Reliability & Maintenance
Keep the automation baseline recoverable, then use evidence to prevent and diagnose failure.
Modern maintenance combines a recoverable PLC and control-system baseline with disciplined reliability methods. Start with cabinet health, verified backups, compatible spares and controlled restoration, then use FMEA, RCM, condition monitoring and failure evidence to focus the work that changes risk.
PLC System Reliability
Reliability Methods
What Is FMEA?
Failure Mode and Effects Analysis, the RPN, and a worked example.
Reliability Centered Maintenance
The 7 questions, the four strategies, and the RCM process.
Root Cause Analysis (RCA)
The process, methods, and a worked manufacturing example.
5 Whys Analysis
Find root cause iteratively, with examples and pitfalls.
Fishbone (Ishikawa) Diagram
The 6M categories and how to build one.
Strategy & Metrics
Condition Monitoring
Vibration Analysis Basics
Reading the spectrum, fault signatures, and PLC integration.
Acceleration vs Velocity
Which parameter to measure at which frequency.
Industrial Thermography
Infrared inspection for electrical and mechanical faults.
Shaft Alignment Explained
Misalignment types, methods, and why it matters.