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[ Newest 10 - Electrical - Mechanical - Maintenance Management - Automation - Engineering - Safety - Opinion - Archived ]
newest 10 engineering, maintenance, management articles:
Electrical and Instrumentation Technicians - Troubleshooting FAQ
Troubleshooting FAQ for new or in-training electrical and instrumentation technicians. It offers best practices and tools for diagnosing issues. Includes video.
Electromagnetic Induction Applications For The Instrumentation Technician
Article about electromagnetic induction and induced voltage uses by Instrumentation Technicians. It includes an induced voltage simulator for new students.
2024 Automation Technician Training Trends
2024 PLC automation trends. Essential for acclimating automation technician training students. Trends in PLC programming languages are also explored.
Palletizing Systems for the Food Industry
The palletizing systems for food industry need special features. This article explores palletizing systems for the food and beverage manufacturing industry.
Electric Motor Under & Over Current Protection
Protect against under and over currents for an electric motor-driven plant and save downtime. Real-world examples of keeping motor currents within limits.
Computer Literacy Skills Required in Industrial Computing
Advice for students asking what computer literacy skills are required in manufacturing and industrial computing. It also explores the pros and cons of PC vs. Mac in the business, industrial, and manufacturing industries. The article discusses the difference between apps and computer software regarding OS and literacy.
Manufacturing Automation Sustainability
Manufacturing automation sustainability significantly improves with maintenance automation training. Two case studies that both focus on the final end-user, the maintenance department.
What do the letters FLA on a motor nameplate stand for?
Before getting to what the letters FLA on a motor nameplate stand for, the how-to-read motor nameplate infographic is below. At the end, we look at the difference between FLA and FLC.
Developing A Manufacturing Training Program For Maintenance
This whitepaper on developing a manufacturing training program for maintenance is for maintenance managers and executives considering implementing one.
The Effect Of Process Changes On Electric Motors
Electric Motor Load Testing: The effect of process changes on electric motors explains the effect of changing process loads on AC induction electric motors.
[ Newest 10 - Electrical - Mechanical - Maintenance Management - Automation - Engineering - Safety - Opinion - Archived ]
electrical Articles:
Allen Bradley VFD Training: Sizing VFD for Motor:
This article shares key points from our Allen Bradley Freak drive training course. Examples are VFD drive working principles, sizing VFD for motors, and VFD Operating Temperatures.
instrumentation and process control training
These are two sections from the Instrumentation and Process Control book (33-page white paper). The two sections excerpted here are Differential Pressure Transmitters and the Capacitance Level Sensor Principle section.
distance learning training simulators
Provided is must-have advice for schools and companies wanting to set up or enhance industrial distance learning programs. Explains how employers can use downtime to prepare their industrial workforce better.
PLC training video transcription: PLC wiring tutorial
This PLC training video transcription is for the PLC wiring tutorial video on the page. NEMA has developed a set of standards for Programmable Logic Controllers. This standard recommends serious consideration be given to using an emergency stop or safety circuit.
electrical preventive maintenance will keep you safe and warm
With much of the nation buried under mountains of snow or enduring freezing temperatures, now is the time to inspect your industrial facilities for potential electrical problems. Without proper preventive maintenance on your electrical systems, disaster can happen before you have time to thaw.
electrical industrial troubleshooting
Electrical industrial troubleshooting - Motors, controllers, and PLC. An article on electrical industrial troubleshooting with sections on industrial motor control and programmable logic controller. The article covers problem-solving with motor tests and short-circuit training.
keys for effective electrical troubleshooting
Analyzing a faulty electrical circuit. Troubleshooting Electrical Circuits and Equipment can be a complex and hazardous process. This article describes the skills required to become an expert troubleshooter.
hazardous area installations
92 % of sites are safer without increasing the costs of compliance. In a recent study by the Health and Safety Executive, UK, 11 out of 12 facilities had potentially dangerous hazardous area electrical & instrument installations. This White Paper attempts to help engineers and managers in the UK and elsewhere understand this subject and address the critical issues involved.
how to troubleshoot like an expert electrician
The 5-Step Electrical Troubleshooting Approach. Electricians must solve problems by replacing defective equipment or components in the least time to troubleshoot electrical equipment expertly.
