Uptime – Essentials: You need these

In the first edition, the second tier of the pyramid was called “control”. Of course the harder we try to control something, the more complex we make things, and the more likely they will go awry. If you have teenage children you can see that very clearly! You want them to learn and mature, but if you try to control how they do it, you will have trouble. Less control, while providing guidelines and advice, and letting them make their choices will work far better. In “Uptime” the emphasis is on successful practice, not control. Control is exercised in how you decide to implement the practices. The practices remain “essential” to your success no matter how you deploy them. The subjects covered in this level of the pyramid have remained much the same throughout all three editions of Uptime but they’ve grown richer in detail, providing more insight, and with emphasis on how tightly integrated they really need to be with each other. [Read more…]

Leadership — Uptime, 3rd edition

Leadership

This is the base of the pyramid – its foundation, comprising Strategy, People, and Teams. It includes a few topics: Strategy and People and Teams. [Read more…]

Show me the money!

Benjamin Franklin’s axiom, “An ounce of prevention is worth a pound of cure”, has been used most commonly when referring to health care. It is also highly appropriate in reliability and maintenance circles.

Of course, we complicate it in business by wanting to know what the prevention will cost and what we save by avoiding the cost of the cure. [Read more…]

Why Do You Let Your Budgets Hold You Back?

The “no brainer” opportunity

Let’s say that you run your own business. You have an opportunity to invest some money and get a payback that is more than your total investment within the first year (payback is more than 100% in the first year). Moreover, that payback will continue for many years. Would you invest?

Most entrepreneurs running their own businesses would say yes. After all, the proposition is a “no brainer”. There aren’t a lot of investments with such huge paybacks. Yet many managers in most larger companies won’t go for it. Why? [Read more…]

The Link Between RCM Facilitation and Effective Maintenance

These are challenging economic times and opportunities abound with many of our customers to add new business value. They are turning to us and asking: “You’ve brought great value to our Reliability Centered Maintenance (RCM-R) program through knowledge capture, personnel education, laying the foundation for a ‘living’ maintenance program and so on. However, what additional value can you provide us beyond what you have already done?”  One answer: “Focus on writing high-value, asset maintenance tasks. i.e. Tactical PM Program Implementations”. [Read more…]

Increase Productivity and Competitiveness

Contributed by: David A DeCastro (Salvador, Brazil).

In traveling the world in search of excellence in MRO Materials Management (indirect materials / spare parts), I noticed two curious facts. First, even in developed countries, both the industrial companies and providers of ERPs (enterprise management systems) are often technologically quite backwards outside the realm of their product specialization. Secondly, those typically smaller companies or subject matter experts who have developed differentiated technology, tend to keep it as a safe and guarded trade secret, failing to commercialize their brilliance. [Read more…]

Trick Question: Do You Want Value or Low Costs?

If you can’t sell all you can produce, then reducing costs is often the only way to improve margins, but that simplistic accounting perspective is not always the case. Cost control is often thought to be key to attaining profitability but it the case of maintenance it can get you into trouble. Cost control can have a big opportunity cost if you don’t take advantage of the opportunities you have. Consider that what you might really want is greater value – more for less, no just less. [Read more…]

Lean or Industrial Anorexia

In 2014, at an IMEC conference organized by the University of Toronto, Art Rice of Maintenance Technology Magazine said that in many cases “Lean is a form of Anorexia”. He was right then, and he is still right today.

When I heard him, I realized that in many cases where I’ve seen attempts at “lean manufacturing” the lean really means “understaffed”. In those cases some of the lean manufacturing tools have been implemented, often with the help of outside expert help but lean results haven’t occurred. The introduction of “lean” in those companies was yet another attempt to cut costs without any deep thought as to what caused the high costs before introducing “lean”. [Read more…]

Do you need Reliability Centered Maintenance (RCM)?

Reliability Centered Maintenance (RCM) is without doubt the most effective method to determine your failure management policies, yet it is sometimes seen as an expensive and time consuming endeavor used to produce what some (mistakenly) believe they can get from manufacturer recommendations and other sources. The naysayers see it as a “gold plated” approach to a relatively simple challenge – produce a decent maintenance program.
They couldn’t be more wrong! And that error, could get them into a lot of trouble if circumstances align against them. [Read more…]

Achieve Results Using RCM

In the field, we know that there are no “quick fixes” or “silver bullet solutions” when it comes to improvements in maintenance management. Many separate conditions and events must come together properly to achieve “schedule success” – i.e.: the high level of compliance to a schedule of planned work as produced by your planners. [Read more…]

Maintenance Excellence – no quick fixes

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Rapid PM Program Deployment

In the first installment of this series we described the basics behind proactive maintenance and some of the considerations users need to make.

The second installment describes RCM – the “gold standard” for reliability program development and physical asset related risk management. This article is for those who are in “panic” or “fire fighting” mode. If you don’t have a proactive program, equipment runs until it breaks and you can’t seem to get ahead of it, then this one is for you. In a few cases you may have a PM program but your not getting the results you want. You could be overdoing overhauls, not doing enough predictive work, not following up on what you find, or the maintenance actions are simply inappropriate for the failures that occur in your circumstances. [Read more…]

Do you want a PM program that really works

Reliability Centered Maintenance – Re-engineered (RCM-R®)…

… is the world’s leading method for identifying maintenance and other activities required to sustain reliable performance of physical assets. Previously I discussed the various maintenance approaches you can use. This method (RCM-R®) is a structured approach to making those choices. If you want a proactive maintenance program that really works, then Reliability Centered Maintenance is the most thorough approach you can take to get there.Since the 1970’s RCM (generic) has been responsible for huge improvements in airline flight safety – crash rates today are 1 / 120^th of what they were before RCM, and the costs of aircraft maintenance programs are way down. We are all comfortable flying in safety. That would not be the case had RCM not come along. [Read more…]

The Basics of PM Programs

Do you replace your car headlights at regular intervals of six months? Do you wait to replace your tires until they wear through? Do you check your car engine oil with some sort of oil analysis before replacing it? Each component and system in your car has a function that is prone to failure. Each of those has consequences – some with little importance and others with great importance. [Read more…]

Planner help us solve the skills shortage problem!

Skilled labor is in short supply. Companies are struggling to find talent. Education systems throughout North America have done a poor job of producing ‘job ready’ graduates. Companies have cut back on training and apprentice program funding. Immigration programs did not prioritize the intake of needed and ready-to-us skills. Governments have been slow to see the problem and even slower to act on it. [Read more…]