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reliability engineering for maintenance

RCM vs. FMEA - There Is a Distinct Difference!

RCM and FMEA are tools in Uptime Elements Reliability Strategy Development [RSD] toolbox

by Douglas J. Plucknette, Christopher Mears and Ramesh Gulati

This article seeks to understand the differences and similarities between these two maintenance approaches/strategies and attempts to answer the question of whether RCM or FMEA.

Reliability Engineering for Maintenance

Maximize Intrinsic Reliability Through Focus in Early Project Phases

by Mohammad Naseer Uddin

Inspired by the June 2012 article by Robert DiStefano in Uptime^® magazine on the importance of implementing a reliability program in the early lifecycle of a project, I would like to share a few examples from real-life scenarios. My contention is by having a proper reliability program in place, many of these avoidable defects could have been eliminated during the early phases of the project, thereby delivering higher asset reliability at a lower lifecycle cost (LCC).

reliability engineering for maintenance

Hidden Failure Q&A - Henry Ellmann

Uptime Magazine's Steve Thomas (left) recently caught up with Henry Ellmann (right) to discuss his keynote address at IMC-2012 in Bonita Springs, Florida, December 4-7th.

Reliability Engineering for Maintenance

Improving the Reliability of a Turbofan Jet Engine

By Larry Tyson

Part 1 of this article appeared in the June/July 2011 issue of Uptime Magazine

This is a follow-up article to one published in the June/July 2011 issue of Uptime magazine.¹ Our component of interest was the fuel control (FC), with a failure mode (FM) of "flameout," where one of two engines shut down in flight. This is called in-flight abort (IFA) and has a direct "safety of flight" impact on aircraft and aircraft missions, as well as the crew, and, of course, is a very undesired consequence.

Reliability Engineering for Maintenance

U.S. Navy Analysis of Submarine Maintenance Data and Development of Age and Reliability Profiles

By Timothy M. Allen

ABSTRACT
In 1961a U.S. Government sponsored task force reported its findings on the effect of scheduled maintenance and aircraft reliability. They stated "In the past, a great deal of emphasis has been placed on the control of overhaul periods to provide a satisfactory level of reliability. After careful study, the Committee is convinced that reliability and overhaul time control are not necessarily directly associated topics." Further studies that also supported this precept led to a new discipline known as "Reliability Centered Maintenance". This RCM discussion focuses on one of the principles of RCM - Hardware may wear out or have random failure - Random is more common - and the U.S. Navy's findings in regard to this principle. In 1998 Naval Sea Systems Command activity SUBMEPP (Submarine Maintenance Engineering, Planning and Procurement) developed the capability to generate Age and Reliability curves utilizing maintenance feedback data. This provided the organization a new means to objectively measure the effects of planned maintenance to engineer optimal maintenance plans. After three years of generating Age and Reliability curves, SUBMEPP is ready to report that the 1961 finding still holds true. In the majority of cases, there is no relationship between overhaul time and reliability.

Reliability Engineering for Maintenance

Failure Modes: A Closer Look at Ductile and Brittle Overload Fractures

Follow up to the article, "Preventing Mechanical Failures - An Introduction to Failure Mode Identification" - Feb/March 2012

Thomas Brown

Is an overload fracture ductile or brittle? This question must be answered when analyzing parts. Mitigating factors that can impact the answer to this question should be considered when analyzing a failed component.

Reliability Engineering for Maintenance

The Seven Causes of RCF (Root Cause FAILURE)

An hour long presentation by Shon Isenhour, CMRP, Director of Education, GPAllied

Root Cause Analysis (RCA) can be a very powerful tool for eliminating defects and increasing efficiency and profits. After witnessing hundreds of RCA efforts in every different type of organization and industry vertical, Shon has experienced the good, the bad, and the ugly. Of those, all of the failed efforts have common traits that are preventing the practitioners from getting maximum value from their RCA efforts. During this presentation, Shon will share with you his first-hand case studies of RCA implementations and tips on how to avoid the seven causes of ‘root cause failure'.

Reliability Engineering for Maintenance

Risk Based Inspection (RBI) and Corrosion Mitigation

A forty-five minute long presentation by Richard Taggs, President, TEAM Global

Managers, learn the principles and value of RBI and corrosion mitigation to increase safety, reduce cost, maximize productivity, prevent catastrophic failures, and how to implement effective and flexible risk based inspection schedules. But you won’t be a hero for when there is no disaster, no one knows you, but should there be a disaster?

Reliability Engineering for Maintenance

Uncover the Risks That Can Haunt You

A forty-five minute long presentation by Jeff Shiver CMRP, CPMM – Managing Principal, People and Processes, Inc.

If you count up the number of protective devices in a typical manufacturing facility, it will surprise you to learn that you have lots and lots of them. Now what is scary is that for roughly 33% of these protective devices, you probably were not aware they even existed in the factory. Even scarier is the fact that only approximately 30-40% of all protective devices that we know about are maintained. That said, upwards of 20% are already in the failed state.

