The document discusses adopting a defect elimination and condition-based maintenance program to achieve the lowest lifecycle costs. It explains that more than 90% of rotating machinery failures are random and unpredictable without condition monitoring. Defect elimination aims to avoid failures from the design process through operation by eliminating any opportunities for defects. Condition-based maintenance allows potential issues to be detected early through monitoring technologies like vibration analysis and oil testing, providing more time for planning repairs before functional or catastrophic failure.
The 5S system is not just for housekeeping but is a problem prevention and identification system. When something is found out of place, the process should be to repeatedly ask "why" until the root cause is discovered. There should be a strong connection between 5S and asking "why 5 times" (5 whys) to fully understand the root problem. A good 5S program builds a culture of self-discipline where standards are followed and small problems can be identified and addressed before becoming bigger issues. Without a 5S system in place, problems would not be visible until they were large or even dangerous situations.
This document provides tips for companies preparing for their first audit. It recommends performing a mock audit beforehand to identify any issues. It also suggests having all documentation in one organized place, either electronically or in labeled filing cabinets. Companies should designate representatives from each department to quickly provide required documents to auditors, as well as assigning a note-taker. Being prepared and addressing findings as opportunities for improvement can help companies feel confident during the audit process.
Calibration is a comparison between measurements – one of known magnitude or correctness made or set with one device and another measurement made in as similar a way as possible with a second device.
Essence of maint the root cause approachPINAKI ROY
The document discusses maintenance strategies and reliability centered maintenance. It begins by describing traditional planned preventative maintenance based on the bathtub curve assumption that older equipment is more likely to fail. However, research in the aviation industry found that only 11% of failures were actually related to age, while 89% occurred randomly. This led to the development of condition based maintenance, where failures are detected by monitoring measurable parameters that indicate equipment condition change. The document emphasizes that maintenance is an effect, not a cause, and failures can be traced to defects from various life cycle sources like design, manufacturing and installation errors. It promotes analyzing failure causes and effects using tools like fishbone diagrams and failure mode and effects analysis.
Lifetime evaluation vs. measurement. part 4Oleg Ivanov
This document discusses using quantitative methods to evaluate reliability and lifetime from HALT (Highly Accelerated Lifetime Testing) data. It presents a mathematical approach using uncertainty analysis and worst-case evaluation to determine reliability metrics from HALT results. An example is shown applying this method using the Life Cycle Simulator software, finding the optimal testing time and number of samples to minimize expected life cycle costs given uncertainty in the product's lifetime distribution.
- The document discusses maximizing uptime in mission critical facilities through predictive analysis and reliability centered maintenance (RCM).
- Key factors that impact uptime are reliability, availability, maintainability, predictability, and scalability (RAMPS).
- To implement an effective RCM program, facilities must collect comprehensive operational data from design through commissioning and ongoing maintenance to predict and prevent future equipment failures.
- Integrating startup and commissioning data into ongoing maintenance is critical for understanding past performance issues and developing an accurate predictive model.
The document discusses key terms related to reliability and safety of equipment and systems. It defines reliability as the probability an item will perform its required function for a stated period of time. Mean time between failures (MTBF) is commonly used to express overall reliability and refers to the average operating time between failures. Availability takes repair time into account and is the proportion of time equipment is able to perform its function. Safety integrity level (SIL) describes the degree of safety protection needed by a process but does not guarantee quality or reliability beyond the safety context.
This document discusses calibration of equipment and instruments. It explains that calibration is important to verify that instruments are still operating within their specifications over time. Calibration involves measuring the actual performance of an instrument using external lab standards that are traceable to international standards. It also discusses the need to calibrate instruments to ensure quality, validate manufacturing processes, and ensure military equipment functions properly.
The 5S system is not just for housekeeping but is a problem prevention and identification system. When something is found out of place, the process should be to repeatedly ask "why" until the root cause is discovered. There should be a strong connection between 5S and asking "why 5 times" (5 whys) to fully understand the root problem. A good 5S program builds a culture of self-discipline where standards are followed and small problems can be identified and addressed before becoming bigger issues. Without a 5S system in place, problems would not be visible until they were large or even dangerous situations.
This document provides tips for companies preparing for their first audit. It recommends performing a mock audit beforehand to identify any issues. It also suggests having all documentation in one organized place, either electronically or in labeled filing cabinets. Companies should designate representatives from each department to quickly provide required documents to auditors, as well as assigning a note-taker. Being prepared and addressing findings as opportunities for improvement can help companies feel confident during the audit process.
Calibration is a comparison between measurements – one of known magnitude or correctness made or set with one device and another measurement made in as similar a way as possible with a second device.
Essence of maint the root cause approachPINAKI ROY
The document discusses maintenance strategies and reliability centered maintenance. It begins by describing traditional planned preventative maintenance based on the bathtub curve assumption that older equipment is more likely to fail. However, research in the aviation industry found that only 11% of failures were actually related to age, while 89% occurred randomly. This led to the development of condition based maintenance, where failures are detected by monitoring measurable parameters that indicate equipment condition change. The document emphasizes that maintenance is an effect, not a cause, and failures can be traced to defects from various life cycle sources like design, manufacturing and installation errors. It promotes analyzing failure causes and effects using tools like fishbone diagrams and failure mode and effects analysis.
