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A Mechanic’s Story: Basic Component Fatigue

A Mechanic’s Story: Basic Component Fatigue

In past articles, we have explored the basics of Erosion, Corrosion, Fatigue and Overload. Our emphasis has been on creating an awareness and appreciation for the value of failed components, to any investigation.

In this article we are going to delve into Fatigue a little bit more (because it is the most common fracture pattern) and see how we can use an evidence-based, deductive logic process to determine what elements of Fatigue may have been at play. We are trying to create an intellectual curiosity within the front lines about ‘making the call’…is it Fatigue, or some other fracture pattern?

[Read more…]

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What is Precision Maintenance?

Precision Maintenance May Be The Key To Unlocking Reliability

Why is it that some individuals perform a PM Routine and always find something and others don’t? And why is that when some individuals perform a rebuild or overhaul, the equipment struggles to start and return to steady state? The answer comes down to how detailed the individuals are during the maintenance activity. But how can this be overcome with such a wide range of individuals in the maintenance team? The answer is precision maintenance [Read more…]

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The “new normal” can be much better

The “new normal” can be much better

The “new normal” can be much better if we choose. Why go back to the same-old, same-old?

As we emerge from the 2020 pandemic and all the measures to contain it, your workforce will be returning to a “new normal”. What’s that? None of us really knows the details, but aside from being a cool phrase, it means being smarter and doing things differently with a great deal of awareness about disease transmission. Keeping our distance, wearing masks when ill, avoiding crowded venues, and patiently waiting for vaccines, will be a part of it, but what else will characterize the “new normal”? 

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Facilitation Skill #3: Asking Probing Questions

Facilitation Skill #3: Asking Probing Questions

FMEA facilitators can generate deep discussion and stimulate creative ideas by asking probing questions.

“A good question is never answered. It is not a bolt to be tightened into place but a seed to be planted and to bear more seed toward the hope of greening the landscape of idea.” – John Ciardi

The Oxford English dictionary defines “probe” as “seek to uncover information about something.” [Read more…]

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Where do the Typical Control Chart Signals Come From?

Where do the Typical Control Chart Signals Come From?

The purpose of control charting is to regularly monitor a process so that significant process changes may be detected.  These process changes may be a shift in the process average (Xbar) or a change in the amount of variation in the process.  The variation observed when the process is operating normally is called common cause variation.  When a process change occurs, then special cause variation occurs. [Read more…]

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Questions About Coefficient of Friction in Fasteners

Questions About Coefficient of Friction in Fasteners

I recently received an interesting LI inquiry that I felt others could learn from the answers that I was able to get. This is not my expertise so I sought out answers from some colleagues who were more familiar with fasteners.

Here is the original inquiry (translated from Portuguese so I hope Google Translator did a good job):

“I would like to know if you can help me clarify my doubts about:

  1. The purpose of conducting a study of the coefficients of friction in screws, threads and nuts?
  2. Is there an accurate standard for such testing?
  3. What methods can be perfected in projects that target this type of trial and application?
  4. Can surface treatments influence changes in results?
  5. Who is responsible for such testing (the manufacturers and suppliers of raw materials, the assembler and/or its various final assembly applications)?
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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…]

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Schedule Risk is a Major Reason for Project Failures

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:

  1. Scope.
  2. Schedule.
  3. Cost.
  4. 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.

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Maintenance and Reliability Maturity – 2

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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Help! They Lost the Data

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!

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Ten Ways to Improve Your Measurement Systems Assessments

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…]

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7 Steps of Clean, Inspect, & Lubricate

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
[Read more…]