Your Reliability Engineering Professional Development Site
OPERATIONAL EXCELLENCE REQUIRES BEST-PRACTICE PHYSICAL ASSET MANAGEMENT, MAINTENANCE MANAGEMENT, AND WORLD CLASS RELIABLE EQUIPMENT, WHICH YOU GET WITH A PLANT WELLNESS WAY EAM SYSTEM-OF-RELIABILITY
Successful Operational Excellence requires a business-wide, life-cycle asset management system with the methods and practices that ensure utmost productivity and top-of-class operational performance
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There are only two ways to get high system reliability: meeting outstanding task quality performance standards so excellence is done everywhere, and by building parallel arrangements where the failure of one has no impact on system performance. Both are done in a PWW EAM System-of-Reliability
Equipment can be configured in series or in parallel arrangements. A series arrangement is when one item or task connects sequentially to the next. It takes only one item to fail in a series arrangement and the whole system will fail. Exceptionally reliable individual equipment is needed to experience a high-reliability system with a series arrangement.
Parallel arrangements are when each item is arranged as a companion, one duplicates another. In this circumstance, exceptionally reliable systems can be formed even if individual equipment has poor reliability.
A system is formed when equipment is combined to do a duty. For example, when a pump, coupling, and electric motor are connected they form a series system used to move liquid through pipes from one point to another.
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ISO 55001 Certification Bodies are accrediting Service Providers to the ISO 55001 asset management standard in the misconstrued belief that a Service Provider’s ‘asset’ is the Contract with a Client. This misunderstanding is dire for service business success.
Having lots of paying clients is the cause of a Service Provider’s success. For a Service Provider, THE ASSET IS THE CLIENT. The Contract with a Client is not the asset!
There is a wonderful ISO 55001 certification benefit you get when YOUR CLIENT IS THE ASSET: The Contract between you and your Client can become your ISO 55001 Strategic Asset Management Plan (SAMP). After all, the Contract explains how you will provide your services to help the Client achieve their organizational goals. That’s exactly what a Strategic Asset Management Plan is meant to do.
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AN ENTERPRISE ASSET MANAGEMENT SYSTEM UNITES OPERATIONS, ENGINEERING, MAINTENANCE, AND THE SUPPLY CHAIN ACROSS THE ASSET LIFE CYCLE TO MEET CORPORATE BUSINESS OBJECTIVES AND PRODUCE HIGH PLANT AVAILABILITY AT THE LOWEST LIFETIME COST AND MOST OPERATING PROFIT
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An enterprise asset management system needs asset reliability improvement processes throughout the life cycle that ensure utmost reliability and eliminate the need for maintenance. You can do that with a Plant Wellness Way EAM System-of-Reliability
What exactly is an Enterprise Asset Management System?
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Here are some truths and hard-won learning for engineers thinking of becoming a Maintenance Consultant, or any other sort of consultant. There are important know-hows covered in this article that you need to understand if you want to build a maintenance consultancy that delivers you consistent cash flow. I could have written a lot more, but there are really only two determinants you must focus on to become a viable consultancy: marketing and innovation. Read about how Lifetime Reliability Solutions Consultants started and what we had to learn to to market ourselves and survive when the business plan turned out to be completely useless.
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Reliability Block Diagrams are a powerful reliability analysis tool. They are visual representation of reliability and risk that exists within machinery or work processes.
They allow the user to notate the reliability of each part or task and calculate the reliability for the whole scenario. The use of Reliability Block Diagrams extends to all aspects of operational processes and procedures, both as series and parallel arrangements.
Once a Reliability Block Diagram is created, you can do “what-if” scenarios to identify the defects that can happen to each part. This information allows you to then make informed decisions about to how to proactively eliminate the causes of each risk or defect, and by extension, eliminate that cause of failure.
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The Care and Conditions You Give to Your Body Show the Values and Principles You’ll Use On Your Organization’s Physical Assets
The ancient Egyptian saying, “As above, so below. As within, so without” contains much truth. What you create outside of you comes from inside of you. Which implies if you want to have a particular thing it’s necessary to first create the capability inside of you. To achieve your goal by any other way is due to random luck.
