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What are the most effective ways to prevent mechanical failure in training processes?

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Mechanical failure can be costly, dangerous, and frustrating for any training process. Whether you are teaching new skills, testing equipment, or conducting experiments, you want to avoid breakdowns and malfunctions that can disrupt your goals and waste your resources. In this article, we will explore some of the most effective ways to prevent mechanical failure in training processes, based on the principles of failure analysis and prevention.

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1 Identify potential causes

The first step to prevent mechanical failure is to identify the potential causes that can lead to it. These can include design flaws, material defects, manufacturing errors, environmental factors, human errors, or external forces. By analyzing the sources of stress, fatigue, wear, corrosion, or impact that can affect your mechanical system, you can determine the most vulnerable components and the most likely modes of failure. You can use various methods and tools to identify potential causes, such as failure mode and effect analysis (FMEA), fault tree analysis (FTA), or root cause analysis (RCA).

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Tony Sovar

Lead Rotating Equipment and Reliability Engineer
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Identifying potential causes is also one of the first steps in improving potential reliability of equipment. Depending upon your role will depend upon how much you can influence equipment at the design stage. As a customer purchasing existing designs several items can be key,ie what standard/s were used in the design, what service factors were used in the selection, what QA/QC was performed with the manufacturing process, what acceptance tests are required to name a few. If there is a population of these in service then the "Failure Investigation" processes can be used to assist with identifying the weak components and consideration can be made to manage/upgrade these. Custom manufactured equipment will require significantly more engagement

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2 Implement preventive measures

The second step to prevent mechanical failure is to implement preventive measures that can reduce the risk or severity of failure. These can include selecting appropriate materials, improving design features, optimizing manufacturing processes, applying protective coatings, installing sensors and alarms, performing regular inspections and maintenance, or providing adequate training and supervision. By applying these preventive measures, you can enhance the reliability, durability, and performance of your mechanical system, and avoid unnecessary downtime, repairs, or replacements.

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Fabio Andre Brand, MSc, CMRP

Reliability Engineer | Maintenance Coordinator | Storeroom Coordinator | RCM | Industry 4.0 | IIoT | Asset Management | MRO Inventory Optimization | SAP-PM | Gerdau
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One of the most important preventive measures is to do regular inspections to evaluate conditions of the assets, then take preventive actions based on the conditions.

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Tony Sovar

Lead Rotating Equipment and Reliability Engineer
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With the condition monitoring element of mechanical inspections the maintenance technicians also require the right training and tools to ensure the measurements are consistently recorded. Key additional information to measurements are the condition assessment comments from the technicians as well.

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3 Monitor and evaluate results

The third step to prevent mechanical failure is to monitor and evaluate the results of your preventive measures. This can help you to verify their effectiveness, identify any gaps or weaknesses, and make any adjustments or improvements as needed. You can use various methods and tools to monitor and evaluate results, such as performance indicators, feedback surveys, quality audits, or reliability tests. By monitoring and evaluating results, you can ensure that your preventive measures are aligned with your training objectives, and that they are delivering the expected outcomes and benefits.

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Tony Sovar

Lead Rotating Equipment and Reliability Engineer
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A comprehensive condition assessment report has the potential to significantly add to the Continuous Improvement process to increase the reliability of equipment. With the correct condition assessments components can be evaluated for potential upgrade of design to increase service life or extend service life of current components. The key element of a report is to have it reviewed and potential improvements evaluated for implementation.

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4 Learn from failures

The fourth step to prevent mechanical failure is to learn from failures that do occur, despite your preventive measures. This can help you to understand the root causes, the consequences, and the lessons learned from each failure, and to apply them to prevent similar or future failures. You can use various methods and tools to learn from failures, such as failure reporting, analysis, and corrective action system (FRACAS), incident investigation, or after action review (AAR). By learning from failures, you can improve your knowledge, skills, and practices, and foster a culture of continuous learning and improvement.

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Tony Sovar

Lead Rotating Equipment and Reliability Engineer
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The failure investigation process is one of the hardest programs to key going within an operating organization. Management support typically changes as the individuals change. This is unfortunate as if a failure is not investigated and understood with improvement/s implemented the failure is most likely to occur again.

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5 Share best practices

The fifth step to prevent mechanical failure is to share best practices that you have developed or discovered through your preventive measures and learning from failures. This can help you to disseminate your insights, experiences, and recommendations to other trainers, trainees, or stakeholders, and to promote a common understanding and standard of excellence. You can use various methods and tools to share best practices, such as reports, presentations, publications, or online platforms. By sharing best practices, you can enhance the communication, collaboration, and innovation within your training community, and contribute to the advancement of your field.

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6 Update and revise plans

The sixth and final step to prevent mechanical failure is to update and revise your plans based on your monitoring, evaluation, learning, and sharing. This can help you to keep your plans relevant, realistic, and responsive to the changing needs, expectations, and opportunities of your training process. You can use various methods and tools to update and revise your plans, such as project management software, feedback loops, or change management techniques. By updating and revising your plans, you can ensure that your plans are flexible, adaptable, and effective, and that they support your continuous improvement and prevention of mechanical failure.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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U?urcan Ero?lu

Associate Professor
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Engaging the students is important. They must know beforehand that we are working on idealized representations of things that exist in physical world, not on some straight lines with empty circles at the ends...

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What are the most effective ways to prevent mechanical failure in training processes?

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3

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7

1 Identify potential causes

2 Implement preventive measures

3 Monitor and evaluate results

4 Learn from failures

5 Share best practices

6 Update and revise plans

7 Here’s what else to consider

Mechanics

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What are the most effective ways to prevent mechanical failure in training processes?

1

2

3

4

5

6

7

1 Identify potential causes

2 Implement preventive measures

3 Monitor and evaluate results

4 Learn from failures

5 Share best practices

6 Update and revise plans

7 Here’s what else to consider

Mechanics

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