Maintenance Management

Guest post by B.D. McLaughlin, ScD, MInstrP

 Using a comprehensive and inclusive definition, risk may be defined as the cost of “failure to add value” per unit time. Such failure includes performance deficiencies for employees, equipment, material and method. It includes the types of “failure to add value” comprising traditional waste such as overproduction, wait time, transportation, processing, inventory, motion and defects. It includes the cost of injury, litigation and damage to company reputation. It encompasses the total cost of failure and not just the cost of remediation. You must minimize risk to stay competitive. Risk is consuming the hidden wealth of your enterprise. It is disguised and concealed as the “cost of doing business.”

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 Users of the Plant Wellness Way EAM methodology use accuracy-controlled procedures to turn their company into an Accuracy Controlled Enterprise: a quality driven, “learning organization” effectively using useful technologies.

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Make Use of a Risk Cost Calculator and Risk Matrix

Risk is probabilistic—a risk event may happen or it may not. The human mind struggles to understand probability until you make a picture.

Here is a simple visual management tool to let you see the impact of changing risk. Combine it with a risk cost calculator and you have an effective way to see how your risk changes with risk management plans and risk abatements

We are blind to risk. Most of us have to suffer a risk event before we know we are in one. We first experience pain and then we realise that we need to stop doing what is causing the pain.

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Maintenance Planning and Scheduling can be learnt on the job, but to become a very good maintenance planner and maintenance scheduler you still need to know the reasons behind why you do things in certain ways when you plan and schedule maintenance work orders.

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Maintenance Audits do not bring You Maintenance Success

The very best monitoring and measuring analysis you can do for your company’s maintenance success is to develop the distribution curves of your range of maintenance KPI’s.

At least they will be useful in the honest decision-making you need to do to continually become a better and better maintenance performer.

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The Most Successful Workplace Safety Improvement Program

Guest post by Aaron Derby

Behaviour Based Safety (BBS) programs address safety culture barriers with effective solutions for changing safety culture and securing a positive safety behaviour change.

Behaviour Based Safety passively and positively changes existing unsafe workplace behaviours by identifying and reinforcing the use of the right behaviours that protect people in real-world safety problems.

In workplaces that want high safety performance, behaviour based safety programs, when properly implemented, significantly improve personal safe performance and greatly reduce workplace injury and illness.

Behavioral Observation Programs using behavior based safety management reduce safety incidents by bringing beneficial workforce safety behavior change.

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 The Plant and Equipment Wellness Way was designed to quickly create Operational Excellence success. You can only get the Plant Wellness Way from LRS Operational Excellence Consultants.

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 To help select which work orders to do first in situations of resource shortage many CMMS provide calculations for maintenance work order priority. Deciding maintenance work priority is a risk decision. The presence of risk totally changes the way to allocate maintenance job priority if you want to compare situations equally¹. When you work with risk you cannot use a linear priority scale. Using linear priority ranking gives the wrong order of importance for doing maintenance work.

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 and Probably Already Has 

 Predictive Maintenance strategy uses condition monitoring techniques to observe plant and equipment health. Based on the equipment’s condition you plan, schedule and perform any necessary maintenance before the breakdown. To use Predictive Maintenance most successfully you must set-up and run your condition monitoring program correctly all the time—predictive maintenance is a never ending strategy that if not done right at every step will still lead to plant and equipment failures. Learn about the many ways your predictive maintenance program will fail and you won’t even know about it! 

Keywords: predictive maintenance, condition monitoring, Con Mon

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Now SFAIRP is the Criterion to Judge If You have Sufficiently Controlled Your Workplace Hazards

Risk Assessment Used to be Based on ALARP to Decide if Workplace Hazards were Sufficiently Controlled, But Today You Need to Use SFAIRP

The original OHS risk assessment process, procedures and techniques identified hazards; assessed risk; established risk controls; reduced and managed risks to ‘as low as reasonably practicable’ (ALARP), but safety laws are now changing to ‘so far as is reasonably practicable’ (SFAIRP) [Read more…]

To not have a problem you must prevent its creation. Once a problem exists you can never stop it repeating until all its roots are eliminated. Doing Root Cause Analysis (RCA) on a problem to try and prevent it has a miniscule chance of working because you can never find all the roots of its cause. The roots you do not eliminate will let the problem grow again. 

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How to use Condition Monitoring Reports to do Maintenance Planning of the Maintenance Work Activities that will prevent Equipment Failure

This article by Peter Brown, a vibration analysis condition monitoring expert, explains how to address and action condition monitoring reports from your condition monitoring service provider.

Abstract

Maintenance Planning From Condition Monitoring Reports.  Having developed the finest condition monitoring programme that provides all the data required to predict plant behaviour it is now necessary to convert that data into information and to plan it in for action by the maintenance team at a time that is compatible with operations.

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Reliability by prevention vs. reliability by failure analysis

Here is a story of multimillion dollar aircraft failures that could have been prevented by spending $25. But no one did the risk analysis right using a financial model of the consequences. It’s also the story of why RCM is a poor maintenance strategy selection methodology. RCM will send you to financial disaster and you won’t even know it. Learn how to decide when doing preventive maintenance is far better for business success than doing the on-condition maintenance recommended by business-destroying RCM analysis.

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To Embed Safe Work Practices You Write Detailed, Strict Workplace Safety Procedures that Get World Class Job Safety

You must select OHS risk management mitigations appropriate to a job safety hazard using a formal method that delivers safe work practices.

Each task safety control will need to be developed, assessed for suitability, and recorded so it’s clear what the plan is, and how it is to be done.

In the end, there is a practically designed, completely resourced, fully scheduled, and totally sure safe work practice procedure approved for use.

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 This is an example of the value of identifying the variability in your business processes and removing them before spending money on new capital works. A simple production rate distribution bar chart shows you whether you have a “hidden factory” and how big it is. 

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