What is Root Cause Analysis? Let us explain.
[Read more…]Error in Inspection Time Interval
IEC 60601-1 says… Estimate the probability per time pe of an electrical failure and of an oxygen leak po. Determine the accepted probability of dangerous failures [fire] per time r. Calculate the inspection time interval tc = r/(0.5*pe*po).
A friend asked, “What’s the 0.5 for? It doesn’t account for the fire event sequence: leak before spark.” I posted correction tc = r/((po/(po+pe))*pe*po) and notified the IEC committee which acknowledged, “We’ll consider your suggestion for edition 4.”
[An earlier, shorter version of this article on www.LinkedIn.com, July 5, 2018. This version describes an inspection-time and risk-analysis template.]
[Read more…]The Pro’s and Con’s of Using Pre-Existing Logic in Root Cause Analysis (RCA)
There has been an ongoing debate for decades as to whether or not the use of pre-existing logic for conducting Root Cause Analyses helps or hinders the analysis results. Does the use of such pre-existing logic expand the thinking of the team members or does it lead the team to pre-determined conclusions and away from other conclusions not considered in the pre-existing logic? We will explore the fine line between these opposing views and see if there is a middle ground for consensus. [Read more…]
Ensuring a Clean and Well Functioning CMMS
The Importance of CMMS Refresher Training and Procedures
Many organizations struggle to get the most out of their CMMS for a variety of reasons. Sometimes it is poor data quality, poor reporting, or the fact that it was not set up or configured properly during the implementation. As a result of the poor performance of the CMMS, many organization work to implement a new CMMS but end up with the same results. Why is this? Well, there are a variety of issues at work, such as poor implementation, configuration, or even the day to day use of the CMMS.
8 Common Pitfalls to Avoid When Implementing an EAM System
Upwards of 95% of all EAM software implementations fail to deliver the desired results. The underlying cause of most EAM failures can be traced back to the early stages of the implementation process. Implementation activities often cost organizations more than the software itself, so it makes sense to learn about concepts and practices that can help prevent implementation failure. It’s important to maximize your chance of success when implementing facility maintenance software in your organization. Avoid these 8 common pitfalls when implementing EAM software:
[Read more…]The Benefits of Proactive Maintenance
The benefits of proactive maintenance are the avoidance of consequences that occur when something fails. If you knew that you were going to suffer a heart attack and roughly when it would happen, wouldn’t you do something to avoid it? Or maybe you would just prepare better so the consequences of it occurring are minimized.
[Read more…]The Purpose of Maintenance of Plant and Equipment in Industrial Operations
Introduction to the Concepts and an Overview of the Purpose of Maintenance at the Turn of the 21st Century
Maintenance management is a key element of enterprise asset management and applies for the whole lifetime of your physical assets. The purpose of maintenance is much more than ‘fixing things up’; it is the appropriate management of asset health for its lifetime.
The philosophy that “a stitch in time will save nine” is very appropriate and is an important part of maintenance. On operating plants where this approach is formally recognised and acted upon, there is a very significant lift in the reliability of the plant.
[Read more…]What is a Black Swan and Why You Need Contingencies?
Guest Post by Andrew Sheves (first posted on CERM ® RISK INSIGHTS – reposted here with permission)
I’m sure you’ve heard people referring to COVID-19 as a ‘Black Swan’ – something that no-one could have seen coming – but is that actually the case?
Terrible though it is, I don’t think it’s accurate to describe the current situation as a Black Swan because we’ve had to deal with highly contagious, deadly diseases before.
Calling this a ‘Black Swan’ is, therefore, a way to excuse a confused response: ‘how could we have prepared for something that no-one could see coming?’
However, genuine Black Swan events do exist and we need to understand these because the consequences can be significant. It’s also useful to know what we can and cannot do to prepare for Black Swans due to the uncertainty that these involve.
[Read more…]The “150% Rule” for Job Promotions
Many corporate professionals feel the frustration of wanting to move up the ladder, but never getting a crack at their boss’s role. In many companies, large and small alike, navigating into a managerial role feels like stumbling around a dark room looking for the exit. Some people find their way; most don’t.
[Read more…]Methodologies of Root Cause Analysis
What to do with Obsolescent Nuclear Engineers?
When nuclear power plants were built, companies had quality assurance programs and US Nuclear Regulatory Commission risk standards. Now the nuclear industry faces obsolescence. Qualifying replacement parts and replacing analog instrumentation and controls with digital systems generates some reliability testing work. NASA solicits unmanned nuclear power plants on the moon and Mars. Nevertheless, the demand for nuclear engineers is decreasing. Fortunately, the nuclear industry spawned risk analyses useful in other industries.
[Read more…]The Need to be a “Little Bit Bold & Outrageous” to Change the Reliability Status Quo
This phrase ‘a little bit bold & outrageous’ was constantly used by my father, Charles J. Latino early in his Reliability career. Charles founded and led one of the first corporate, global Reliability Engineering R&D groups in the U.S. for a company called Allied Chemical at the time (known as Honeywell today). This was in 1972!
[Read more…]Who Should You Align With?
With over twenty years in the Manufacturing Reliability Consulting business, I have been approached at least a dozen times to align or partner with other companies who sell services and or equipment that don’t compete with the services I provide. While our community consists of thousands of individual companies around the globe, if you’ve worked in our world for more than five years and attended two to three of the major conferences each year, you’ll notice many of the same faces but often wearing a different shirt.
[Read more…]The Failure Mode Effect Analysis
Should You use a Top Down or Bottom Up Approach?
A Failure Mode Effect Analysis (FMEA) or a Failure Mode Effect Criticality Analysis (FMECA) are great tools to help develop an effective maintenance strategy. These tools enable organizations to dive down to the failure mode level and develop preventive, predictive, or other tactics to prevent or mitigate failures.
However, there is a struggle that takes place with FMEAs of how much is enough detail and what is too much or too little. This often comes with experience and the level of risk an organization is willing to accept. The more detail, the more time, resources and effort the FMEA will take, even if the consequences are minimal.
Determining the level of detail can be determined based on the type of FMEA, and whether it is a Top-Down FMEA or a Bottom-Up FMEA.
Air Mover and Air Amplifier Problems.
Air Mover And Air Amplifier problems! Touted as great maintenance savers and a very efficient means of moving large volumes of air, they can in fact be extremely energy hungry. Based on using a small amount of compressed air to draw through a large amount of entrained air they can cause huge energy waste if an air compressor is run in order for the air mover to operate. It is wasteful to install an air mover on a plant air system unless the air compressor is always running well under peak demand.
[Read more…]