Lifetime evaluation vs. measurement. part 4Oleg Ivanov
This document discusses using quantitative methods to evaluate reliability and lifetime from HALT (Highly Accelerated Lifetime Testing) data. It presents a mathematical approach using uncertainty analysis and worst-case evaluation to determine reliability metrics from HALT results. An example is shown applying this method using the Life Cycle Simulator software, finding the optimal testing time and number of samples to minimize expected life cycle costs given uncertainty in the product's lifetime distribution.
- The document discusses maximizing uptime in mission critical facilities through predictive analysis and reliability centered maintenance (RCM).
- Key factors that impact uptime are reliability, availability, maintainability, predictability, and scalability (RAMPS).
- To implement an effective RCM program, facilities must collect comprehensive operational data from design through commissioning and ongoing maintenance to predict and prevent future equipment failures.
- Integrating startup and commissioning data into ongoing maintenance is critical for understanding past performance issues and developing an accurate predictive model.
The document discusses key terms related to reliability and safety of equipment and systems. It defines reliability as the probability an item will perform its required function for a stated period of time. Mean time between failures (MTBF) is commonly used to express overall reliability and refers to the average operating time between failures. Availability takes repair time into account and is the proportion of time equipment is able to perform its function. Safety integrity level (SIL) describes the degree of safety protection needed by a process but does not guarantee quality or reliability beyond the safety context.
This document discusses calibration of equipment and instruments. It explains that calibration is important to verify that instruments are still operating within their specifications over time. Calibration involves measuring the actual performance of an instrument using external lab standards that are traceable to international standards. It also discusses the need to calibrate instruments to ensure quality, validate manufacturing processes, and ensure military equipment functions properly.
This document discusses preventive maintenance programs and how they can be improved. It suggests that many programs are flawed because they rely on time-based tasks rather than identifying potential issues. Drivers should perform thorough pre- and post-trip inspections to find defects early. Additionally, preventive maintenance should focus on preventing breakdowns rather than just fixing current issues. Predictive maintenance uses fleet data to identify trends and predict failures so repairs can be done proactively.
This document discusses the concept of "Jishu Hozen" or autonomous maintenance in TPM. It explains that the goal of Jishu Hozen is to improve operators' ability to identify abnormalities before they cause defects, breakdowns or accidents. It does this by developing their capability to detect issues at microscopic levels through a seven step approach. This increases inspection accuracy and establishes a culture of continuously monitoring equipment to maintain basic working conditions. Jishu Hozen is described as the "power" in TPM that enables sustainability of improvements from other pillars by catching issues early and eliminating root causes.
With the economy as it has been for the past decade it is important to understand how we all can make the bottom line better and maintain our equipment more efficient. This book is not in any way designed to be the end all to your maintenance problems, but rather a guide to help understand the importance of empowering your mechanics so they will be able to improve the work they do. The better they are at what they do, the better they will be to reducing maintenance costs.
10 Things an Operations Supervisor can do Today to Improve ReliabilityRicky Smith CMRP, CMRT
Continuing the series that started with maintenance technicians and supervisors, if you are new to the position of Operations Supervisor, what are some of the things you can begin working on immediately to improve reliability within the area you work?
The document identifies various risks that could occur during a photo shoot for a magazine and strategies to prevent or overcome them. It discusses risks such as illness/injury of the model, memory cards becoming full, low battery, broken equipment, the model not meeting expectations, issues with lighting, props, electrical equipment, software problems, and not following magazine conventions. For each risk, it identifies that the photographer is responsible and describes strategies like having backup plans, testing equipment beforehand, bringing extra supplies, using photo editing software to fix issues, and regularly saving work.
Wait A Moment? How High Workload Kills Efficiency! - Roman PicklPROIDEA
Join me in this talk about why high workload leads to increasing waiting times and is detrimental to your project’s efficiency. We will not only talk about queueing theory and capacity management, but also about strategies to cope with high utilization and how to start a virtuous circle.
Preventive maintenance programs that rely solely on time-based tasks are often ineffective and result in high equipment failure rates. Research shows over 80% of failures are not related to age or use. To improve reliability, the author migrated to a proactive approach focusing on asset health monitoring to determine maintenance needs. This approach identifies specific failure modes and uses predictive technologies to catch issues early. The result is significantly reduced failures and improved reliability, availability, and cost savings. Sharing successes from pilot programs encourages management support to roll out the approach for all critical assets.
The document discusses using mathematical modeling and sensitivity analysis to troubleshoot product design issues. It describes how sensitivity analysis can help identify which design aspects most impact performance when physical testing all design variations is impractical. It provides an example of using these methods to investigate failures in an auto-injector device late in production. Combining mathematical modeling, finite element analysis, and Taguchi experimental design principles allowed efficiently conducting a sensitivity analysis to determine potential causes and solutions.
