Reliability and Maintenance Management Beliefs

"IDCON - A Reliability and Maintenance Management Consulting Firm"  

Excellent leadership is an essential success factor for lasting results for any improvement initiative an organization undertakes, including improvements of Reliability and Maintenance performance. As a leader you need to create an organization of disciples that will follow you to make your vision, or future organization, a reality.

shutterstock_443688484

As a leader I have found it very important to develop and communicate your beliefs to your organization. These beliefs will then be guiding your organization on their journey to your goals.

In this column I will share two beliefs of my own and that I hope can serve as a guideline to develop your own beliefs.  

christer_idhammar

Christer Idhammar
Founder and CEO of IDCON INC. 
Raleigh NC, USA

info(at)idcon.com

Lost Production Reports

In most organizations the operations department is viewed as an internal customer to the maintenance department, and the maintenance department view themselves as a service organization to the operations department. This working relationship is often reflected in the lost production reports. Lost production is reported by department e.g. Operations, Mechanical, Electrical and Instrumentation etc. This serves no purpose more than to find someone to blame. It is also very often wrong because it frequently reports the symptom instead of the cause of the problem.  E.g. an electric motor failed and caused lost production. This is often reported as down time due to an electrical problem, but the cause to the motor failure can be something different. If you want to create a partnership between operations and maintenance the common goal between these two departments is reliable production. 

1

Solve and Eliminate Problems

This belief shall be documented and reinforced in a mission statement. An example of a production, or manufacturing mission statement could be. “In a partnership between operations and maintenance we shall safely deliver continuously better production reliability”.  Then all work processes, including lost production reports, must be designed according to the mission statement.

Instead of reporting lost production by department it should be reported where, when and what happened. A trigger is set to filter what events shall go through a Root Cause Problem Elimination (RCPE) activity. In a RCPE process the first step is to clearly describe the problem in a problem statement, and then ask “why” or “how” can the problem occur? This process will help build a partnership. Also notice we talk about problems, not failures. The term failure will lead thoughts to equipment and maintenance, while the perm problem is more inclusive of everybody.

2

Keep Things Simple

Sustainable improvements in reliability and maintenance performance is “90 percent” about getting skilled people to work in a disciplined system. The technology part is important and easy to get people interested in. E.g. buying a new handheld data collector for equipment condition monitoring can be interesting, but to use it in a disciplined system, report failures, plan correction of found failures, schedule execution of correction of failures, report what was done, and to use this information to avoid repetition of the failures, that is more of a challenge. 

Technology is the only thing that has changed significantly in the last 50 years. The principles on how to manage maintenance are pretty much the same. New names on well-known concepts occur frequently and this can be very confusing to people. 

Perhaps it started many years ago when a new manager implemented “Planned Maintenance”, this lead to short, but not sustained improvements. The next initiative, often with a new manager, was “Predictive Maintenance”. Again short-term results were generated. When results disappeared the next action was to implement TPM (Total Productive Maintenance). When also this initiative failed to give the significant sustained results that had been expected it was time to enter into AM (Asset Management) and then RCM (Reliability Centred Maintenance), RBM (Reliability Based Maintenance), 5S, Six Sigma, Total Production Reliability (TPR), Lean etc. Nothing wrong with all these initiatives but it is of vital importance to stick with one holistic system and clarify the difference between the system and the tools used to enhance the system performance. Almost all initiatives were initiated by changes in management. Best performing organizations have documented and implemented best practices for reliability and maintenance and over time consistently executed these practices better and better. While seeing results every year, after two to seven years they have been rewarded with break-through results.

Because of the confusion all these concepts and tools it is important to simplify as much as possible. Successful organizations have done that and focused on continuously improving the basic processes: Prevention, Inspections, Planning, Scheduling and Execution of work.  

3
Asset Management | 22.11.2016

Latest articles

Research report: Predictive Maintenance 4.0

A growing number of companies want to use big data analytics in their predictive maintenance and are also investing in the resources needed for this. Of the companies already using this technology, no less than 95 percent say that they have already achieved concrete results. This is the conclusion of a follow-up study conducted by PwC and Mainnovation among 268 companies in the Netherlands, Germany and Belgium.

Asset Management | 17.1.2019

12 Helpful Tips for Doing IT Service Desk

Over the years, the evolution of technology and the adaptability of the people to it, has been increasing drastically. This process has brought about a boom in the service sector, making the IT subunit of it, the most successful.

Cmms | 27.12.2018

It’s About “Time”

At Bentley Systems, we have been talking to our users, especially owners, and it has become clear that despite our collective best efforts, there is a gap in the market.  Owners need easy access to real-time, accurate, engineering information and they need tools that make it simple to keep engineering data up-to-date, especially those engaged in brownfield and revamp projects.  It takes too much time and effort to gather and verify the information they need to make decisions effectively. And for older plants that do not have 3D models, there is simply no visual way to verify and check information easily.

Partner Articles | 10.12.2018

How to Choose an Air Compressor, According to Science

Buying an air compressor, for the first time, can be challenging in many ways. There is a lot going on behind this power tool that offers faster and more efficient performance. Before we get to know about the details of an air compressor then, let’s understand how it works. How do air compressors work?

Applications | 10.12.2018

8 Ways to Identify and Eliminate Noise Hazards in the Workplace

Occupational noise hazards are one of the most common workplace safety concerns. Our hearing is sensitive and it does not take much to temporarily impair or permanently damage it. 

HSE | 10.12.2018

Bacterial Bandages, Natural Dyes and Recycled Fibres: Aalto Brings Materials Revolution to Slush

New materials play an important role in sustainable development and combatting climate change. New uses for old materials can also be a major industrial opportunity: for example, the value of biomass from forests in Finland can be doubled if used for manufacturing products of higher added value.

R&D | 4.12.2018

Maintenance: A Necessary and Important Function in the Future

Euromaintenance 2016 will take place in Athens at the end of May. It is the ideal moment to reflect on maintenance in a European context. Euromaintenance is known as the summit for all involved in maintenance across Europe, it’s the place to be. The conference, with the support of the EFNMS, is the only commercially independent conference covering the topics we deal with in the maintenance world.

EFNMS | 20.5.2016