Your Reliability Engineering Professional Development Site
In our daily lives we often become immune to risks around us. For example, there are around 40,000 annual fatalities from automobile accidents in the US and yet we do not think twice before getting into their cars. We eat a burger ignoring the risks of heart problems!
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It is easy to get caught in this trap. After months of working on an issue, you are asked to provide an informational update to a group of senior decision makers. You understand that no decision will come from your presentation. And there is not much on the agenda, so you are free to make as much as 30 minutes to provide your update.
Your presentation can be a little less formal and use the entire time, right? Wrong.
Does procedural and/or regulatory compliance with RCA guidelines ensure Operational Reliability? Does it ensure improved Safety? Operational Reliability involves the aggregation of Equipment, Process and Human Reliability methods and techniques.
What is the difference between troubleshooting, problem solving and ‘RCA’? Are the outcomes different when we use The 5-Whys, The Fishbone or a Logic Tree/Causal Factor Type Tree?
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Here’s an example of how a metallurgical failure analysis led to identification of the root cause of a failure, and to identification of the corrective actions needed to prevent the failures from recurring.
As I discussed in my previous article, metallurgical failure analysis can be used to improve product reliability. The information from failure analysis of a failed component is used to determine the root cause of the failure. Once the root cause is identified, the failure analysis data and findings is used to help identify the corrective measures required to prevent the failure from recurring.
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The Board of Adjustment was having a hard time making a decision. The property owner’s new woodworking shop extends six feet into the required side-lot setback. Even worse, it blocks the scenic view of the neighbor, who paid a premium for the lot.
“So, whose fault is it that the building was built in the wrong place,” asked the board chairman. “Clearly, it was shown on the approved drawing in the right place.”
“I am still trying to figure it out, “replied the property owner.” I hired the best surveyor in town and one of the best contractors. I know it will cost me over $30,000 to move it over six feet. I paid a premium to make it look good like my house, and I am afraid it will look worse after the move. And I don’t have the $30,000 to move it.”
In rebuttal, the neighbor explained, “right is right.” The building location violated the town’s planning and zoning codes. The correct location had been formally approved by town staff, and there was no relief they could provide because this was clearly wrong. Leaving the building in the wrong place would devalue his property much more than $30,000. If the Board of Adjustment did not uphold the ordinance, he would be the victim of something he had no control over.
Much like the song, “Lookin’ for Love in All the Wrong Places” sung by Johnny Lee; risk management professionals need to ask the question “Are we searching for risk in all the wrong places”? Are risk professionals being deluded or deluding themselves by seeing risk based on media driven analysis; applying outmoded tools, models, etc. that no longer reflect the reality of risk?
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Split And Clamped Mounting Hub For Shaft Attachments. For speedy and easy maintenance it is best to use a clamped hub to mount attachments to shafts when possible. This article presents a conceptual design of a split hub bolted and clamped to a shaft. The required attachment is then mounted to the removable hub.
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In manufacturing environments, especially in high-volume production processes, it is important to ensure the highest Machine availability rate for critical equipment as a crucial factor in achieving the expected output goals. The more the availability value there is, the better the plant’s capacity to achieve production requirements since the time available for each piece of equipment will be maximized.
[Read more…]Are you procrastinating on bringing a goal alive?
If you think dumping a few gallons of water in your oil reservoir would be bad for your rotating equipment, consider the consequences that “striving for perfection” has on your happiness and productivity.
I call it the Prison of Perfection and it’s wicked. It’s where our goals go to die 👿.
A few weeks ago I met with Cesar de Leon who is a pipeline safety expert (http://www.pipelinesafetyconsultant.com) – he worked at the DOT Office of Pipeline Safety for over 23 years and currently resides in Boerne, Texas. Cesar was telling me about legal and technical issues arising in the field of natural gas pipelines from existing regulations… I will discuss these issues in greater details in latter posts. Before getting into current issues, I would like you to read the following guest post from Cesar that provides a brief overview of pipeline integrity management plan.
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How did railroads handle depreciation, repair, and fixed asset life-cycles in the mid 19th Century?
They were experienced in design, construction, project management and business.
They planned for maintenance and for repair.
They knew about wear mechanisms from aggressive operation and thought it was management’s role to contain this.
They shared data and used it. They gathered data from handwritten records, making spreadsheets, graphs, and KPIs by hand.
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The comment is a common one.
“It does not surprise me that they do not want to save $60,000,” quipped the second-in-command of the electrical department. “They are more concerned with being popular and helping their friends.”
“By ‘they,’ I assume you mean the Board and me as the interim Town Manager?” I asked.“Well, not really you, but them – yes,” came a frustrated response.
I decided to move to a more productive line of discussion.
In recent years, “Defect Elimination” has become a hot topic in the reliability world. But what exactly does defect elimination mean? How does it differ from other maintenance practices? Is it more than just a new way to describe planned and predictive maintenance? This article will seek to answer these questions in a very practical manner.
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What’s in a word?
The right word at the right time can make all the difference between a successful negotiation with an amicable agreement and collaborative banter, or a bitter and twisted tête-à-tête with an entrenched stand-off, raised hackles and, at best, fog-horn diplomacy. But what is the ‘right word’; unfortunately, it depends on the time and place and people’s personality but one thing is almost certain, if it begins with “n” it is oftentimes not considered to be right and many consider it to be downright wrong.
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Jim and Richard explore the world of parts, what it takes to keep a proper storeroom, and why forecasting demand is crucial for it.
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