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Become a Friendlier Person for your Reliability Culture

Friendly ST.
Photo by Tim Green

Dale Carnegie founded his training program in 1912.

Over 100 years later, the same course is taught to students, business people, and leaders. The course is not just about public speaking, but building relationships, influencing people to your way of thinking and finally becoming a leader.

In 1936 he wrote his famous book, How to Win Friends and Influence People.

It is from this book, that the principles to winning friends and influencing people were born. Using his key principles as a guide, we can bring about change within our organization.

How these principles enable a Reliability Culture will be covered in this and the next two posts. [Read more…]

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Usability and Its Impact on Risks

Usability and Its Impact on Risks

Guest Post by Howard M. Wiener (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

How we design and implement systems and processes can play a large role in determining their usability.

Poor usability can contribute to avoidable risks.  This post addresses the need to employ risk identification and mitigation techniques in the course of designing things in order to minimize the probability of negative outcomes. [Read more…]

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Valuable Secrets in Every Work Order Report

Valuable Secrets in Every Work Order Report

The work order report is the maintainer’s opportunity to advise the engineer what problems exist with equipment out in the plant.

It can also provide an accurate record of what was found during the repair. This makes it important that work order reports are completed in detail and are reviewed by managers and engineers.

Keywords: CMMS, computerized maintenance management system, breakdown, corrective, work order, implementation. [Read more…]

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Introduction to Design for Reliability

Introduction to Design for Reliability

Chapter 7 Design for Reliability of the book Practical Reliability Engineering starts with:

The reliability of a product is strongly influenced by decisions made during the design process.

The key message here is reliability occurs at the point of decision. Each time someone makes a decision, selects a component, chooses a material, assumes a use profile, the eventual product reliability takes shape.

Design for Reliability, DfR, is about making good decisions across the organization concerning reliability. [Read more…]

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When Management Doesn’t Listen

When Management Doesn’t Listen

A Bloomberg articles details the Takata airbag recall series of events. The line that caught my attention is:

…company documents suggesting that Takata executives discounted concerns from their own employees and hid the potential danger…

“Sixty Million Car Bombs: Inside Takata’s Airbag Crisis”, Susan Berfield, et.al. Bloomberg Business Week, posted June 2nd, 2016, https://www.bloomberg.com/news/features/2016-06-02/sixty-million-car-bombs-inside-takata-s-air-bag-crisis

There are other examples where management doesn’t seem to listen when engineers raise concerns. Have we cried wolf too often? Has management gotten used to taken risks as a good business practice?

At times reliability risks are real and need to be clearly communicated. Let’s talk about how you can effectively get the message across. [Read more…]

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RCM Leaders and Followers

RCM Leaders and Followers

Funny how times change.

When I first began speaking at conferences in 1999 some of the statements I made regarding how to most effectively manage a Reliability Centered Maintenance program were publically criticized by practitioners of other methodologies.

Sixteen years later it seems that those who were at first critical of RCM Blitz® seem to have adopted nearly every change I made to make RCM easier to Manage, Facilitate and provide a return on investment (ROI) for the time it takes to train people, perform the analysis, implement the results, and perform the RCM tasks. [Read more…]

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Managing Failures Before They Occur

Managing Failures Before They Occur

Welcome to part eight of my 10-part series of blogs called “Uptime Insights”, where we explore a journey of excellence in maintenance.

To stay on top, managers must implement strategies that keep operations performing at high levels. In these articles, I will show you how to achieve excellence in maintenance – a critical business process in any capital intensive industry.

Uptime Insights Part Eight:

Asset Reliability

Being proactive with your assets is all about managing failures before they occur.

You can reduce or eliminate the consequences of failure by forecasting what is likely to happen and deciding in advance about what to do about it.  The advantage to doing this is that major business impact due to equipment breakdown can be avoided.

High performing companies manage proactively – they foresee and avoid problems.

It’s good for business! [Read more…]

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5 Days to a Reliability Culture

What you can do to foster a reliability culture at your operation

Reliability culture is like clockwork
© William Warby

Improving reliability is easier said than done.

Often times you can develop great PM routines, improve equipment and have the right processes in place, but reliability doesn’t improve. Why is that?

It all comes down to people. People are the heart of reliability, whether they run the equipment or maintain it.

Changing people’s perception of reliability can be a very difficult task. So where do we start?

When trying to implement such change, you will often hear of change management and change framework.

This is a great exercise and contributes greatly to success. But what if you are a Maintenance Supervisor who needs a tangible action that you can run with? [Read more…]

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Unconscious Risk Management

Unconscious Risk Management

Guest Post by Ed Perkins (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

While we look at risk-based decisions and making decisions under uncertainty, these approaches all have one basic assumption – that the participants in these processes are doing so consciously, with eyes open and with an appreciation of the risks and consequences involved. [Read more…]

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Siegel-Tukey Test for Differences in Scale

Siegel-Tukey Test for Differences in Scale

There are a few different reasons we explore differences in scale.

Keep in mind that the scale of a dataset is basically the spread of the data. For most datasets, we’re examining the variance.

Hypothesis tests comparing means vary depending on the assumption of equal variances. Thus testing that assumption requires methods to adequately test the homogeneity of variances. The F-test should come to mind as it is a common approach.

Some datasets do not lend themselves to using the F-test, which is applicable using real numbers. Some datasets gather information that is ordinal or interval data, thus we need another approach to test for differences in scale. [Read more…]

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Support Systems Improve Efficiency

Support Systems Improve Efficiency

Welcome to part seven of my 10-part series of blogs called “Uptime Insights”, where we explore a journey of excellence in maintenance.

To stay on top, managers must implement strategies that keep operations performing at high levels. In these articles, I will show you how to achieve excellence in maintenance – a critical business process in any capital intensive industry.

Uptime Insights Part Seven:

Support Systems Improve Efficiency

Computerized systems are important and now seemingly indispensable tools for business.  Just remember the last power failure you experienced and you’ll understand.

There isn’t much that isn’t computerized these days.  Technology and its business applications continue to grow and proliferate.  The world of maintenance is no exception.

Most maintenance work is not computerized, but it is complex and managing it requires sophisticated tools. Using those tools effectively will improve the efficiency with which you deliver maintenance services.

Use them poorly and you only add cost. [Read more…]

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Do You Make This Critical Mistake? Find Out If You Are Contributing to Reactivity

Do You Make This Critical Mistake? Find Out If You Are Contributing to Reactivity

What is the one thing that all operations have? If you guessed a breakdown hero or fire fighter, you are correct.

You know the person who swoops in like Superman and repairs a machine quickly. These breakdown heroes are the people who reduce the time to repair, but do they contribute to or reduce the reactivity of the site? [Read more…]

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Never Purchase a Retired Rental Car

Never Purchase a Retired Rental Car

If you look around you day to day you can see a lot of examples of reliability testing.

When you are at the hardware store and looking at new power tools, notice which have broken switches, triggers, handles.  Many of us often just think it’s a defective one.  But it’s not.  It’s the weakest model of the bunch.

If all the models were put on display at similar times they have all been going through life cycle testing.  Every person that walks by picks it up and pulls the trigger, flips the switches bangs it around a bit.

It’s getting its life cycle testing done right in front of you. The one with the broken features is the model with the shortest life.  [Read more…]