Most companies don’t measure mean time between failures (MTBF), even though it’s the most basic measurement that quantifies reliability. MTBF is the average time an asset functions before it fails. So, why don’t they measure MTBF? Let’s define reliability first before we go any further.
Reliability: The ability of an item to perform a required function under stated conditions for a stated period of time
So why don’t we measure Mean Time Between Failure. This articles discusses this issue.
The document discusses the importance of thoroughly testing machines before they are used for production. It notes that vendors may not adequately test custom machines, leaving companies to find problems once the machine is in use. It recommends asking vendors three key questions to ensure a machine has been properly tested: 1) Do they have a documented risk assessment process? 2) Do they have a documented testing process? 3) Do they have a documented and systematic project management process? Thorough testing through documented processes for risk assessment, testing, and project management can help minimize potential issues once a machine is installed for production use.
Many companies limit the adjustments that technicians can make to the tablet press during a production run, even though such adjustments are a normal part of tabletting. This article discusses what adjustments may be necessary and encourages manufacturing managers to support their tablet technicians.
This white paper discusses the importance of procedure based maintenance in facilities. It argues that relying only on the skills and experience of maintenance staff can lead to failures and inconsistencies. Effective, repeatable procedures are needed to ensure safety, reliability, and sustainable results. The paper recommends making staff aware of issues, training them on procedures, implementing procedures, continuously improving, and monitoring results. Procedure based maintenance can help reduce variation and human error.
“My maintenance staff is highly trained and do not like using procedures.” If the statement is valid, and the cost of asset failure is not important to our operation, then your staff must have an unlimited and infallible memory – congratulations!
Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
If safety is number one in your organization, then repeatable, effective work procedures should be as well.
This document provides tips for becoming an elite flood adjuster. It discusses the importance of ongoing training, soft skills like listening and professionalism, attention to detail when completing reports and estimates, using proper equipment like cameras and measuring devices, and efficiency by establishing workflows and addressing issues quickly. The overall message is that striving for accuracy and continuous self-improvement can help adjusters rise to elite status and preferred assignments.
This document provides tips for becoming an elite flood adjuster. It discusses the importance of training, soft skills, attention to detail, proper equipment, and efficiency. It recommends taking certification courses annually and using online training resources to stay up-to-date on coverages and best practices. Soft skills like listening to insureds and addressing their concerns are emphasized. The document stresses proofreading reports to avoid mistakes that waste time and damage credibility with examiners. Having the right equipment like quality cameras and measuring devices can improve efficiency and the claims presentation. Striving for continuous improvement and not repeating mistakes is key to achieving elite status.
Debugging Intermittent Issues - A How ToLloydMoore
Debugging intermittent issues present a unique set of challenges and requirements to the developer. Of particular interest is question “did this fix actually solve the problem, or am I just getting lucky today?” This talk will show you how to determine, with some level of confidence, if the issue is really solved or just not showing up. In addition issues which only show up rarely have a habit of accumulating until some issue seems to be happening all the time. Techniques for untangling the interaction of multiple issues will be discussed.
This document provides guidance on selecting the right treadmill by considering features like programming options, safety features, user profiles, heart rate monitoring, convenience, interval training, fitness tests, durability, warranty, and service support. Key factors include preset and custom programs to keep workouts fresh, security features for safe operation, storing user profiles to track progress over time, heart rate control for effective workouts, and a lifetime frame warranty along with service support from the seller. Choosing a treadmill with these elements can help buyers find a durable machine that keeps them motivated to exercise regularly.
This handbook is written to show how greater control can be gained over total product reliability by the utilization of Accelerated Stress Testing techniques (AST)
This document outlines common mistakes made by new performance test engineers. It discusses 6 main mistakes: 1) only checking HTTP status codes without validating transactions, 2) using improper think and pause times, 3) prematurely identifying bottlenecks without root cause analysis, 4) making false assumptions during tests, 5) attempting analysis before tests complete, and 6) getting stuck on anomalies that don't reproduce by only running tests once. The document emphasizes the importance of validation, realistic timing, methodical testing, letting tests complete before analysis, and running tests multiple times to avoid non-reproducible issues.
Maintcon 2018 - Deepak Sahoo, CEO - Arrelic PresentationArrelic
The document discusses how machine learning, artificial intelligence, and the industrial internet of things will change operations and maintenance practices in manufacturing. It outlines how integrating sensors, data collection, analytics, and machine learning can enable remote monitoring, real-time optimization, continuous improvement, and predictive maintenance to improve operations. The integration of these technologies is poised to disrupt industries and drive business transformation.
isk-Based Inspection (RBI) is a systematic approach that enables users to make informed business decisions regarding inspection and maintenance expenditure. It identifies, assesses and maps industrial risks (due to corrosion and stress cracking), which can compromise equipment integrity in both pressurized equipment and structural elements.
