10 Reasons Why You Should Audit Your Vibration Monitoring Program NOW!

by Alan Friedman

If you are currently running a vibration monitoring program in-house or outsourcing it to a consultant, before you potentially throw any more money in the toilet, you really need to audit your vibration monitoring program and ask yourself if you are getting any value out of it.

If you do not know what benefits you are getting from a program, you are probably not getting any benefits at all! On the other hand, if you are getting benefits but not documenting them, then your program is at risk for being cut. Either way, you need to know what is going on with your program and document it if it is good or fix it if it is not.

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Is Safety a Backseat Driver?

by Holcombe Baird III, Reliability Center, Inc.
This article originally appeared in IMPO’s April 2015 print issue.

We have all experienced it when in a car. The voice from the back that says, “You are following too close,” “You are driving too fast” or “You just went through a red light.” It’s the backseat driver.  Backseat drivers are quick to point out when the driver falls short in obeying the rules of the road. They observe the driver’s actions and compare them to the set of rules they learned of what is proper and acceptable for a similar situation.  When they observe a negative deviation, they immediately bring it to the driver’s attention. Their intention is to point out the driver’s error so the driver will remember the correction when a similar situation happens again.  These “backseat” corrections lag behind the thought process used to determine what actions to take.   Continue reading

The Financial Benefits of Reliability

by Bruce Hawkins, CMRP, Emerson Reliability Consulting
This article originally appeared in IMPO’s April 2015 print issue.

When manufacturing organizations look to asset reliability to improve their facilities, there is often one main driver behind this decision: financial performance. There are many reasons to employ reliability practices including improved safety and production, but many companies focus on reliability initiatives because they touch so many aspects of the business and yield strong financial results. Continue reading

A Twist on Particle Evaluation: Redefining the ISO Cleanliness Code

by Matt Spurlock

For over 20 years, users of oil analysis have used the ISO cleanliness code to help determine solid contamination levels in both new and used oils. The current ISO standard for reporting cleanliness is ISO4406:99. Using this standard, analysts and end users alike have managed to establish cleanliness goals and develop key performance indicators (KPIs) with the expectation to allow for preemptive action to avoid early machine damage. While this has produced some success, relying specifically on the ISO code as it is currently reported has its limitations. Continue reading

Fluorescent Cleaning NDT

by James Deardorff, President, Superior Coatings, Chillicothe, MO

New integrated process combines traditional cleaning methods with fluorescence-based inspection.

In recent years, the tremendous growth of available technologies and the resulting trend towards component miniaturization and increased product reliability has challenged many companies to upgrade their current cleaning operations to satisfy the higher quality standards required by new product designs.

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7 Ways Leaders Fail

by Gregory Alford

To mangle a 270-year-old sonnet written by Elizabeth Barrett Browning—How do we dislike our bosses? Let us count the ways.

Survey after survey, Americans (and everyone else) trash their bosses. Gallup reports only 12 percent of American workers are engaged. Research conducted and published by Inc. reveals 75 percent of employees say their boss is the worst part of their job. And two-thirds add a new (better) boss is even more desired than a pay raise.

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Shining a Black Light on Coating Inspections

by James Deardorff, Superior Coatings Co.

The highest-quality, longest-lasting coatings available to consumers are installed at the factory. Factory finishes are applied in a controlled environment using quality materials and highly specialized equipment. Also, prefabricated metal will never be cleaner or in better condition than when it is used to manufacture new products. The longer the original coating lasts, the higher its value to the asset and the owner. Continue reading

Ten Steps to Pump Reliability – Part 1

By Tom Dabbs and Dan Pereira

Pump reliability is an old topic, but it is just as relevant today as it was the first time we heard it a few decades ago. There are some very good reasons to focus on improving pump reliability:

  • The average annual maintenance and operations spending on centrifugal pumps is 50 percent greater than for any other type of rotating machine (FiveTwelve Group, August 2006).
  • Centrifugal pumps in many plants consume more than 50 percent of total plant motor energy (Hydraulic Institute).
  • Pumps consume more energy than any other class of industrial equipment (U.S. Department of Energy, 2005).
  • A Finnish Research Center study of centrifugal pump performance (“Expert Systems for Diagnosis and Performance of Centrifugal Pumps,” 1996) found that the average pumping efficiency was less than 40 percent for 1,690 pumps reviewed across 20 different plants, including all market segments. The study also revealed that 10 percent of the pumps were less than 10 percent efficient.

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