With your maintenance strategy, have you covered all the bases? Does your strategy include all of your protective devices and processes to either find them in the act of failing or even once failed to prevent a multiple failure? How do you treat standby or redundant equipment from a strategy perspective? Is the maintenance strategy the same for the duty and redundant equipment?

Join Jeff Shiver for an insightful 45 minute webinar as he uncovers the concepts from the RCM2 world around hidden failures, protective devices, and the associated maintenance strategies necessary for preventing or reducing those failure consequences.

Reliability Engineering for Maintenance

Understanding & Comparing Risk

By Brian Y. Webster

In the Oct/Nov11 edition of Uptime (Risk & Criticality), a concept of risk was introduced that utilized a Euclidean distance of probability and consequence, mathematically written as

Risk2 = Probability2 + Consequence2

The author claimed that "this [method] provides for accurate comparison of relative risk."¹ The purpose of this article is to explain the conflict between traditional risk calculation methods and distance methods, as well as the potential poor business decision that could result from using distance methods. For the purpose of this article, the Euclidean distance for assessing risk as described in the original article will be called the "positional risk."

Reliability Engineering for Maintenance

Preventing Mechanical Failures - An Introduction to Failure Mode Identification

By Thomas Brown

Failure mode identification is often regarded as a specialized skill requiring years of study and training to master. However, it is much like vibration analysis. One does not have to be able to solve mathematics functions like Laplace transforms or Fourier series to be an excellent vibration analyst. Nor does the failure analyst have to solve linear elastic fracture mechanics problems to be effective.

Reliability Engineering for Maintenance

Mitigating Asset Failure Consequences Using Root Cause Analysis

An hour long presentation by Reid Jenner, Managing Director, The Asset Performance Group (APG)

In this webinar, we will outline best practices for determining the root cause and mitigating consequences arising from an asset failure or out-of-tolerance condition within the framework of the PAS 55 specification. This will include discussion on the process steps, critical questions, key involvement and recommended discipline to efficiently and effectively identify the root cause of a defect to correct or improve the condition of failing and failed assets.

Reliability Engineering for Maintenance

Implementing and Sustaining RCM

An hour long presentation by Mike Fess, Application Consultant, Ivara Corporation

Implementing the findings and sustaining the reliability improvements recommended from an RCM analysis is challenging due to many factors including company culture, employee buy-in, skill level and training as well as the shear amount of data to monitor and manage. Many RCM projects result in overly complex processes and poorly integrated systems resulting in increased likelihood of errors as well as inefficiencies. Some projects result in thick binders sitting on shelves for long periods following the analyses or stagnant databases full of reliability program content that are never implemented.

Reliability Engineering for Maintenance

Failure Reporting and Corrective Action - much more than RCA

iPresentation - 1:03:28
By Steve Turner - Director and Mark Liddell - Vice President /Americas, OMCS International

Most organizations conduct problem solving as part of their daily activities. Problems that require solving range in category from personal, technical, logistical, software and the list goes on. They range in complexity too and the solutions may be easy or difficult. They may be costly or cheap.

Reliability Engineering for Maintenance

Keep it Contained: Reducing Risk with Mechanical Integrity

A 45 minute long presentation by Michael Warren, Product Manager – Mechanical Integrity, Meridium

In a comprehensive Asset Performance Management program, people, processes, and technology are all equally important to maximize the value you should expect from your Mechanical Integrity solution in order to improve safety, reliability and environmental compliance in high-risk industrial environments.

Reliability Engineering for Maintenance

Reliable Operation at Start-up

An 45 minute long presentation by Kevin Lewton, Vice President, Met Demand, Inc.

Maintenance and Reliability Best Practices should be implemented from the very first time equipment and processes are commissioned. Learn what best practices will contribute to a vertical start-up.

reliability engineering for maintenance

RCM and FMEA are tools in Uptime Elements Reliability Strategy Development [RSD] toolbox

Maximize Intrinsic Reliability Through Focus in Early Project Phases

Hidden Failure Q&A - Henry Ellmann

Improving the Reliability of a Turbofan Jet Engine

U.S. Navy Analysis of Submarine Maintenance Data - Part 3

U.S. Navy Analysis of Submarine Maintenance Data and Development of Age and Reliability Profiles

U.S. Navy Analysis of Submarine Maintenance Data - Part 2

Failure Modes: A Closer Look at Ductile and Brittle Overload Fractures

The Seven Causes of RCF (Root Cause FAILURE)

Risk Based Inspection (RBI) and Corrosion Mitigation

Uncover the Risks That Can Haunt You

Risk Calculation Methodology

Understanding & Comparing Risk

Preventing Mechanical Failures - An Introduction to Failure Mode Identification

Mitigating Asset Failure Consequences Using Root Cause Analysis

Implementing and Sustaining RCM

Failure Reporting and Corrective Action - much more than RCA

Risk & Criticality: Understanding Potential Failure

Keep it Contained: Reducing Risk with Mechanical Integrity

Reliable Operation at Start-up