Adding power-factor correction capacitors to a factory can improve electrical efficiency at the distribution level, but it can also create a serious power-quality problem. In facilities with variable frequency drives (VFDs) and other electronic equipment, capacitor banks may amplify existing harmonic currents instead of improving overall electrical performance. The risk Continue Reading
Brandie Jordan
Thermal Expansion Can Make a Good Machined Part Look Out of Tolerance
A precision-machined component can pass inspection at one temperature and fail at another without any permanent change to the part. The difference may come from thermal expansion rather than poor machining. This is especially important when manufacturers inspect components immediately after machining, move them between production and quality laboratories, or Continue Reading
Regenerative Servo Drives: Why Recovered Braking Energy Does Not Guarantee Big Electricity Savings
Regenerative servo drives can reduce industrial electricity consumption by recovering energy when motors slow down or when loads drive the motors. However, the amount of energy generated during braking is not necessarily the amount of electricity a factory will save. Some braking energy is lost through friction and electrical conversion. Continue Reading
Cp vs Cpk: Why Good Capability Numbers Can Still Mislead Manufacturers
A strong process capability score does not automatically mean a manufacturing process is ready for production. Before trusting Cp or Cpk, engineers need evidence that the measurement system is reliable, the production process is stable, and the collected data represents actual operating conditions. These checks matter because a capability calculation Continue Reading
What If the Car Body Became the Battery? A £7 Million Program Is Testing Structural Power Composites
Structural power composites are pushing a provocative engineering idea toward a serious test: instead of carrying a battery inside a vehicle, part of the vehicle itself could store electricity. A new £7 million UK research programme gives that idea five years of concentrated work, shifting the harder question from “can Continue Reading
Wastewater Upgrade: From Violations to Compliance and 30% Water Reuse
The world of environmental rules is changing fast, mainly for cities in the U.S. The Texas Commission on Environmental Quality (TCEQ) has made big changes. Now, how well cities follow the rules is checked every six months. This looks at all the rule-breaking over five years. For many places, the Continue Reading
Why Predictive Maintenance Dashboards Need More Than AI Alerts In 2026
Predictive maintenance systems can collect more factory data than ever, but useful alerts still depend on matching sensors to failure modes, validating equipment data, and measuring real maintenance outcomes.
U.S. Machine Tool Orders Just Hit a Record—What the Manufacturing Investment Surge Means for Plant Engineers
Machine tool orders have become a useful signal of how aggressively U.S. manufacturers are preparing for future production. June 2026 pushed investment to a record first-half level, but plant engineers face a more practical question: can each facility absorb new equipment without simply moving the bottleneck somewhere else? A new Continue Reading
Predictive Maintenance Options: Vibration, Thermal, Ultrasound, and Oil—What to Use When
Modern industry needs a smart, tech-driven way to keep assets running and save on labor. This method, called predictive maintenance, uses a variety of predictive maintenance sensors and techniques. Choosing the right tool is key. Not every technology works for every asset. The best match depends on the asset type Continue Reading
Lubrication and Contamination Control for Custom Equipment
For custom machinery, reliability is key. A shift in mindset is needed. The goal is now to prevent contamination, not just control it. Controlling contamination is a reactive step. Preventing it is the goal to reduce risk. It involves looking at the whole process, from start to finish. This approach Continue Reading