Should Industrial Reliability Be Considered a Patriotic Initiative?

The latter half of the 20th century saw the rise of globalization, characterized by increased international trade, communication, and cultural exchange. Advancements in technology and transportation broke down barriers between nations, leading to the expansion of multinational corporations and global supply chains.

Although globalization facilitated economic expansion and progress, it also prompted apprehensions regarding sovereignty and resilience. This is exemplified by the evolution of manufacturing in the United States: while it accounted for 27% of GDP in 1957, its share steadily declined, reaching 11% by 2022.

A country owning its manufacturing needs is crucial for economic stability, job creation, innovation, and national security. By producing goods domestically, a nation can reduce its vulnerability to global market fluctuations and geopolitical tensions, fostering confidence among businesses and investors. Reliable domestic manufacturing also helps protect the environment by reducing emissions and waste associated with long-distance supply chains. Moreover, domestic manufacturing generates employment opportunities, stimulates innovation, and enhances technological advancement, driving long-term economic growth. Expanding domestic manufacturing capabilities supports new projects and technological development, further strengthening the nation’s industrial base.

Owning key industries also ensures strategic autonomy and a stable supply of essential goods, bolstering national security. Additionally, it preserves cultural identity by promoting locally made products and traditional craftsmanship.

Analysis by the McKinsey Global Institute suggests that restoring growth and competitiveness in key manufacturing industries could boost US GDP by more than 15 percent over the rest of the current decade, while adding up to 1.5 million jobs by locally bringing back production of apparel, pharmaceuticals, communication equipment, semiconductors + its components, textiles, medical devices, etc. Launching large-scale industrial projects is essential to achieving this restoration and maintaining global competitiveness.

Industrial reliability and vibration analysis: a part of the solution?

Patriotism often extends beyond mere expressions of national pride to encompass actions that contribute to the strength, resilience, and prosperity of a nation. As seen above, if empowering manufacturing organizations can bring such positive impact nation-wide, then making sure these organizations are reliable can be considered a patriotic initiative.

Far from being just a technical concern, maintenance and reliability practices play a crucial role in safeguarding a nation’s economic stability, security, and overall well-being:

• Establishing pragmatic goals and organizational vision in consideration of political and economic circumstances.
• Ensuring alignment between sales, marketing, operations, and maintenance to minimize constraints and manage losses, including scrap and rejects (with the goal of achieving a 0% scrap and reject rate).
• Prioritizing reliability in the design of new assets and new equipment.
  • Revisiting fundamental requirements and favoring dependable, easily inspectable, maintainable, repairable, and replaceable components over complex electronics or non-repairable/recyclable parts.
  • Implementing comprehensive maintenance plans and standard operating procedures (SOPs) from the outset to minimize mean time to repair (MTTR) post-commissioning. It is important to understand the difference between planning and scheduling: planning defines what work needs to be done and how, while scheduling determines when and by whom the work will be performed. Work should always be planned before it is scheduled for execution.
• Strengthening the foundation of asset reliability through meticulous management:
  • Ensuring the computerized maintenance management system (CMMS) contains a detailed, accurate, and complete master equipment list. Conducting an audit of maintenance and reliability processes is essential to identify gaps and improvement opportunities.
  • Optimizing parts inventory for easy ordering, unique identification, and optimal stocking levels.
  • Ensuring bills of materials (BOMs) are accurate and comprehensive.
  • Regularly updating criticality rankings for assets.
  • Defining maintenance strategies based on asset criticality and failure modes to ensure timely and appropriate maintenance tasks are performed. Control systems and procedures should be in place to monitor equipment and prevent failures, especially in electrical systems.
  • Maintaining cleanliness in the plant and ensuring proper lubrication of assets. Cleaning is a key part of preventive maintenance routines to support equipment longevity and early detection of issues.
• Enhancing craft skills and fostering accountability:
  • Training craftspeople in precision maintenance techniques to ensure proper installation, alignment, balance, and torque. Mechanics play a vital role in inspections, troubleshooting, and maintenance activities.
  • Empowering operators to participate in defect elimination efforts. Engaging employees in reliability initiatives is crucial for sustained improvement.
  • Implementing competency development plans for all trades, emphasizing team collaboration and the value of a skilled team.
• Strategically deploying high-tech solutions, such as live-monitoring technologies, exclusively on the most critical assets. The use of modern tools, software, and data for condition monitoring—including vibration measurement devices and integration of new equipment—enhances reliability and operational efficiency.

Managing maintenance budgets, reviewing lubrication practices, and creating tailored maintenance programs are essential to meet client and customer needs. Regular review of lubricant types and storage systems helps control contamination and improve operational efficiency. Developing and implementing structured programs, such as a program of the month, ensures consistent execution and continuous improvement.

These initiatives are focused on assets and processes and can typically be implemented within a few years. However, their successful execution relies on the commitment of industry leaders and their collaborators/providers. Being committed to customer success, working closely with clients, and supporting site-specific projects such as machining and welding are vital.

Ongoing research and development are necessary to develop new solutions, and it is important to remain interested in continuous improvement and maintain a sense of urgency when failures occur. Setting clear priorities for maintenance work and planning for timely replacement of critical components are also key to achieving operational excellence.

Role of a Reliability Engineer

A reliability engineer is at the heart of any successful manufacturing facility, driving operational excellence by ensuring that equipment and systems perform at their best. Their expertise is critical in developing strategies that minimize maintenance costs while maximizing the reliability and performance of both new and existing equipment. By taking a holistic overview of the plant’s operations, a reliability engineer identifies potential points of failure.

One of the key responsibilities of a reliability engineer is to implement advanced techniques such as vibration analysis and oil analysis. Vibration analysis allows for early detection of mechanical issues in rotating equipment, helping to prevent unexpected breakdowns and costly downtime. Oil analysis, on the other hand, provides valuable insights into the condition of machinery, enabling timely oil changes and targeted maintenance that extend equipment life and reduce overall costs.

Beyond these technical skills, reliability engineers are instrumental in developing and optimizing maintenance schedules. They prioritize critical tasks, ensuring that essential systems receive the attention they need to operate safely and efficiently. By focusing on proper alignment, balance, and lubrication, reliability engineers help maintain the integrity of equipment, reduce the likelihood of failures, and support the organization’s commitment to quality and safety.

Ultimately, the reliability engineer’s role is about more than just maintenance—it’s about creating a culture of reliability that supports the long-term success of the organization. Their strategies and expertise not only protect the facility’s assets but also contribute to the broader goals of industrial resilience and national prosperity.

Conclusion: Reducing maintenance costs

Ensuring economic stability relies on prioritizing maintenance practices to guarantee the smooth operation of industrial machinery, supported by a comprehensive range of professional services that include maintenance, repair, installation, consulting, and training. These services help minimize costly downtime and disruptions while fostering investor confidence and sustaining steady industrial output. This maintenance not only safeguards national security interests by fortifying critical infrastructure but also promotes environmental sustainability through waste and emissions reduction. Additionally, it prioritizes public safety by adhering to rigorous safety standards and fosters technological innovation, positioning nations at the forefront of progress and driving economic growth and prosperity.

These key elements embody the spirit of patriotism. As nations navigate the challenges of the 21st century, prioritizing maintenance and reliability is not just a matter of practicality—it’s a patriotic imperative that lays the foundation for a prosperous and resilient future.

Yoann Urruty, Eng., CMRP
Director of Technologies – Spartakus Technologies
[email protected]