Blog

In my 30 years of experience, I’ve seen countless reliability programs chase complex solutions to complex problems while ignoring the fundamentals. What I’ve learned is this: your machines aren’t that complicated. If they could talk, they’d tell you, “Friction, Lubrication, Alignment, and Balance—fix these first!” We call it FLAB, and it’s where every asset reliability journey should begin. Add the power of ultrasound analysis—both airborne and structure-borne—and you’ve got the ultimate toolkit for keeping your equipment running smoothly. Here’s why FLAB, combined with ultrasound, is the foundation of reliability success: Friction: The Silent Saboteur What is it? Friction is the resistance between moving surfaces. It’s like sandpaper in your gears—a slow, grinding force that wears everything down. Why is it important? Left unchecked, friction eats away at your equipment, generating heat, increasing energy consumption, and causing catastrophic failures. How is it managed? Ultrasound analysis is a game-changer here. It picks up the high-frequency sounds that friction creates, even before vibration or heat becomes noticeable. By listening to these ultrasonic “whispers,” maintenance teams can pinpoint and address friction early—before it screams for attention. When is it critical? Every time parts move against each other—bearings, gears, or conveyor systems. Who should care? Maintenance teams and reliability engineers who are tired of hearing, “The equipment broke again.” Lubrication: The Lifeblood of Machinery What is it? Lubrication is the magic sauce that keeps your moving parts moving. It reduces friction, dissipates heat, and flushes out contaminants. Why is it important? Too little lubrication and your bearings burn out. Too much, and you risk damaging seals, creating leaks, or introducing contamination. Either way, poor lubrication management is one of the biggest reasons equipment fails prematurely. How is it managed? With ultrasound-assisted lubrication. This technique lets you “listen” to bearings in real time, ensuring you add just the right amount of lubricant. No more guessing or over-greasing. It’s precise, efficient, and saves money on lubricant and repairs. When is it critical? Always. A dry bearing is a dying bearing. Who should care? Lubrication technicians, reliability engineers, and anyone who wants their machines to hum along happily. Alignment: Keeping Things Straight (Literally) What is it? Alignment ensures that components like shafts and belts are perfectly positioned to work together seamlessly. Why is it important? Misaligned parts vibrate, wear unevenly, and put unnecessary strain on bearings and other components. It’s like running a marathon in mismatched shoes—you’re asking for trouble. How is it managed? Ultrasound detects the subtle high-frequency signals that indicate misalignment. These signals let you catch problems before they escalate into vibration you can feel—or failures that shut you down. When is it critical? Every time equipment is installed, repaired, or moved. Misalignment doesn’t fix itself. Who should care? Installation crews, maintenance planners, and anyone who’s tired of misaligned equipment wrecking their day. Balance: The Zen of Rotating Equipment What is it? Balance ensures rotating machinery distributes mass evenly around its axis, keeping operations smooth and steady. Why is it important? Imbalance causes vibration, noise, and stress on bearings and structures. Left unchecked, it leads to failures that are as dramatic as they are expensive. How is it managed? Ultrasound can detect imbalance by picking up changes in vibration signals before they become severe. Combine this with dynamic balancing techniques, and you can keep your equipment spinning happily. When is it critical? Anytime something rotates—fans, turbines, or pumps. Who should care? Vibration analysts, reliability engineers, and everyone tired of hearing, “What’s that weird noise?” Why FLAB + Ultrasound Is Your First Move Most reliability programs aim big, chasing complex solutions to complex problems. But FLAB isn’t complex; it’s fundamental. Add ultrasound to the mix, and you’re not just addressing the basics—you’re doing it smarter, faster, and more effectively. Friction, Lubrication, Alignment, and Balance: these are the villains your equipment faces every day. Equip your maintenance teams with ultrasound analysis, and you’ll be the hero who saves the day. Your machines will thank you, your downtime will plummet, and your budget will breathe a sigh of relief. Now, go tame your FLAB and let your reliability journey begin. If you'd like to see how well you are managing FLAB, take our short assessment and get a specific report. Click here . Until next time. Ian Ware