Your Reliability Engineering Professional Development Site
A proximity switch is the common name for a range of detectors that generate an electrical signal when a physical mass cuts through their sensor field. Upon detection of an object, the electrical signal is sent to a controlling device and is used to monitor and control the operation of the equipment.
You know the type. That person who demands the center of attention at all times and hardly pauses for a breath. The person everybody on site avoids or talks about when they aren’t around. Usually, younger people suffer the most from Knowing Everything All The Time (KEATT). Sometimes, though, it persists long after it should and people never recover.
For me, this lasted about two years after graduating. I’m not sure precisely what caused the change, but a moment came when I realized I didn’t know jack. By that time the damage had been done; many knowledgeable people didn’t like or trust me, I was frustrated and it was difficult to learn because nobody wanted to teach me. Thankfully, I did and you can recover from the disorder of Knowing Everything All The Time (KEATT).
The term “Physics of Failure” is used when referring to the underlying mechanism that has driven a failure mode. I have issue with the words “Physics” in this phrase as a “catch all.” This implies we are only working with physical or kinematic interactions when studying product wear-out. Wear-out failures are rooted in chemistry as well. Most electronic failures are chemistry based. If a failure can be 
tracked back to a material property change, dielectrics, brittleness, transformation (oxidation), strength loss based on property change without fatigue, we have a chemistry problem. Mechanical physics does not play a part in understanding the input and response relationship or assist with creating an accelerated life model in these cases.
I’m not an Engineer
Engineers want order. Everything should happen in a programmed sequence making an expected result predictable. It’s one of the traits that gives Engineers a reputation for being boring. When things happen out of order or sequence the engineers of this world become quiet while their brains churn out what they know the expected order should be and what might have occurred to upset the process. [Read more…]
Design of Experiments (DOE) is often only taught as a series of tools. Instead, we have used it as a tool in the Decision-Making Process which enhances implementation.
Each section below contains a 2-minute video to expand on the topic provided.
The setup and project definition are important for future success. Often, people want to jump to a solution. Then, they can start implementation and testing. Briefly pulling back to define the goal and appropriate outputs will help tremendously.
Consider these questions: How many recommendations are needed to address the root cause of a high-risk problem? If the FMEA team is addressing an issue with high-severity and high-occurrence ratings, is it usual to have a single recommended action to reduce risk? Why not? Read on, to learn the essential elements of FMEA recommended actions, and answers to this questions.
“I have been impressed with the urgency of doing. Knowing is not enough; we must apply. Being willing is not enough; we must do.”
Leonardo da Vinci
With the design FMEA complete, the equipment should have high inherent reliability. The equipment can then be installed in the plant, and provide a high level of performance to the business, at least initially. This is where Maintenance comes in. Maintenance can enable a low Life Cycle Cost, by preserving the reliability of the equipment. [Read more…]
The practice of maintenance has been developing for the past 300 years. Since the start of the Industrial Revolution machinery and their control systems have played a critical part in our ability to produce consumer and industrial goods. Over that time different maintenance philosophies have developed in response to changing technology and increasing costs.
The progression in philosophies started with breakdown maintenance (BM), then to time-based maintenance such as preventative maintenance (PM) and shutdown maintenance. More recently condition-based maintenance (CM) has become significant. The next step is predictive maintenance. [Read more…]
Guest Post by Geary Sikich (first posted on CERM ® RISK INSIGHTS – reposted here with permission)
Exposure to threats, hazards and risks leads to vulnerabilities that an organization must deal with. Commonly these are addressed via a mitigation process. Once mitigation is accomplished, often times the organization feels that the risk, threat, hazard does not need to be revisited. However, as a result of the mitigation efforts on the part of the organization, the risks, threats, hazards reconfigure and re-emerge in a different form.
In order for mitigation to be successful it has to be a constant and ongoing process that produces a resilience to the negative effects of risks, threats and hazards that are realized. [Read more…]
Good day, friends and colleagues. I am excited to join Accendo Reliability to bring you a weekly column titled, “Advanced Engineering Culture.” The goal of this column is to bring awareness and solutions to common challenges technical people face in the workplace. New articles will post every Monday.
My name is Katie Switzer, and I am a Senior Reliability Engineer at a chemical manufacturing plant in West Virginia. I hold a Bachelor’s of Science in Mechanical Engineering from Clarkson University, and I have been an ISO Category III Vibration Analyst since 2009. Industries I have experience in include aerospace, nuclear power, corn milling and chemical manufacturing. [Read more…]
When you woke up this morning, how did you feel? Was it giddy excitement for what the day ahead holds? If not, then you are likely not living your purpose. Not pursuing your life’s work.
For me, the idea of pursuing my life’s work became exponentially more important in 2013. Over the past 3 years, I had gotten married (yay!), became a mother to my husband’s 5 year old son (double yay!), had a daughter (triple yay!), lost my mother to 5 year battle with lung cancer (tears! lots and lots of tears!), and become pregnant with a baby boy (due January 2017!). [Read more…]
It can be hard as a reliability engineer to influence the greater organization. Reliability engineers have that awkward dynamic of not just executing the tools they are expert in but directing others to incorporate them into their own process. If the perception is that reliability engineers only instruct others what to do, like a coach, then the perception may be that “they don’t have skin in the game”. If they take complete ownership of reliability activities the effectiveness of any tools influence on the product greatly diminishes. “DfR principle #1, You can’t “Design for Reliability” if the design team isn’t using reliability tools in the design process.
The face you make when you know it’s supposed to be a team meeting yet the word you keep hearing most is “I”! Unless your working with a group of Optometrists it’s usually not a good sign!
One of the more important topics in the FMEA body of knowledge is how to audit the effectiveness of FMEAs. Performing FMEAs properly and to a high quality standard is essential to obtaining the best possible results. This FMEA Q and A goes to the heart of FMEA effectiveness audits.
“Without a good question, a good answer has no place to go.”
Clayton Christensen
Products and equipment start with a design. The functions and performance occur or do not occur according to the capabilities designed into the system.
I learned early in my career, as a manufacturing engineer, that some products were much easier to manufacture (less yield loss) ten others, and it was often the design of the product that made the difference.
I also learned that once we purchased and installed factory equipment it was very difficult to improve the reliability performance. [Read more…]
