As I’m writing this, it’s December of 2019 and you should be putting the final touches on your reliability plan for 2020 before the holidays.
What should you include in your reliability plan?
If your data quality is average or better, you should be able to make a bad actors chart for the last 12 months. Most people do the chart like the following:
This chart is useful because you can see the units that are causing you the most downtime and create your plan around tackling those units (in this case, Gearbox A & Diesel Generator A).
But you’re forgetting cost
I recommend doing it like the following chart. What’s the total cost of these failures? In total cost, I’ll include lost production (opportunity cost), maintenance cost (labor, spare parts, etc.) and social benefits (safety incidents, environmental incidents, reputation, etc.). How does it compare?
In this, made up, example, you would work on the hydraulic units (B, C & potentially A) versus Gearbox A and Diesel Generator A, that have higher downtime.
Putting it all together
Once you have your selection of the top bad actors, you’ll have to estimate how much time it would be to work on them and the type of work (RCA, RCM, defect elimination, etc.). Fit those into your schedule, get to work and save your company millions in 2020.
Reliability Never Sleeps,
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