Your Reliability Engineering Professional Development Site
“Aircraft LRUs test NFF (No-Failure-Found) approximately 50% of the time” {Anderson] Wabash Magnetics claimed returned crankshaft position sensors had 89-90% NTF (No-Trouble-Found), Uniphase had 20%, Apple computer had 50% [George].
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In this episode, we answer two questions: 1) What is Reliability? 2) How do we get the Reliability we need from our machines? Nancy also discusses how we design our Reliability both literally and figuratively. The quality of our proactive maintenance and Default Strategies largely determines the Reliability we get from our equipment. Inherent Reliability is explained.
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Lithium batteries catch fire if the anode and cathode materials contact each other. What causes short-circuit leading to anode-cathode contact?
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About 13 years ago, I began a reliability journey at a large paper mill. At that time, the mill was pretty reactive and I was naïve enough to think I was going to single handedly turn it around. While I thought I had all the answers and was going to teach the mill a thing or two about reliability, it ended up teaching me a hell of a lot more.
[Read more…]Value Stream Mapping is a business process improvement tool. It derives from the Toyota Production System where it was used to identify the seven wastes in a production process. It is now used across all business processes because the principle of finding and removing waste applies throughout every business.
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The Pareto Principle, or more commonly the “80/20 rule”, is based upon the observation that 80% of the consequences of something are attributable to 20% of the causes. The quality guru Joseph Moses Juran named the Principle in 1941 after the Italian economist who, in 1896, observed that 80% of the land in Italy was owned by 20% of the population. The centenarian also similarly observed that 80% of quality problems result from 20% of the causes. In the business world we also see that 80% of a company’s revenue is generated by only 20% of its customers. As with life, things are not distributed either evenly or even fairly.
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As the quality manger for a tier two automotive supplier, I recently had the opportunity to hire a quality supervisor following the retirement of a long-time member of our team. Our company’s human resource manager and I worked together through the entire selection process. Given the status of our region’s economy and the recent closure of several large factories, I wasn’t surprised when our mailbox started filling up with resumes in response to ads on the popular Internet job sites. The typical respondent was a mid-career professional with over 15 years of experience in manufacturing that had either been recently laid-off due or who wanted to move up in their career.
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Last year, the Government Accountability Office (GAO) reported that the Chemical Safety Board (CSB) is not meeting its statutory mandate by investigating major chemical accidents.
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Technological inheritance, defect inheritance, and quality inheritance transfer to the future. To create a better future for your organization you first must create a better past so it can later inherit the preordained successes you designed and imbedded into your company.
[Read more…]“That’s a Red Flag!” goes the cry from some when something amiss is recognised. However, many project participants don’t realise that their Project sails through a sea of flags and that, on some occasion, the flags can be read as red by somebody at some time.
In a similar nautical vein the Roman writer Ovid once poetized “The man who has experienced shipwreck shudders even at a calm sea“. While written some 2,000 years ago it is as true today as it ever was and a reminder to us all that risks lurk everywhere. Some risks may not be identified, let alone assessed and may go unnoticed until they strike. We need to be aware and vigilant and avoid a complacent belief that a risk register is the be all and end all.
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How is failure testing done on the Space Station? Could FTA (Fault Tree Analysis) be used in reverse to detect multiple failures given symptoms? That’s what NASA was programming in the 1990s. I proposed that the ratios P[part failure]/(part test time) be used to optimally sequence tests. Those ratios work if there are multiple failures, as long as failure rates are constant and failure times are statistically independent.
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What does asset management have to do with TIME? Everything.
My mentor, John Moubray, taught me that our most valuable resource is TIME. Time is WAY more valuable than money.
How you spend your TIME determines IF and HOW your asset management efforts will pay off. In other words, will your efforts help you achieve the kind of equipment Reliability you’re looking for?
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On July 27, 2009 OSHA launched its National Emphasis Program (NEP) targeted at chemical facilities. The NEP will operate as a one-year pilot program during which OSHA will conduct planned inspections of chemical facilities.
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There are many opinions about the use of the breakdown flag in SAP-PM. I would like to offer my opinion on this debate. First, I do not like the term “breakdown”. With a name like breakdown, nobody will want to check the box! No one likes to admit that a something has failed or is broken. I wish the field were named “reliability event” to take away this negative connotation. I will discuss this in more detail later.
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Using Reliability Principles for a Cheap Way To High Pumping Circuit Availability. High plant availability is achieved by having redundant equipment that can be brought on-line as soon as the operating unit has failed. Redundancy is expensive as there are two items to buy, two to install and two to maintain at full operating capacity. There is an alternate option for maintaining high pumping circuit availability by designing quick methods to bring mobile equipment into the circuit when pumps are down. This article explains how to set-up piping for a mobile pump to maintain operation when the normal duty pump is out of use.
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