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108 matching articles

Aug 13, 2026

Reliability Engineering

Identifying Risk – where do failures really come from?

We previously explored what risk is and how it differs from reliability. The next step is identifying it, and while that sounds straightforward, in practice, it often isn’t. Failures don’t just “happen” When something fails in service, it’s often treated as an isolated event: But failures are rarely random or standalone. They are usually the […] The post Identifying Risk – where do failures really come from? appeared

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Aug 13, 2026

Condition Monitoring

When Your PM Created the Failure

The Problem A technician performs preventive maintenance on a pump motor. Checklist followed, torque wrench used, bearing repacked, everything signed off clean. Two weeks later, the same motor fails. The RCA opens with “premature bearing failure” as the problem statement. The team pulls vibration data, checks the operating envelope, reviews the load history. Nobody looks […] The post When Your PM Created the Failure

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Aug 13, 2026

Reliability Engineering

Mentorship in African Engineering

Somewhere in Africa right now, a brilliant young engineer is figuring it out alone. Not because they lack ability. Because no one with experience decided their growth was worth an hour a week. There is a conversation I have had more than once with young engineers across different industries on this continent. It usually starts […] The post Mentorship in African Engineering appeared first on Accendo Reliability.

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Aug 12, 2026

Reliability Engineering

DFMEA Glidepath

The Design Failure Mode and Effects Analysis (DFMEA) glidepath represents a systematic approach to risk assessment and management throughout product development cycles. This methodology provides engineers with a visual framework to track and mitigate potential failure modes before they impact production or end users. The S×O methodology simplifies traditional DFMEA by focusing on two critical […] The post DFMEA Glide

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Aug 11, 2026

Reliability Engineering

Leveraging Process Failure Mode & Effects Analysis (PFMEA)

Guest Post by Duke Okes (first posted on CERM ® RISK INSIGHTS – reposted here with permission) The primary core use of a pFMEA is to analyze a new process to identify potential failures within the process and evaluate the planned prevention & detection controls to determine the degree of risk (see Table 1). Unfortunately, once the […] The post Leveraging Process Failure Mode & Effects Analysis (PFMEA) appeared first

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Aug 10, 2026

Reliability Engineering

Restoring Control and Performance at the Momence Plant

Case Study: The Challenge When ReliabilityX began working with the Momence Plant, the situation was critical. The facility was operating with an ineffective maintenance and operations strategy. Overall equipment effectiveness (OEE) had dropped to 40 percent, and the plant was entrenched in a reactive culture. Leadership and maintenance teams lacked the training and skill sets […] The post Restoring Control and Perfor

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Aug 6, 2026

Reliability Engineering

Reliability vs Risk – why they’re not the same thing

In the previous article, we introduced risk as something distinct from reliability – not just probability, but the combination of uncertainty and consequence. Reliability vs Risk – a simple distinction Reliability is about how likely something is to fail. Risk is about what happens when it does. At first glance, that might sound like a […] The post Reliability vs Risk – why they’re not the same thing appeared first o

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Aug 4, 2026

Reliability Engineering

How Plant Wellness Reduces Failure Rates and Maintenance Costs

Let a Plant Wellness Way EAM System-of-Reliability End Your Business Risks Forever The focus of maintenance should be upon maintaining the ‘wellbeing’ of the plant and equipment. When the task becomes to ‘fix the machine,’ then maintenance has failed in its basic mission. Many current maintenance strategies involve significant wasted effort; scheduled intrusive actions on […] The post How Plant Wellness Reduces Failu

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Aug 3, 2026

Reliability Engineering

The Financial Competitive Advantage of Reliability

Reliability is more than just a technical goal; it is a strategic financial advantage. Organizations that prioritize reliable assets, equipment, and operations outperform competitors by reducing costs, improving efficiency, and maximizing return on investment (ROI). Reliability-driven companies experience lower maintenance costs, higher production efficiency, and increased profitability. When reliability is built int

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Aug 1, 2026

Reliability Engineering

FMEA and AI: Three Important Principles

Principles are like lighthouses. They are natural laws that cannot be broken. – Stephen Covey In my new book on FMEA, I am writing a chapter called “Harnessing the power of AI in FMEAs.” I include three high-level principles that are critical to successful integration of AI with FMEA. There are many other principles that […] The post FMEA and AI: Three Important Principles appeared first on Accendo Reliability.

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Jul 30, 2026

Reliability Engineering

Four Important Things You Should Know About Asset Life

Getting the definitions right, anchoring estimates in probability rather than intuition, and forecasting in ranges instead of points are what separate a defensible asset management plan from a guess. The post Four Important Things You Should Know About Asset Life appeared first on Accendo Reliability.

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Jul 30, 2026

Reliability Engineering

Survivor Bias: When Long-Life Components Mislead Maintenance Decisions

Some components will always outlive the maintenance interval. That fact alone is sometimes used to justify extending replacement frequencies. “We have units still running beyond 3,000 hours. Maybe we’re replacing them too early.” It’s a reasonable question. But is it the right conclusion? The Dataset What the Reliability Curves Tell Us Reliability Function — R(t) […] The post Survivor Bias: When Long-Life Components

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Jul 30, 2026

Reliability Engineering

How to Conduct a Root Cause Analysis in Five Steps

Most Plants Fix Problems. Few Actually Solve Them. There is a pattern I have seen repeat itself across African industrial facilities more times than I can count. A piece of equipment fails. The maintenance team responds quickly, replaces the damaged component, gets the line running again, and everyone moves on. Two months later, the same […] The post How to Conduct a Root Cause Analysis in Five Steps appeared first o

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Jul 27, 2026

Asset Management

Lifecycle Management in Asset Management

Lifecycle Management in Asset Management: Maximizing Value from Start to Finish Asset-intensive industries rely on effective lifecycle management to optimize performance, reduce costs, and extend asset longevity. Lifecycle management in asset management is a strategic approach that ensures assets deliver maximum value from acquisition to decommissioning. By understanding and managing each phase of an asset’s […] The

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Jul 26, 2026

Pipeline Integrity

Failure Mechanism vs. Failure Cause

Failure mechanism refers to the physical, chemical, electrical, or thermal process—or chain of events—that directly leads to a failure mode. It is the actual process by which a component or system degrades to the point of failure. For example, in a mechanical system, fatigue cracking, corrosion, or wear are classic failure mechanisms; they describe how […] The post Failure Mechanism vs. Failure Cause appeared first o

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