Measure twice, cut once. This is what the sign read in our Apprentice Training shop at Eastman Kodak. Anyone who has worked for a living in the trades understands the true meaning behind this phrase. The intent is to help your company save time and money by doing things right the first time.

The sign really could be posted on the wall of every shop, every office and every conference room in every manufacturing plant around the world. It applies to more than the skilled trades. The sign in fact applies to every person and every job.

Do it right the first time! [Read more…]

Quality, Reliability & Useful Life

The Impact of Precision Installation & Maintenance

Over the last several years I have been working on and off with customers to among other things build a maintenance strategy for their equipment that will insure the designed reliability of their assets.

A while back I was asked by one of these customers to come in perform several RCM (Reliability Centered Maintenance) analyses on some new equipment that was struggling to deliver the expected/promised production rates. As the team worked its way through the process of identifying failure modes I continued to ask the following questions: [Read more…]

Defining Precision Maintenance

Ask 10 people to tell you what Precision Maintenance means. While some will use a few of the same words or give a few similar examples of what they think Precision Maintenance is you are going to get 10 different answers.

While few would argue the importance of Precision Maintenance, I find it interesting that in the world that offers Certifications in Asset Management and Equipment Reliability (CRE, CRL, CMRP) you won’t find an agreed-on definition of what Precision Maintenance means. [Read more…]

Equipment Reliability Depends On Understanding Failure Modes!

One of the curses of Reliability Centered Maintenance and Root Cause Analysis is a great Facilitator makes the process look easy. So easy in fact that after watching a good facilitator lead one event we’d like to believe we could jump right up and facilitate the next one with no training or assistance. In Mentoring RCM Blitz™ facilitators during the certification process we work to perfect 2 dozen skills with the hope of turning out great facilitators. The skill we typically spend the most time working on is writing failure modes.

[Read more…]

The Problem With Our Top Down Reliability Effort!

I’m using this week to get my office in order. This morning I found this series of drawings I did back around 1987. While I know my old friends from Building 317 will get a kick out of this, I also know that we weren’t the first and won’t be the last team of people who worked to make our plant a better place to work.  I also know the last slide from this series is missing that showed the team alone saying “If you want to know how it happened, it pays to give credit where credit is due.” [Read more…]

Reliability Amnesia!

The condition that occurs when an Engineer, Supervisor, or Manager who once had responsibility for the reliability of your assets gets promoted or transferred to the operations side of the group.

Symptoms of Reliability Amnesia

1.      Ignoring information from Condition Based Technologies that clearly show a major component is in the process of failing. The subject may be overheard saying something like “I can’t afford to stop the line now, if we do I won’t make my production goals.” [Read more…]

The 6 Things Every Asset Management Strategy Needs to Be Successful

I want my customers to be successful, every one of them. Yet there are times I can see the writing on the wall and I know as hard as I might try to show them a clear path to what it takes to be successful they have their own plan. Some of them are so complex that people become confused just trying to make sense of them, and others get so hung up in the minutiae of even the simplest of steps like listing a 3 part failure mode they will word-smith themselves to a point where folks just give up. I find myself asking “why do people have to make what is really so simple into something that appears to be complex?” [Read more…]

The Elevator Pitch, and No it’s not a Major League thing….

I was taking questions from the audience following my presentation at a conference last spring when a young lady stood up and asked me if I could give my Elevator Pitch.

She must have noted the confused look on my face because she repeated herself this time adding further details.

“If you were riding an elevator with someone and you had a quick minute to sell your RCM services what would you say?” [Read more…]

5 Reasons Why Your Top Performers Leave and What You Can Do to Keep Them!

Those who know me well know I am a voracious reader.  From newspapers and magazines to business related books and novels it’s a rare site to find me without my Kindle or some type of printed reading material.  Lately I have noticed a number of articles on the reasons why your best employees are leaving your business and I have to say I saw this problem trend coming more than a decade ago. [Read more…]

The 6 Signs of a Reliable Plant

Having visited hundreds of manufacturing plants in the last 17 years, someone recently asked me if there were any traits the most reliable plants all had in common. I have listed below the top 6 signs of a reliable plant. [Read more…]