How to extend Industrial UPS Battery Life
An Uninterrupted Power Supply (UPS) is a perfect solution for industries that want to enable continuous power supply. It is essential to understand what factors lead to a reduced life span of your UPS batteries. This article and the included infographic will help.
residential electrician to industrial electrician career guide
Automated industry and retiring baby boomers increase demand. This article is a Career Guide for Residential Maintenance and Residential Electricians. The residential maintenance persons should keep the higher-paying Industrial Maintenance career option as an industrial career pathway.
how a photoelectric sensor saved my job
A more advanced photo sensor on canning equipment An article by author Larry Bush about how a more advanced photo sensor on a canning equipment seamer in the food processing industry had saved his job.
planning for emergency power
Covered are permanent backup, mobile power, and sourcing equipment. Electricity is never more precious or more scarce than after a disaster. When lights are out, telephones are disabled, and businesses shut down.
infrared applications: Thermography applications for businesses
Infrared Applications: With many examples of thermography applications for businesses, this article shows how the Online Infrared Training Center grows both careers and business revenues!
what is infrared thermography?
What is infrared thermography? It also includes a video on what thermography is. Both contain what thermography is, how thermal imaging works, and its industrial applications like thermographic surveys, infrared thermal imaging, and more.
how to reduce data errors on infrared surveys
Here is some help with common problems in gathering accurate infrared data. This article is about reducing infrared data errors when conducting infrared scanning surveys for electrical equipment testing and building scanning. This infrared data article is an excellent addition to our many resources for troubleshooting electrical problems.
[ Newest 10 - Electrical - Mechanical - Maintenance Management - Automation - Engineering - Safety - Opinion - Archived ]
mechanical articles:
Rotating Machinery Testing: Questions that need to be asked
Ask these rotating machinery testing questions if you want reliable and safe rotating equipment. It will help you develop sound technical integrity strategies.
6 secrets of best bearing grease and oil care
This article by mechanical engineering expert Mike Sondalini explains the best machinery bearing lubricant grease and oil care. Grease and oil are the primary lubricants used throughout the industry to reduce friction between metal parts. Lubricants can only reduce friction if their immediate environment sustains their lubricating properties. Read to learn how.
mechanical aptitude test practice guide
What is the mechanical aptitude test (MAT)? And why you should take a mechanical aptitude practice test. It is not just a mechanical test but an electrical one, too. One could call it a maintenance test or a maintenance mechanic test.
how to prepare for mechanical engineering career aptitude tests.
Mechanical engineering career aptitude tests are one of the most common, measuring knowledge of mechanical engineering technology and electrical and physical concepts. Learn how to be prepared, outperform the competition, and get hired.
mechanical engineering newsletters for students
A peek inside 10 editions of our industrial mechanical engineering newsletter PDFs. Mechanical Engineering Newsletter for Students (Easy to understand practical application examples and tips). Here, we outline one of the weekly Mechanical Engineering Newsletter PDFs for you and give you free access to the first 10 editions of volume 1.
industrial valve maintenance
Extending the life of your valves and reducing industrial valve repair with valve maintenance. Poorly maintained valves don't last as long as they should because they're prone to sudden failures.
maximum hydraulic component life
Help with defining Fluid Temperature and Viscosity Limits. Many factors can reduce the service life of hydraulic components. Incorrect fluid viscosity is one of these factors.
innovative cleaning and inspection plays a critical role in refinery debottlenecking
Increase production while reducing expenditure within the oil and gas refinery industries and reduce CO emissions with this article on clean heat exchanger tubes.
[ Newest 10 - Electrical - Mechanical - Maintenance Management - Automation - Engineering - Safety - Opinion - Archived ]
maintenance management articles:
Top-Gun Maintenance Planner Scheduler Job Description
Excerpt from the Maintenance Planner Scheduler Course PowerPoint. The Maintenance Planner Scheduler job description is where we start. It is much more than a Preventive Maintenance Planner job description.
