Mike Sondalini — Thought Leader

An example of an Accuracy Controlled Enterprise ACE 3T (Target – Tolerance – Test) Procedure with reliability standards to install taper spherical roller bearings on adaptor sleeves in Plummer blocks with taconite seals for 30mm-250mm diameter conveyor shafts 

 Machine performance is totally dependent on human beings. To address the problem of human error causing equipment failure, an Accuracy Controlled Enterprise sets best practice quality standards and uses 3T Target-Tolerance-Test work task quality control that assures high quality workmanship for high reliability results. Their work procedures are standardised so everyone follows the same methods to produce the same results, their training teaches people how to do craftsmanship work that creates outstandingly reliable plant and machinery. They create the reliability they want and as a result achieve operational excellence.

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ENSURING YOUR MANAGEMENT DESIGN-IN OPERATIONAL EXCELLENCE TO GUARANTEE THE LASTING SURVIVAL OF YOUR COMPANY IS WHY QUALITY GURU W. EDWARDS DEMING ASKED HIS FAMOUS “WHAT?” AND “HOW?” QUESTIONS.

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Deming would expect that managers had a solid answer to the question: “If you want your company to reach Operational Excellence in the next five years, then explain to us all, EXACTLY HOW will you do it?”

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WHEN YOU DO A RELIABILITY FAILURE STUDY LOOKING TO PROTECT YOUR BUSINESS AGAINST LARGE UNCOMMON FAILURES, AND THOSE FAILURES THAT ARE VERY COMMON BUT THOUGHT TO BE TOO SMALL TO BE A SERIOUS PROBLEM, BE SURE TO DO LIFETIME FINANCIAL ANALYSIS WHEN DECIDING THE FAILURES TO INVESTIGATE

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I am to do a reliability failure study and would like to know the definition of repetitive failure with respect to some recognized reliability standard.

We want to apply the recommendations in the standard for failure codes in our CMMS system to decide which equipment failures need a reliability failure study. For example, we have a centrifugal pump bearing fail twice in a year. I am of the opinion this is a repetitive failure.

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 All machines and equipment fail for two reasons—distortion or degradation. Distortion causes parts to suffer such high stress or fatigue that their atomic structures fail. When parts degrade their atomic structure is attacked by environmental elements. Physics of Failure methods lets us analyse equipment for situations that cause their parts’ atomic structures to suffer excessive stress, or to degrade. We can identify the real causes of atomic failure and so institute the fewest maintenance and operational activities to keep equipment at its highest reliability, and the operating plant at its highest availability.

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The aim of being in business is to satisfy customers in ethical ways while making a profit. To achieve this, variable and fixed costs should be as low as possible without sacrificing on quality products or customer experience.

The term Operational Excellence is often used to refer to a range of technical, soft-skills, and culture components. Regardless of how it is phrased, the core definition and goal are the same – to produce better operational results, and create value for customers and shareholders. In short, Operational Excellence performance is to produce the best quality products or services customers will buy for the lowest expenditure to maximize operating profit. The most successful businesses have built systems and processes that automatically keep their costs low and profits high

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 With the Quality that Improves Reliability

 Ultimately reliability is in the hands of the people that use, build and rebuild equipment. High equipment reliability requires precision workmanship and steady, considerate operation (known as Degradation Management). Both equipment operator and equipment maintainer need to be precise, they need to know exactly what to do to always produce great reliability. Most procedures and check sheets are so poorly written that they cause equipment to be failed. Standard operating procedures can create reliability if they ensure that users meet minimum quality standards. World-class standard operating procedures set not only a minimum level of quality, but they also set a highest level of quality that when achieved deliver amazing equipment reliability.

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Figures 1 and 2 are examples of getting stuck trying to fix your current business when instead you ought to throw your troubles away and build a better business system. 

This business is a renowned company in its home country. It is well respected and profitable enough. But it could easily be much wealthier. There are vast new fortunes sitting in the business, but they will never be seen by its owners and managers. They are totally focused each day on trying to make the existing business processes and system work properly. In reality, their operational processes need to be redesigned to remove the problems stopping them from delivering the organization’s purpose. [Read more…]