RBI combines the principles of risk with operational experience to obtain a safe and cost effective inspection program targeting inspection where and when it is needed. Also addresses risks that can be controlled through proper inspections and analysis.
This document discusses preventive maintenance programs and how they can be improved. It suggests that many programs are flawed because they rely on time-based tasks rather than identifying potential issues. Drivers should perform thorough pre- and post-trip inspections to find defects early. Additionally, preventive maintenance should focus on preventing breakdowns rather than just fixing current issues. Predictive maintenance uses fleet data to identify trends and predict failures so repairs can be done proactively.
This document discusses the concept of "Jishu Hozen" or autonomous maintenance in TPM. It explains that the goal of Jishu Hozen is to improve operators' ability to identify abnormalities before they cause defects, breakdowns or accidents. It does this by developing their capability to detect issues at microscopic levels through a seven step approach. This increases inspection accuracy and establishes a culture of continuously monitoring equipment to maintain basic working conditions. Jishu Hozen is described as the "power" in TPM that enables sustainability of improvements from other pillars by catching issues early and eliminating root causes.
With the economy as it has been for the past decade it is important to understand how we all can make the bottom line better and maintain our equipment more efficient. This book is not in any way designed to be the end all to your maintenance problems, but rather a guide to help understand the importance of empowering your mechanics so they will be able to improve the work they do. The better they are at what they do, the better they will be to reducing maintenance costs.
10 Things an Operations Supervisor can do Today to Improve ReliabilityRicky Smith CMRP, CMRT
Continuing the series that started with maintenance technicians and supervisors, if you are new to the position of Operations Supervisor, what are some of the things you can begin working on immediately to improve reliability within the area you work?
The document identifies various risks that could occur during a photo shoot for a magazine and strategies to prevent or overcome them. It discusses risks such as illness/injury of the model, memory cards becoming full, low battery, broken equipment, the model not meeting expectations, issues with lighting, props, electrical equipment, software problems, and not following magazine conventions. For each risk, it identifies that the photographer is responsible and describes strategies like having backup plans, testing equipment beforehand, bringing extra supplies, using photo editing software to fix issues, and regularly saving work.
Wait A Moment? How High Workload Kills Efficiency! - Roman PicklPROIDEA
Join me in this talk about why high workload leads to increasing waiting times and is detrimental to your project’s efficiency. We will not only talk about queueing theory and capacity management, but also about strategies to cope with high utilization and how to start a virtuous circle.
Preventive maintenance programs that rely solely on time-based tasks are often ineffective and result in high equipment failure rates. Research shows over 80% of failures are not related to age or use. To improve reliability, the author migrated to a proactive approach focusing on asset health monitoring to determine maintenance needs. This approach identifies specific failure modes and uses predictive technologies to catch issues early. The result is significantly reduced failures and improved reliability, availability, and cost savings. Sharing successes from pilot programs encourages management support to roll out the approach for all critical assets.
The document discusses using mathematical modeling and sensitivity analysis to troubleshoot product design issues. It describes how sensitivity analysis can help identify which design aspects most impact performance when physical testing all design variations is impractical. It provides an example of using these methods to investigate failures in an auto-injector device late in production. Combining mathematical modeling, finite element analysis, and Taguchi experimental design principles allowed efficiently conducting a sensitivity analysis to determine potential causes and solutions.
Most companies don’t measure mean time between failures (MTBF), even though it’s the most basic measurement that quantifies reliability. MTBF is the average time an asset functions before it fails. So, why don’t they measure MTBF? Let’s define reliability first before we go any further.
Reliability: The ability of an item to perform a required function under stated conditions for a stated period of time
So why don’t we measure Mean Time Between Failure. This articles discusses this issue.
The document discusses the importance of thoroughly testing machines before they are used for production. It notes that vendors may not adequately test custom machines, leaving companies to find problems once the machine is in use. It recommends asking vendors three key questions to ensure a machine has been properly tested: 1) Do they have a documented risk assessment process? 2) Do they have a documented testing process? 3) Do they have a documented and systematic project management process? Thorough testing through documented processes for risk assessment, testing, and project management can help minimize potential issues once a machine is installed for production use.
Many companies limit the adjustments that technicians can make to the tablet press during a production run, even though such adjustments are a normal part of tabletting. This article discusses what adjustments may be necessary and encourages manufacturing managers to support their tablet technicians.
This white paper discusses the importance of procedure based maintenance in facilities. It argues that relying only on the skills and experience of maintenance staff can lead to failures and inconsistencies. Effective, repeatable procedures are needed to ensure safety, reliability, and sustainable results. The paper recommends making staff aware of issues, training them on procedures, implementing procedures, continuously improving, and monitoring results. Procedure based maintenance can help reduce variation and human error.
“My maintenance staff is highly trained and do not like using procedures.” If the statement is valid, and the cost of asset failure is not important to our operation, then your staff must have an unlimited and infallible memory – congratulations!
Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
If safety is number one in your organization, then repeatable, effective work procedures should be as well.
This document provides tips for becoming an elite flood adjuster. It discusses the importance of ongoing training, soft skills like listening and professionalism, attention to detail when completing reports and estimates, using proper equipment like cameras and measuring devices, and efficiency by establishing workflows and addressing issues quickly. The overall message is that striving for accuracy and continuous self-improvement can help adjusters rise to elite status and preferred assignments.
This document provides tips for becoming an elite flood adjuster. It discusses the importance of training, soft skills, attention to detail, proper equipment, and efficiency. It recommends taking certification courses annually and using online training resources to stay up-to-date on coverages and best practices. Soft skills like listening to insureds and addressing their concerns are emphasized. The document stresses proofreading reports to avoid mistakes that waste time and damage credibility with examiners. Having the right equipment like quality cameras and measuring devices can improve efficiency and the claims presentation. Striving for continuous improvement and not repeating mistakes is key to achieving elite status.
Debugging Intermittent Issues - A How ToLloydMoore
Debugging intermittent issues present a unique set of challenges and requirements to the developer. Of particular interest is question “did this fix actually solve the problem, or am I just getting lucky today?” This talk will show you how to determine, with some level of confidence, if the issue is really solved or just not showing up. In addition issues which only show up rarely have a habit of accumulating until some issue seems to be happening all the time. Techniques for untangling the interaction of multiple issues will be discussed.
This document provides guidance on selecting the right treadmill by considering features like programming options, safety features, user profiles, heart rate monitoring, convenience, interval training, fitness tests, durability, warranty, and service support. Key factors include preset and custom programs to keep workouts fresh, security features for safe operation, storing user profiles to track progress over time, heart rate control for effective workouts, and a lifetime frame warranty along with service support from the seller. Choosing a treadmill with these elements can help buyers find a durable machine that keeps them motivated to exercise regularly.
This handbook is written to show how greater control can be gained over total product reliability by the utilization of Accelerated Stress Testing techniques (AST)
This document outlines common mistakes made by new performance test engineers. It discusses 6 main mistakes: 1) only checking HTTP status codes without validating transactions, 2) using improper think and pause times, 3) prematurely identifying bottlenecks without root cause analysis, 4) making false assumptions during tests, 5) attempting analysis before tests complete, and 6) getting stuck on anomalies that don't reproduce by only running tests once. The document emphasizes the importance of validation, realistic timing, methodical testing, letting tests complete before analysis, and running tests multiple times to avoid non-reproducible issues.
Maintcon 2018 - Deepak Sahoo, CEO - Arrelic PresentationArrelic
The document discusses how machine learning, artificial intelligence, and the industrial internet of things will change operations and maintenance practices in manufacturing. It outlines how integrating sensors, data collection, analytics, and machine learning can enable remote monitoring, real-time optimization, continuous improvement, and predictive maintenance to improve operations. The integration of these technologies is poised to disrupt industries and drive business transformation.
isk-Based Inspection (RBI) is a systematic approach that enables users to make informed business decisions regarding inspection and maintenance expenditure. It identifies, assesses and maps industrial risks (due to corrosion and stress cracking), which can compromise equipment integrity in both pressurized equipment and structural elements.
RBI combines the principles of risk with operational experience to obtain a safe and cost effective inspection program targeting inspection where and when it is needed. Also addresses risks that can be controlled through proper inspections and analysis.
Arrelic is a fast-growing deep technology firm aiming to bring the next level of IoT based sensor technology to transform the mode of manufacturing operation and maintenance practice of various industries with extensive expertise in Reliability Engineering, Predictive Maintenance, Industrial Internet of Things (IIoT) Sensors, Machine Learning and Artificial Intelligence.
We provide a single ecosystem for catering all industry needs from Consulting to IoT and Analytics as well as providing Training and Development courses for different stakeholders.
We aim to help manufacturing industries to improve their overall plant productivity, reliability and minimize total production cost by 25-30% by eliminating machine downtime, lightening management decisions by analyzing the machine data with right mind and expertise; for a worry free operation.
Expert and well informed in Ferro-alloys industry Building a program that is most financial viable and long term sustainable
Single point contact for building strategy and providing solutions
Over 15+ years of combined experience Bringing the best practices from 16 industries and 5 continents
ARLYTIC™ is a big data based multi-connected IoT analytics platform offers unprecedented advantages for machine manufactures as well as the plant managers who are end-users of the machines to avoid machine downtime through analysing the sensors data.
ARLYTIC™ relies on collecting data on the edge to uncover actionable insights, using the right tools and techniques, at the right time, to help a organization achieve its most desired business outcomes.
Asset Performance Management (APM) is a methodology that focuses on maximizing asset performance, optimizing operation and maintenance costs, and mitigating asset failure risks. It ensures efficient asset lifecycle decision-making to optimize value. APM helps achieve goals like improved safety, compliance, and profitability. Arrelic is a firm that provides APM consulting, analytics platforms, IoT solutions, and training to help clients improve plant productivity, reliability, and reduce costs by 25-30% through eliminating downtime and optimizing asset maintenance.