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VITAL PLANT AND EQUIPMENT RELIABILITY TIPS FOR WORLD CLASS PRODUCTION RESULTS WITH A PWW EAM SYSTEM-OF-RELIABILITY
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With Plant Wellness Way EAM you will change to engineering, operating, and maintenance methods that guarantee world class reliability practices are done throughout your company and its operations
Imagine your business without breakdowns, fewer spare parts in a smaller parts Store and lower operating costs everyday. All the while you enjoy world class reliability success that delivers outstanding plant availability in all of your operating plants. To get to this world you will need to Change the Game to one where you guarantee fantastic reliability success! [Read more…]
As The Saying Goes, “How You Do Anything Is How You Do Everything.”
Your work quality should bring you great joy every time you do your job. There’s a little secret that will let you love work and draw happiness from every task you do.
Competition against others only gives you satisfaction when they lose, and you beat them. It’s such a sad, poor way to live life. Yet competition against yourself brings you joy every time you use it.
I love making my bed to world-class work quality in the morning. It makes me happy. That’s because the job satisfaction is entirely in my control. Whether you leave your bed looking like a tornado hit it, or you leave it like a 5-star showroom display, is completely up to you and you alone. I leave my bed made up to 5-star world-class work quality every day because it makes me proud. And being proud of my work brings me satisfaction and happiness.
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The total cost of downtime extends across the business. In the worst cases, it impacts the entire organisation and customers.
From the moment of failure to the restart of production, no saleable product is made. Instead, money is spent on repairs, with continued fixed costs, and any potential profits that could have been made from saleable products is lost. The graph below illustrates what happens to production time and costs when operations stop due to equipment breakdown (t1). The time and costs required to repair the equipment to operational levels (t2) is unknown at the start of the breakdown.
During this time (t1 to t2) resources and money are needed to return the equipment to operation. Additional costs due to loss of production and therefore potential profit losses are also incurred in this time.
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With thousands of opportunities to make human errors and mistakes in a job an ACE 3T standard operating procedure is a powerful way to get work done right-first-time. When the situational risk from errors is too high a Plant Wellness Way EAM System-of-Reliability uses ACE 3T SOPs to ensure work tasks and activities are correct and error-free.
We’re all human, and humans make mistakes—lots of them every day. The image below warns that 10 to 30 errors per 100 opportunities is typical for trained people not using a standard operating procedure. Mistakes happen to all of us. The more complicated the job and the more stressful the situation the higher is the human error rate. A PWW EAM System-of-Reliability protects against human error by giving people an ACE 3T standard operating procedure to follow and be 100% successful.
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ISO 55000 and ISO 55001 are frameworks into which you must add the correct policies, procedures, knowledge, and actions that deliver world class physical asset management. They cannot of themselves cause asset management, maintenance and operational excellence. Users of ISO 55000 and ISO 55001 must turn the framework into a full set of the correct and proper processes and practices used business-wide and life-cycle-long in your company to cause it to operate at world class performance.
What is missing in ISO 55001 you do with the Plant Wellness Way enterprise asset management methodology. There is but one rule to follow in the PWW EAM methodology to get the best asset management and operational excellence solution: Produce the least atomic stress state in component materials-of-construction all the time. Select strategies, procedures and practices that cause that result and you have the best asset management solution to feed into an ISO 55001 framework. Plant Wellness Way EAM perfectly complements ISO 55000 and ISO 55001 so that when used together you build a life cycle EAM system with the processes and practices that ensure outstanding equipment reliability and great enterprise asset management success.
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Use Equipment Criticality to Match Planned Maintenance Strategy to the Operational Risks
Planned maintenance has the purpose of rejuvenating equipment before parts start failing. Use maintenance strategy based on continual renewal to reduce operating equipment risk of failure so that you have your plant and equipment in good condition and thus free of age and stress related defects waiting for the chance to fail.
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The true cost of maintenance to a company includes the lost production time, cost of utilities not used, overhead costs, handover costs and more.
A 6-step procedure that guides you and your organization, department, and team to analyze your business and operational risks, and develop an enterprise asset management system that is purpose-built to deliver your organization world class reliability.
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Most equipment failures have no relationship to length of time in-service. Most failures are unpredictable. But if you detect a future failure early, you can plan and do the repair cost effectively before it becomes a breakdown.
With only about 15% to 20% of your equipment failures being age related, and the other 80% to 85% being totally time-random events, how can you improve the uptime of your plant and facility? This article explains how to detect the random failures that make-up the vast majority of maintenance expense and production downtime by using simple, low cost condition monitoring methods.Keywords: equipment condition monitoring, random equipment failure, equipment failure patterns
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