Industrial Maintenance Technician's Guide App.
It used to be a printed pocket guide for purchase; now, we have converted it to a free online app that can be updated regularly and added as a living document and reference guide designed for maintenance and operators alike. As it is browser-based, it works on any device. It will help its readers to run and maintain plants and equipment better than they have ever done before.
State Incumbent Worker Training Reimbursement Programs
Reduce incumbent worker training costs with state employee training reimbursement programs and retraining tax credits. Next-level jobs with workforce-ready grants and other cumbersome grants may be your second choice.
what is a pareto chart and the 80 20 rule?
Before reading this article, you probably thought you knew everything about "What is a Pareto chart?" and the 80/20 rule. With real-world Pareto chart examples, this article will show you critical application knowledge and understanding left out of textbooks and Wikipedia. Your Pareto chart could be focusing your attention on the wrong area, and you never realize it. Everyone will learn something new here or, at a minimum, have a better understanding.
how to calculate ROI for downtime big data
This article introduces the two elements that need to be added in most industrial big data initiatives that fail for end-users to realize their Return On Investment (ROI) goal. Gain insight on calculating ROI for industrial big data collection using a real downtime costing system, True Downtime Cost™ (TDC).
lean | TPM | autonomous maintenance steps
This article introduces Lean TPM autonomous maintenance step 0 and provides implementation solutions and advice. You may know the 7 steps of Autonomous Maintenance, but did you know there is a step 0 before Autonomous Maintenance Step 1? AM Step 0 first educates operators on understanding how equipment works and general maintenance best practices like TPM, predictive maintenance, RCA, etc. By starting with step 0, operators have a better understanding and increased buy-in of the other 7 AM steps, significantly improving your AM program's success and return on investment.
alternatives to lean six sigma failures
Industrial and Manufacturing Wellness (IMW) way is a systemic approach to Lean Six Sigma alternatives. Lean business systems, industrial process systems, ISI 9001, and Six Sigma failures can be avoided by the Industrial and Manufacturing Wellness way. In this article, world-renowned author Mike Sondalini explains why the lean business model only works for some.
CMMS implementation advice
CMMS implementation guide and recommendations for small to medium-sized companies. With the decrease in the cost of highly reliable and robust IT equipment, the benefits of a CMMS are well within reach of any organization, regardless of size.
TPS lean principles: respect for people
As you will see in this article, the TPS Lean principle of respect for people is a difficult and often misunderstood task. For the TPS (Toyota Production System ) principle of respect, many fail to succeed because their priorities focus on what people are doing more than who the people are.
training cost justification (ROI)
This training cost justification example highlights the key ROI for a training cost analysis of our PLC and Electrical training video courses. The PLC and electrical video courses have a unique advantage, as one purchase trains unlimited employees.
what is the true downtime cost (TDC)?
Predetermine the "True" cost of downtime for each profit center category. TDC is a methodology of analyzing all cost factors associated with downtime and using this information for cost justification and day-to-day management decisions.
lean maintenance management via the six sigma black belt
The LEAN Maintenance Six Sigma Black Belt article explores why there are so few Six Sigma black belts in Six Sigma maintenance departments. In the manufacturing future, there will be fewer humans and more automation, thus focusing more on lean maintenance management.
pass 55 via the plant wellness way
This article introduces the equipment reliability program PWW (Plant Wellness Way) by the ISO 55001 asset management specialists. This article's free PDF and spreadsheet help with PASS 55 implementation and prepare you for ISO 55001.
training half-life, worker refresher training?
