve it, some struggle to do so. If they can achieve that, then they are being efficient.

[Read more…]

by Larry George 1 Comment

Estimation of a Hidden Service-Time Distribution of an M(t)/G/∞ Self-Service System

(This is chapter 5 of User Manual for Credible Reliability Prediction – Field Reliability (google.com), cleaned up and typeset for AccendoReliaiblity Weekly Update.)

The nonparametric maximum likelihood estimator for an M/G/∞ self-service time distribution function G(t) extends to nonstationary, time-dependent, Poisson arrival process M(t)/G/∞ systems, under a condition. A linearly increasing Poisson rate function satisfies the condition. The estimator of 1-G(t) is a reliability function estimate, from population ships and returns data required by generally accepted accounting principles.

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by Steven Wachs Leave a Comment

How Does SPC Complement My Automatic Inspection System?

Background

More companies are leveraging high speed vision systems to inspect multiple quality characteristics on their products.

For example, in a high volume baking operation, a vision system can test for bun height, bun length, slice thickness, topping distribution, surface color, and more. This happens automatically on the line at high speeds. In bottling or other plastic manufacturing, a vision system may inspect multiple dimensions and surface properties. [Read more…]

by George Williams Leave a Comment

Clean to Inspect for Best in Class Operator Care

Cleaning is an important first step in Operator Care and reliability gains because:

Insufficient cleaning causes losses and
The cleaning activity itself exposes hidden defects

Dirt in rotating parts, sliding parts, pneumatic and hydraulic systems, electrical and control systems, sensors, etc. causes malfunctions, reduce function, failure by wear, clogging, resistance, speed losses, etc. are different types of defects. Defects are anything that is abnormal from the expected ideal condition. Insufficient cleaning causes forced deterioration. All these losses are solved through a thorough cleaning of equipment and countermeasures to keep the equipment clean.

[Read more…]