Safety First

In all cases, even if not specifically mentioned in the writeups, verify that the tip does not violate any relevant code, standard, or practice. Always use the appropriate safety equipment and procedures when applying the maintenance tips.


In all cases, even if not specifically mentioned in the writeups, verify that the tip does not violate any relevant code, standard, or practice. Always use the appropriate safety equipment and procedures when applying the maintenance tips.

Quick shaft fix

Problem: A bearing becomes loose on a shaft and a spare shaft is not available. How can you quickly rework the shaft and provide a tight bearing fit?

Solution: Remove the bearing from the shaft. Using a hammer and center punch, pit the shaft uniformly around its circumference in the bearing area (see detail). The impact of the center punch creates a small crater surrounded by a ridge. The ridges hold the bearing in place and minimize downtime.

Contributor: Luc Raeckelboom, Curing Engineer (retired), Michelin Tire Co.

Cleaning paint rollers

Problem: Cleaning paperboard core paint rollers is a time-consuming job. Is there a faster, easier way?

Solution: Shove a short extension handle into the ground and screw a paint roller handle onto it. Slide on the dirty roller. Using a garden hose and sprayer, saturate the roller. With a strong spray stream, get the roller to spin quickly, throwing off the paint. (You may want to stand to the side during this operation). Stop rotation with the spray, resoak the roller, and spin it in the other direction. When thoroughly clean (usually three or four spins), let the roller dry. It will look as though it just came out of the wrapper. Note: this method only works for water-based paints.

Contributor: David Fischer, Plant Engineer, Loparex, Inc.

Moving heavy ladders

Problem: Fiberglass ladders are safe to use in most applications in a plant, but they are heavy. Is there a way for one man to easily carry them?

Solution: Take a piece of scrap, 11/2 in. thick, rigid polystyrene foam insulation and cut it for a tight fit inside the upright channels of the fiberglass ladder. Place one piece on each side of the ladder at the balance point. This makes a nice cushioned pad for setting the ladder on your shoulder while carrying it.

Contributor: Frank Kerkvliet, Maintenance Engineer, Sterner Lighting Systems, Inc.

Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
October 2018
Tools vs. sensors, functional safety, compressor rental, an operational network of maintenance and safety
September 2018
2018 Engineering Leaders under 40, Women in Engineering, Six ways to reduce waste in manufacturing, and Four robot implementation challenges.
GAMS preview, 2018 Mid-Year Report, EAM and Safety
October 2018
2018 Product of the Year; Subsurface data methodologies; Digital twins; Well lifecycle data
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
October 2018
Complex upgrades for system integrators; Process control safety and compliance
September 2018
Effective process analytics; Four reasons why LTE networks are not IIoT ready

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
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