Refresher training case study and advisory for worker retraining advocacy. An informative article by Sam McNair (CMRP) on job retraining. Points out employee retraining every 2-3 years and turnaround on that worker retraining investment.
developing competencies during the economic downturn
Developing competencies opens new roads to worker productivity in the workplace, employability, and sustainable development. Armando Justo's article points out that competency-based training to improve employee skills will be key differentiators for the future success of organizations and countries.
maintenance managers in the pursuit of world-class performance
Detail how a savvy maintenance manager can cause organizational change and why. Improve the management and control capabilities of the maintenance function by using the proper KPIs. These advanced knowledge and insights are invaluable for the Maintenance Manager's career planning.
total productive maintenance definition as married to TPM
Total Productive Maintenance: What is it? TPM is much like a successful marriage. After the honeymoon, he has his stereotypical job, and she has hers. We can easily trace the common denominator when we consider that a similar but much more severe phenomenon has occurred for decades in the industry.
recession survival tips for the manufacturing industry
Recession survival tips on how and why not to cut training. About the methods for US Manufacturing Industry to adjust for the knowledge vacuum caused by retiring baby boomers with training, while dealing with tight training budgets during a recession.
CMMS systems integration
CMMS integration with current systems, solutions - and implementation. This article offers insight into integrating your CMMS or Maintenance Management Systems with your inventory, accounting, purchasing systems, and other enterprise management systems. Within are some examples of CMMS/Accounting system integration while touching on shop floor data systems and SCADA.
equipment failure and the cost of that failure.
Excerpts from Mike Sondalini's book 'Defect and Failure True Costing'. The details of the defect cost and equipment failure cost are covered. Excerpts from the author's book about DAFT Cost Management explore production cost and the cost of failure, which is a must-read for business operations management.
maintenance management of your company's PLC
PLCs are the brains of your operation. When the PLC (Programmable Logic Controllers) is not functioning properly, lines shut down, plants shut down, and even city bridges and water stations cease to operate. A company can lose thousands to millions with one little PLC in an electrical panel you never knew existed.
the Japanese path to maintenance excellence
The Japanese way to decide equipment criticality Equipment criticality determines what level of preventative maintenance to use. What type and amount of condition monitoring is to use, and what kind and amount of observation from the operators is required? We can learn from Mike's visit to a major Japanese manufacturer.
overall equipment effectiveness (OEE)
Many maintenance departments today still do not effectively utilize the OEE tool. Overall, Equipment Effectiveness is a benchmarking tool as well as an analysis tool. This article covers what OEE is, why you should use it, and how to use it.
the change management plan
Focus On Results and Change the Culture Along the Way. Equipment becomes more reliable, costs go down, and behaviors change along the way. The key is focusing on results that will get people's attention on the plant floor and the key decision-makers offices.
- Change Management Plan and Business Case Study. Also see Change Management Article, Reliability to Reduce Downtime.
CMMS error codes
CMM/CMMS - Facility Maintenance Management Software Facility and fleet computerized maintenance management software help. While recording downtime, this article will make you more effective.
CMMS ROI calculator
How to cost-justify your CMMS program. A Return on Investment (ROI) calculation results in a value that represents the benefits received from a project against the total costs of the project.
CMMS to reliability
A Computerized Maintenance Management System is an essential aspect of CMMS software. The criteria for CMMS are to satisfy facility reliability and validity needs.
asset management
The Japanese Path to Maintenance Excellence. Asset management series by world-renowned maintenance author, Mike Sondalini who visits Japan to report on the Japanese way of doing maintenance.
see also our PDF Maintenance and Engineering Articles.
[ Newest 10 - Electrical - Mechanical - Maintenance Management - Automation - Engineering - Safety - Opinion - Archived ]
automation articles:
PLC SCADA System Training Advice
Working with SCADA systems when not properly trained and qualified can be almost as dangerous as working with PLCs without proper PLC training. This article explains the best way to learn SCADA. The author references their own company’s approach to developing the best training approach while remaining very cost-effective.
CNC Programs Software Vs. PLC Programs (Ladder Logic)
The article "CNC Programs Software Vs. PLC Programs" details CNC programs (not Mastercam software) vs. PLC ladder logic. Think G code, M code, etc., vs. PLC programming ladder logic.
automated data collection for production monitoring
Whitepaper on automated data collection for production monitoring and analysis. A 5-step guide to manufacturing data collection critical to Industry 4.0 operations.
