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RCA is the Bedrock of a Reliability Program

RCA is the Bedrock of a Reliability Program

Basic Reliability Definition

Occasionally, I like to step back and reflect on reliability in basic terms.

In that spirit, the basic premise of reliability is usually stated as “The probability that an item will perform a required function, without failure, under stated conditions, for a stated period of time.”

To use the reliability equation, the definition of failure must be defined, so you can tell if your equipment has indeed failed.  This way you can include it in the MTBF (Mean Time Between Failure) calculation.

After you have defined a failure and recorded them appropriately, you can plug the numbers into the reliability equation, R = e ^-(λ*t)  where λ is the failure rate which is defined as λ= 1/MTBF and come up with an objective value for the reliability. [Read more…]

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Process Optimization

Process Optimization

Welcome to the final blog in my 10-part series 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 Ten:

Process Optimization

Whenever you are following a set of steps to achieve some goal you are following a process.

Your people do their jobs through day to day implementation of those processes in order to deliver results.  If the processes are ill-conceived or inefficient things move slowly and results are more expensive to obtain than they need to be.

Well designed, efficient processes that integrate with other related business processes keep things running smoothly, costs down and help to keep people motivated. [Read more…]

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Introduction to Ongoing Reliability Testing

Introduction to Ongoing Reliability Testing

This type of reliability may have different names. A quick search of a few references in my library and I didn’t find ongoing reliability testing, ORT, in any of them.

It does exist and you may have heard of it before or even use some form of ORT. Or not.

Ongoing reliability testing or ORT is the continued evaluation of your product typically using samples drawn from production. The testing evaluates the reliability performance of recent production units.

The focus is on finding anomalies or changes that may occur in the design, supply chain, or production process that significantly changes field reliability performance. [Read more…]

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10 Things a Maintenance Supervisor Can Do to Improve Reliability

10 Things a Maintenance Supervisor Can Do to Improve Reliability

A few months back, I wrote a blog resulting from a conversation I had with a group of Maintenance Technicians who were attending the International Maintenance Conference (IMC) in 2011.

While the group was enjoying the conference and learning some new things, the general consensus was that they felt they would not be able to apply the tools and techniques they were learning because “management will say they support reliability, but when it comes right down to it, talk is cheap.” [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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37 – The Benefits of Processes with Scott Kelley

37 – The Benefits of Processes with Scott Kelley

The Benefits of Processes with Scott Kelley

In this episode of the rooted in reliability podcast, Scott Kelley talks about the benefits of the processes. A process is a visual representation of work depicted in flow diagrams that demonstrate the path you have chosen along with alternative paths to accomplish your goals, also including the decision making.
A process gives you the insight into the most efficient methods of doing your work and then document them for future use. These processes are directly tied to policies and procedures of an organization. You can also use CMMS for gathering information and then implement these methods accordingly in a better way as you will know exactly what kind of system you need depending upon your requirements.There are following things that you need to know while building a process map; who does the work? Who authorizes the work? Who hands-off the work and who they hand out to? Who verifies the work? Who approves the changes? This part continues until all the stakeholders such as suppliers, owners, customers, community, employees, and regulators are involved.
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World Has Limited Resources..Is Intelligence One of Them?

World Has Limited Resources..Is Intelligence One of Them?

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

It has been suggested that Stone Age man had a higher IQ than today’s modern homo sapiens.

“That cannot be,” says the modern man, but if one thinks about such an assault on our modern-day ego and self-confessed superiority, the alleged ‘primitive’ man was able to survive in extreme conditions, traveled the planet and set the foundations for today’s societies. [Read more…]

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The Unpredictability of Uncertainty

The Unpredictability of Uncertainty

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

Introduction 

Recently I wrote an article titled “Can You Calculate the Probability of Uncertainty?” The article posited that the heavy dependence on mathematics to determine the probability of risk realization may actually create “false positives” regarding the basis for the determination of probability.

My point was that there is too much uncertainty, things that we just do not know, to be able to calculate the probability of uncertainty with any degree of confidence. I received several comments from readers telling me that I was confusing the issue and that determining the probability of risk is all about “uncertainty”.

I have to say that this gave me pause to think. And, my conclusion is that risk is all about the probability of identified certainties that carry an uncertain realization. [Read more…]

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How to Measure Success: The 7 Key Performance Indicators You Must Measure

How to Measure Success: The 7 Key Performance Indicators You Must Measure

Being able to see what world class Reliability & Maintenance looks like is one thing. Communicating that success and level of performance to non-maintenance people can be difficult. Not to mention, that we always need to improve, and how can we if we only use qualitative measures?

I remember one time, trying to explain how Maintenance Planning & Scheduling has improved our maintenance department. I used explanations like; “The team isn’t wandering around looking for parts” and “They don’t need to leave the job to get the manuals anymore”. I was met with blank stares and was asked “How much were we saving on labour” and “How much were we able to reduce planned downtime”. [Read more…]

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Future Proofing the Process of Active Analysis

Future Proofing the Process of Active Analysis

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

Overview 

The ability to effectively respond to and manage the consequences of an event in a timely manner is essential to ensure an organization’s survivability in today’s fast paced business environment. With the emergence of new threats, such as cyber-terrorism and bio-terrorism; and the increasing exposure of companies to traditional threats such as, fraud, systems failure, fire, explosions, spills, natural disasters, etc. an “integrated” approach to Business Continuity Planning is essential. [Read more…]

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Building a Highly Successful Team Model

Building a Highly Successful Team Model

Welcome to part two 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 Two:

Building a Highly Successful Team Model

Any organization is nothing more than an extension of the people who make it up.  It stands to reason that we need to focus on people if we want our organizations to thrive and change.  Without your people nothing happens.  They are the most important part of your business.  If you want excellence your people need to choose it with you. [Read more…]

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The Top 10 Signs That You Have a World Class Reliability & Maintenance Program (Part 1)

The Top 10 Signs That You Have a World Class Reliability & Maintenance Program (Part 1)

During a recent business trip, I had the opportunity to attend a sister plant in another part of the world. I had been told how good the plant was in Planning & Scheduling. When I attended the weekly planning meeting, I was shocked.   It was chaos and confusion, with the planner writing notifications to be put on next week’s schedule, which started the next day. They thought this was good practice.

Often, we don’t know, what we don’t know. This leads the belief that an operation is not world class when it is and vice versa. [Read more…]