Preventive Maintenance (PM) Optimization increases equipment reliability by uniquely identifying potential gaps in PM performance and frequencies. The process lowers overall facility maintenance costs by comparing site PMs to industry best practices.
Arrelic end-to-end Reliability Management allows you to;
Identify and rectify equipment problems before they happen, Reduce maintenance costs and unplanned downtime.
RCM is used to develop scheduled maintenance plans in an efficient and cost-effective manner that will provide an acceptable level of operability and risk. It focuses on processes and systems to reduce the overall cost to maintain and operate assets. Arrelic Consulting assists industries in integrating assets and increasing return on investment by enhanced asset performance and reliability.
Maintenance strategy development and optimisation through Critical Asset Ranking, RCM Approach and cost benefit analysis ensures you the best maintenance plan.
rrelic has developed a highly effective Total Reliability Framework for the implementation of reliability methods, tools and services in order to achieve your desired end results.
Total reliability Framework (TRF) Provides a management system for all reliability and Maintenance activities; focus on improving the performance of both the personnel and the plant equipment.
Arrelic is a predictive analytics startup firm that helps manufacturing industries improve plant productivity, reliability, and reduce costs through approaches like predictive maintenance. It offers predictive analytics services using tools like vibration analysis and infrared thermography. Arrelic also provides consulting services in reliability engineering, asset management, and training to optimize asset performance. Its goal is to create a world-class team through graduate programs, experience transfers, and talent development.
This document discusses lean manufacturing and Industry 4.0. It summarizes lean manufacturing in 10 dimensions grouped into 4 factors related to suppliers, customers, processes, and control/human factors. Industry 4.0 uses cyber-physical systems and internet technologies to enable mass customization. The document examines how Industry 4.0 technologies can enable each of the 10 lean manufacturing dimensions by facilitating real-time communication and data sharing across the value chain. It provides an overview of Arrelic, an IoT and analytics company that aims to help manufacturers improve productivity and reliability through predictive maintenance and machine learning techniques.
Benchmarking is the process of measuring products, services, and processes against those of organizations known to be leaders in one or more aspects of their operations.
It is a way of discovering what is the best performance being achieved – whether in a particular company, by a competitor or by an entirely different industry. This information can then be used to identify gaps in an organization’s processes in order to achieve a competitive advantage.
Benchmarking can help you identify areas, systems, or processes for improvements—either incremental improvements or dramatic improvements.
Total Quality Management (TQM) | Arrelic InsightsArrelic
Total quality management is a management system for a customer focused organization that involves all employee in continual improvement of all aspects of the organization. TQM uses strategy, data, and effective communication to integrate the quality principles into the culture and activities of the organization.
Dust collection systems are widely used in mineral processing plants to control dust and lower worker exposure. Local exhaust ventilation systems (LEVs) are commonly used to capture dust at the source through ductwork and transport it to filtering devices. This prevents dust from contaminating the plant atmosphere and workers. LEV systems use negative pressure to capture dust before it escapes processing operations. Key areas that generate dust include transfer points, specific processes like crushing and drying, operations with air displacement, and outdoor stockpiles disturbed by mining activities.
5S is a workplace organization method that consists of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke. The steps are: 1) sort, 2) straighten, 3) shine, 4) standardize, and 5) sustain. 5S aims to establish order and discipline in the workplace through visual controls and labels to reduce waste and improve safety, quality and efficiency. Implementing 5S provides benefits like increased productivity, improved safety and quality, and reduced costs through waste elimination.
Motor Current Signature Analysis (MCSA) | Arrelic InsightsArrelic
Motor-current signature analysis (MCSA) is a non-destructive technique that analyzes current waveforms to detect mechanical and electrical problems in motors and other electric equipment. It can identify issues like rotor bar faults, stator faults, and phase imbalances. MCSA involves measuring current and voltage remotely using transformers, then processing the data with fast Fourier transforms to obtain a baseline and detect faults by comparing to the baseline. It has applications for diagnosing problems in motors, motor-operated valves, solenoid valves, and other machines.
5S is a methodology for organizing the workplace to improve safety and efficiency. It involves five Japanese words that start with S: seiri (sort), seiton (set in order), seiso (shine), seiketsu (standardize), and shitsuke (sustain). Implementing 5S helps eliminate waste, increase productivity, improve safety, and engage employees. It is a low-cost method that is the foundation for continuous improvement programs like lean manufacturing and total productive maintenance.
Asset integrity management (AIM) ensures that assets perform their planned functions successfully and productively throughout their lifecycles. AIM programs aim to anticipate safety issues and minimize risks of failure for critical infrastructure. Effective AIM considers risks at all stages from design to decommissioning. While some risks can never be eliminated, systematic risk management can significantly reduce likelihood and impacts of failures.