PLC Programming: Simple Manual And Automatic Control
We wrote the PLC programming example in this article to answer a specific request from a learner, so we decided to share it with our website visitors. This PLC programming example is for manual control and automatic control.
What Is Original Equipment Manufacturer (OEM) PLC Training?
Whitepaper: A closer look at OEM PLC Training using a CNC manufacturer and PLC training example. A machine manufacturer uses other OEM parts in their equipment.
What is RSLinx Classic for PLC Communication?
What is RSLinks Classic for PLC Communication article with simulation to walk through, practice, and test the Rockwell RSLinx software RSWho connect to PLC.
industry 4.0 and IIoT security design and architecture
This article covers IIoT (Industrial IoT) Security. Top Industry 4.0 solutions given on the Internet of Things security and official references on industrial IoT to keep your smart manufacturing operation secure and smart factory running. It is also very informative to anyone dealing with IoT devices, even consumers.
Siemens PLC Programming - Counters
We offer this additional Counter PLC programming example article to supplement our PLC programming tutorial video. Also, some screenshots are easier to study as pictures rather than videos, so you can click on them to enlarge and study.
PLC programming: random number generator
A universal PLC programming example of generating a more authentic exponential random number. This PLC programming example is how to program in ladder logic, the logic to generate a random number in PLCs that do not have an RND function built-in. This example is the PLC ladder logic needed to create a more authentic random number.
How to do basic automation control troubleshooting.
While this heat treat case study started as an assumed PLC troubleshooting challenge, once you go through the process and details, you may notice it was a Robotic troubleshooting / Servo troubleshooting exercise. (A 2-axis robot)
What Is Original Equipment Manufacturer (OEM) PLC Training?
Whitepaper: A closer look at OEM PLC Training using a CNC manufacturer and PLC training example. A machine manufacturer uses other OEM parts in their equipment.
PLC examples from the entertainment industry
This article demonstrates that working with PLC SCADA can be even more fun than you thought. We explore PLC applications in the Las Vegas entertainment industry and the advantage gained from that diverse PLC programming background. From theme park rides, sports simulators, choreographed water, and light shows to theatrical productions and much more!
PAC - PLC troubleshooting guide
When asked, "How do PLC troubleshoot?" most scholastic types, OEMs, etc., reply with how to troubleshoot a PLC. When most people are really asking about real-world troubleshooting equipment and processing using a PLC or PAC, not how to troubleshoot the PLC itself, this article explains the latter.
what is the easiest pLC to program?
A widespread question by those just starting is, "What is the easiest PLC to program?". This article answers that question and explains how we derived the answer. It also answers questions about the top PLC brands and the applications of PLCs.
PLC safety and reliability
Most seasoned vets in the industry know that PLC safety is typically covered well in the specification and design phases. They also know that during start-up [commissioning], PLC safety risk starts to increase. But what about the other 90% of the lifecycle of the equipment? This article covers 90% of the risk of working with automation. Please share this one. The life you save may be your own.
CNC maintenance | PLC troubleshooting | flowchart-article
The CNC PLC troubleshooting flowchart example in this article explores the scenario in which the CNC machine won't cycle start because the safety door is closed, and the CNC is not detecting the signal. From machine operator level CNC troubleshooting to maintenance technician PLC troubleshooting.
industry 4.0 in USA: risk
A significant drawback to Industry 4.0 that only some write about is the maintenance of an Industry 4.0 plant. The maintenance aspect is a much more substantial and immediate drawback than even the commonly known significant concern of security and the lesser concern of system integration standards. Maintenance of 4.0 systems has and will continue to result in considerable increases in process downtime. In this article, we explore the barriers to overcoming the maintenance/downtime drawbacks of a 4.0 system.
PLC technician training certification
What PLC Technician training should a company look for in their new hires and current employees? With your electricians, you look for hands-on instructor-based training and evaluation (not just academic education); why should your PLC technician training requirements criteria be anything less?
PLC controller failure rate (PLC MTBF)
This article answers the question, 'What are PLC controller failure rates?' It also covers equipment failure rate from a PLC failure rate perspective (automation controller).
