50 Ideas for an Effective Maintenance Program - Reliable Plant
Here are 50 ideas to get you started: Learn the 12 elements of effective reliability management. Be sure your organization understands these important elements and the impact they have on performance – starting at the very top. Without this leadership focus for your maintenance program, nothing else matters.
Maintenance Planning and Scheduling: An Overview - Reliable Plant
Maintenance planning and scheduling are two different functions that, when used together, form a maintenance program. Maintenance planning can be defined as an end-to-end process that identifies and addresses any possible issues ahead of time. This involves identifying the parts and tools necessary for jobs and making sure they're available and ...
Condition-based Maintenance (CBM) Explained - Reliable Plant
The goal of condition-based maintenance is to continuously monitor assets to spot impending bearing failure, so maintenance can be proactively scheduled before the failure occurs. The idea is that this real-time monitoring will give maintenance teams enough lead time before a failure occurs or performance drops below an optimal level.
Mean Time Between Failure (MTBF) Explained | Reliable Plant
MTBF = (12 hours per day x 10 days) / 1 breakdown = 120 hours. The MTBF calculation requires more steps when you have longer periods of time with increasing occurrences of failures. For example, say the bottling machine that operates for 12 hours a day fails twice in 10 days.
Motor Testing: An Overview - Reliable Plant
Motor testing assesses the integrity of a motor through the use of computer-supported equipment or tools that monitor trends within the motor. The main objective of motor testing is to reveal hidden problems and prevent unnecessary failure. Specific to electric motors, motor testing evaluates static parameters like insulation, wire damage and ...
Vibration Analysis Explained - Reliable Plant
Envelope analysis: Envelope analysis is a form of vibration analysis that can detect impacts with very low energy often hidden by other vibration signals. It's a popular diagnostic tool for damaged gear teeth and roller bearings. Orbit: The orbit is defined …
Lockout/Tagout Explained | Reliable Plant
The Occupational Safety and Health Administration (OSHA) defines lockout/tagout (LOTO) as a specific set of practices and procedures to safeguard employees from unexpected energization or startup of machinery and equipment, or the release of hazardous energy during service or maintenance activities. Failure to control hazardous energy (lockout ...
Fishbone Diagram Explained - Reliable Plant
A fishbone diagram is a cause-and-effect discovery tool that helps figure out the reason (s) for defects, variations or failures within a process. In other words, it helps break down, in successive layers, root causes that potentially contribute to an effect. Sometimes called an Ishikawa diagram or cause-and-effect analysis, a fishbone diagram ...
Overall Equipment Effectiveness (OEE): An Overview - Reliable Plant
The quality part of the equation is calculated as: (12,000 - 3,000 defects) / 12,000 = 75 percent Quality. Another way to look at it is 3,000 bottles / 60 bottles per minute = 50 minutes lost quality. So, to calculate the overall equipment effectiveness (Availability x Performance x Quality = OEE), we'd take 62.5 percent x 66.7 percent x 75 ...
Kaizen Explained | Reliable Plant
The word "kaizen" is a Japanese word meaning "change for the better." In English, kaizen translates to "improvement" and encompasses both short- and long-term improvement processes. In lean manufacturing, kaizen refers to brainstorming ideas and implementing daily activities that continuously improve processes.