The document discusses various root cause analysis tools including 5-Why analysis, thought mapping, process mapping, cause-and-effect matrices, FMEA, process behavior charts, and data mining. 5-Why analysis involves repeatedly asking "why" to identify the root causes, while thought mapping explores multiple influences without assuming a single cause. Process mapping catalogs variables and process behavior charts detect shifts or outliers in process data. Combined, these tools provide thorough root cause identification and analysis.
Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapte...University of Maribor
Slides from talk presenting:
Aleš Zamuda: Presentation of IEEE Slovenia CIS (Computational Intelligence Society) Chapter and Networking.
Presentation at IcETRAN 2024 session:
"Inter-Society Networking Panel GRSS/MTT-S/CIS
Panel Session: Promoting Connection and Cooperation"
IEEE Slovenia GRSS
IEEE Serbia and Montenegro MTT-S
IEEE Slovenia CIS
11TH INTERNATIONAL CONFERENCE ON ELECTRICAL, ELECTRONIC AND COMPUTING ENGINEERING
3-6 June 2024, Niš, Serbia
A review on techniques and modelling methodologies used for checking electrom...nooriasukmaningtyas
The proper function of the integrated circuit (IC) in an inhibiting electromagnetic environment has always been a serious concern throughout the decades of revolution in the world of electronics, from disjunct devices to today’s integrated circuit technology, where billions of transistors are combined on a single chip. The automotive industry and smart vehicles in particular, are confronting design issues such as being prone to electromagnetic interference (EMI). Electronic control devices calculate incorrect outputs because of EMI and sensors give misleading values which can prove fatal in case of automotives. In this paper, the authors have non exhaustively tried to review research work concerned with the investigation of EMI in ICs and prediction of this EMI using various modelling methodologies and measurement setups.
Harnessing WebAssembly for Real-time Stateless Streaming PipelinesChristina Lin
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Defect Elimination | Arrelic Insights
1. DEFECT ELIMINATION
A R R E L I C I N S I G H T S
Adopting defect elimination
In this article, we are going to discuss
on adopting a defect elimination and
condition-based maintenance program
to achieve the lowest lifecycle costs.
We will start with an overview of the
maintenance practices and then take a
quick look at the predictability of the
failure of rotating machinery if we
know how they fail we can better
choose the most appropriate
maintenance strategy and understand
how to avoid failure then we will take a
more detailed look at defect elimination
doing everything possible to avoid
failure from the design and procurement
process all the way through to the
operation of the machine and adding
QA and QC checks and condition
monitoring and finally we will propose
a roadmap to reliability the steps you
can take to implement a successful
reliability improvement program in your
plants but first we're going to look at
maintenance practices we all know that
machines are going to fail at some point
hopefully we'll get lots of life out of a
machine but we do have to deal with the
fact that they may fail so what can we
do about it the first and easiest is
reactive maintenance or runs a
failure maintenance and that can be a very
costly and unsafe strategy but if you have
an asset criticality ranking you will
determine that some machines should be
maintained in that way in other words let
them fail because it is not economically
justifiable to do anything to avoid the
failure sure if you hear them making a
strange sound you can stop the machine but
performing any predictive maintenance or
anything else really isn't necessary the
next alternative is to use preventive
maintenance performing maintenance
actions to prevent some the component
from failing so taking pre-emptive action
so for example we can have a shutdown we
can replace bearings seals and other
components and perform other intrusive
work and inspections with the idea that we
will not allow the machines to fail in
between time and we will breathe new life
into the machine. Unfortunately, in many
cases we do quite the opposite the machine
might have been in very good condition we
open it, make a change and we introduce a
problem so that introduces predictive
maintenance or condition-based
maintenance the idea is we will take
measurements on the machines and perform
small tests to determine what the current
condition of that machine or acid is and if
we use those technologies properly we can
2. learn potentially months in advance if
there's going to be a problem and that
it may fail and with that information
we can then look at our maintenance
strategy and our maintenance schedule
I should say and demands on
production and the availability of
parts and all those sorts of things to
determine when is the best time to
perform that maintenance and we'll
explore that in a little more detail in a
moment when we look at the
predictability of failure but so far in
particular with reactive maintenance
and predictive maintenance all we are
doing is reacting to problems that
come up sure with predictive
maintenance we'll perform tests and
get a heads up and take the
appropriate action but often we're
reacting to problems that should never
exist and that's where we introduce
precision maintenance. Now we are
going to change the way we work with
the machines so whether it's installing
the bearings, performing lubrication,
doing our alignment and balancing
performing steps that are likely door
that will increase the life on that
machine we will improve the
reliability of the machine because we
avoid introducing the sorts of
problems that cause the machine to
fail and if we take that to the all from
a degree we have defect elimination
defect elimination is is a case of
standing back and saying what
happens through the entire life of
"More maintenance is not
the answer—it only adds
more expense without the
benefit of defect
elimination."
