Improving Safety: 10 Tips, Tricks, Rules and Suggestions

According to the U.S. Bureau of Labor Statistics, workers sustained a collective 2.9 million workplace injuries and illnesses in 2015, and nearly 5,000 workers were killed on the job—an average of 13 employees every day.

As employers try to curtail those shocking numbers and improve safety throughout their facility, it’s important to examine the relationship between a safer workplace and ensuring uptime, reliability and quality asset performance.

These 10 health and safety tips for safety managers easily translate to the reliability and uptime maintenance sectors, and show you how they can help your company. Asset managers, in particular, can use these tips to acquire, operate and maintain assets in a safe, efficient manner.

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Discovering Valuable Trends in Machinery Reliability

Much can be said about trends that relate to equipment reliability in one way or another. Like everything else, they come and go randomly. Just like carbonated water, trends that are reduced to the flavor of the month can fizzle out and disappear rapidly. Trends probably always existed in all fields of endeavor and have been observed for years in the field of machinery reliability improvement. This article focuses on some recent ones that are on relatively solid ground and should be of interest to you. Continue reading

Engineers Need a Nap

The overwhelming majority of industrial accidents result from human error. Engineers who sleep less than eight hours per night are less productive and almost 10 percent more likely to cause an accident, and many don’t get enough sleep. The solution: take a short nap. Continue reading

Cleanliness is Indicative of Quality

Outward appearance is often considered a strong indication of what can be expected of the final product. That’s why this shop goes the extra mile to look good in all areas of its business.

A first impression is a lasting one. The folks at H&R Screw Machine Products (Reed City, Mich.) understand the impact of this axiom when their parts are delivered to customers. If oil is soaking through the box or parts are dirty, the customers are going to be much more skeptical about what they are paying for. The company produces millions of parts a year and sends a majority of them through its aqueous cleaning system to ensure that the customers like what they see. Continue reading

Why Organizations Leave Money on the Table

Why are organizations leaving money on the table by not investigating failures that cost them money? One would venture to say that all manufacturing companies have failures each year that cut into their profit. The prevailing question is: What do you do when that failure occurs? Do you simply fix the equipment, get back up and running, and return to whatever you were working on at the time? Or, do you stop what you are doing and diligently try to understand why the failure occurred and put measures in place to prevent recurrence? Is the culture at your facility one that seeks to understand why something failed or is it in a mode where you need to get back up and running as fast as possible? How about your commercial team and management external to your facility? Is there perceived pressure and a lack of understanding that have driven your organization to a place where failures are not fully understood?

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From Screwdrivers to Testers: Vibration Analysis Comes of Age

Most machines have rotating parts and those rotating parts vibrate. Measuring how and how much those parts vibrate can tell you a lot about the health of a machine. Whether it’s the rumble of worn bearings or the shaking, shimmying, or thumping of loose, misaligned, or unbalanced parts, machines have a tale to tell those who are willing and able to listen. Continue reading

11 Tips for Effective Workplace Housekeeping

To some people, the word “housekeeping” calls to mind cleaning floors and surfaces, removing dust, and organizing clutter.

But in a work setting, it means much more. Housekeeping is crucial to safe workplaces. It can help prevent injuries and improve productivity and morale, as well as make a good first impression on visitors, according to Cari Gray, safety consultant for the Ohio Bureau of Workers’ Compensation. It also can help an employer avoid potential fines for non-compliance. Continue reading

Opening the Envelope on Bearing Vibration

A sophisticated signal processing technique can help to pinpoint bearing failure at an early stage. Chris Hansford, Managing Director at Hansford Sensors, explains.

Experienced operators can often tell if a machine is not working properly, on the basis that is does not ‘sound right’. The same principle can be applied – using modern electronics – to identify the exact cause of the problem. Continue reading