PLC PAC difference - PAC automation controller defined
This PLC PAC Difference article defines the PAC automation controller in relationship to the PLC, a PLC vs PAC comparison. This article explains the need to differentiate when requesting and delivering PAC and/or PLC training.
industrial networking solutions security - PLC, SCADA
Industrial network security solutions essential to today's PLC - SCADA security. Lack of security on an industrial network could cause a severe threat to the system and the personnel involved; in fact, production machine networks without proper protection can cause physical damage to man and machine. This article should help you.
converting AB PLC DH485 to USB
Converting AB PLC DH485 to RS232 and then to USB can be tricky. ... This article is a guide to connecting a PLC to a laptop with only USB ports. This article covers finding the port number for a USB converter, the dos and don'ts of using Allen Bradley cables with a USB converter, and some money-saving tips when purchasing cables.
PID controller design, model-based control tuning.
Model-Based Tuning Methods for PID Controllers. Discussed are the qualities required for "good" dynamic process data and tuning methods for dynamic modeling the process data for controller design. Performing process data studies with the PID controller in an automatic (closed loop) is standard.
M2M device networking
Networking is enabling New Possibilities for Preventive Maintenance. Read about how the ability to extract raw data from a device, machine, or appliance and convert that data into useful information transforms decision-making from an art to a science.
OEE - automated data collection
OEE Reports - Automated Capturing & Recording of Availability Data Moving Beyond Manual Data Collection & Manual Data Compilation. Automated capturing and recording of "Availability Information" is covered in this article. Future articles will address the automated data collection of Performance Rate and Quality Rate.
This GE and AB PLC configuration resource helps you with PLC hardware configuration and PLC configuration management.
[ Newest 10 - Electrical - Mechanical - Maintenance Management - Automation - Engineering - Safety - Opinion - Archived ]
engineering articles:
The Important Use Of Simulation Software In Education
Simulation-based learning is no longer a novelty in undergraduate education. Generally, simulations can serve as a supplement or even a replacement for role-playing, lab experiments, or field trips. College technical instructors or vocational teachers can leverage simulation software to clarify or introduce a topic and foster exploration and process learning.
Equipment Reliability Examples - Reliability Engineering Basics
These equipment reliability examples convey the basics of reliability engineering. Interestingly, you will learn the 4 system reliability factors to address while doing a reliability analysis on drinking glasses.
hydrogen fuel cells will revolutionize the mobile robotics industry
This article discusses how the hydrogen fuel cell (hydrocell) will revolutionize the military and industrial autonomous robots industry, especially the mobile robot industry. It explores how the scaling laws of physics reveal the advantages of hydrogen fuel cell systems.
automated predictive maintenance - phase angle diagnostics of rotating equipment
Phase Angle Diagnostic results in earlier detection than Vibration Diagnostics. The science of predictive maintenance (PdM), a Condition-based Maintenance (CBM) program, and how to detect PdM earlier and automate PdM.
why so much theoretical in electrical engineering degree programs?
Answers the common question Electrical Engineering students have: Why is there so much theoretical and so little practical application instruction [hands-on] in college Electrical Engineering degree programs? Senior Instructor Don answers that common question in this article with a unique analogy that may help clarify that question for students.
supply chain management with RFID systems
Articles and white papers are all about RFID systems for pharmaceutical distributors and the FDA regulations on drugs. The pharmaceutical supply chain is an excellent example of supply chain management, utilizing RFID for tracking and tracing systems.
hydrocarbon traces in purging nitrogen (by chromatography)
Chromatograph removes hydrocarbons in catalyst hydroprocessing - regeneration. When the reactors of hydroprocessing units, reformers, and other plant equipment are used for maintenance or for the catalyst's regeneration, removing all residual hydrocarbons from the system becomes necessary.
[ Newest 10 - Electrical - Mechanical - Maintenance Management - Automation - Engineering - Safety - Opinion - Archived ]
see also our PDF Maintenance and Engineering Articles.