the asset from the time it's on the
drawing board and it goes
through the procurement process
and the transportation the
storage the installation and the
operation of that asset and we
could go all the way through to
the disposal of the asset but from
a defect elimination point of
view we are looking at every
single opportunity there is to
introduce a defect which will
result in premature failure and
doing everything possible to
eliminate those defects and that
is the way to achieve the highest
level of reliability. So how do
we make these stratergies work
and particularly how do we make
defect elimination work so what
is it we know about the failure
modes of rotating machinery if I
was to ask you how long the
bearings normally last and when
do they fail commonly it's
believed that you will get a
certain life out of a bearing that
is fairly predictable and then it
will fail and if we took 30
bearings from different
applications and so on but if
they're all properly specified for
those applications then you
might expect that they will all
fail at around the same sort of
time so if we were planning our
maintenance action and this is
really what this yellow
PAGE 2
3. bar you know at what point do we perform our maintenance
action. You know preventative maintenance replacing the
bearing, for example, well what we want to do is to do it as
late as possible so that we don't have any failures you know
if we leave it any longer then that one's going to fail. So we
just need to come up with a with a period of months that if
we replace those bearings then we restart its life if you well
that would be fantastic if only it were true in actual studies
from plants and just in laboratory with bearings being run
under a certain load and set of conditions the response ISM
more like this it's very random. What we mean, is these are
actual test results so you can see that some did not last very
long and others lasted for a long time. So if we make that
same assessment as far as when is the appropriate time to
perform preventive maintenance replace the bearing
regardless of its actual condition just based on its perceived
condition we've got a problem here, because you know if we
chose this particular interval then we see we still get
failures we catch some just at the right time and others we
waste because these bearings would have lasted a lot longer
we would have achieved a much longer life from those
bearings. But we pulled the mouth and replace them and
when we did that we might have introduced problems such
that now they don't take very long to fail at all so that's the
reality of the situation. Particularly in a plant that hasn't
really taken a good hard look at how they can improve
reliability and eliminate these sources of defects and look
there are lots of studies and it's not the real point of this
article but the studies indicated that approximately 90% of
your rotating machinery will have random failures we
cannot predict without using condition monitoring
technologies. What the life will be there may be an infant
mortality period but then at some point it's going to fail
during its lifetime it could be ten weeks, it could be ten
years some we have this running sort of process with the
infant mortality. In other cases that's just random all the
way through in other cases, we may have a period where
there is less likelihood of failure but that's 90% now made
very slightly in your particular industry but that's what
you've got to keep in mind. That's why just using preventive
maintenance is not the solution the other thing we have to
keep in mind is the way rotating machinery fail and what
sort of notice they provide to us so in this case we're
looking at a graph which is you know time along here you
know months passing by and the condition so while it's up
high it's indicating that the condition is good we can keep
operating that machine.
So if we live our little animation go along we can see its
defect-free it's running along and it's reliable and we get in
good trouble-free life and obviously, we want that to happen
for as long as possible. But at some point in time the defect
is initiated and that could be because the machine was not
lubricated properly operated properly an original
installation problem resulted in this problem there was
misalignment there was unbalance there are so many
reasons why bearings fail and therefore the defect might be
introduced at any time anywhere along its life so we get to
the point in time where something is causing it to begin to
fail and for a certain period.
P A G E 3
Defect Elimination
4. The problem hasn't degraded that much that the
condition has really suffered but we get to a point
in time that you know in the text we call the
potential failure from now on the fact that the
defect has been initiated it will be detectable. So if
we keep watching what's going to happen is with
the passage of time the conditions going to get
worse and worse and worse so the conditions
getting worse it's coming down off the y-axis. But
at certain times certain condition monitoring
techniques will enable us to detect the problem but
what you can see there is that as it moves closer
and closer to its ultimate catastrophic failure there
is a time perhaps before the ultimate catastrophic
failure where we can say that it is functionally
failed it's no longer doing the job that we know
purchased and installed that machine to do it may
not be producing the proper head if it's a pump it
may be making a noise which means we have to
stop it you know for some reason we can no longer
use the machine so we have this period of time
between the potential failure where afterwards we
could detect that there's a problem and the
functional failure you know at that point we don't
want to use the machine any longer. So the
question is you know how long is that interval and
if it's a good healthy interval of a matter of months
then we can use technologies and we've indicated
some of them there that will indicate to us that the
problem exists so what we want to do though is
detect it as early as possible. The earlier we detect
it the more time we have for planning the lower
the risk and the lower the cost associated with the
repair. But the longer we leave it and you can see
the different technologies now very generously
showed that this ultrasound might pick it up you
know in this is a lubrication problem vibration
detected might detect it at a certain point may be
the same point we use oil analysis and these
various technologies we don't need to go into in
much detail. But the longer we leave it the later
we detect it and the later we act the risk goes up
the cost goes up the planning time goes down and
the situation becomes more and more sort of
urgent and reactive until the point where you know
it failed and you know the costs are obviously
much greater at that time. So that's the thing to
keep in mind failures are random but in the vast
majority of cases with rotating machinery, we can
predict it so the aim is to consider this factor.
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