Search Results for: Change Management

Becoming A Reliability Pro – How To Harness, Store, And Use Failure Data For Future Use

The manufacturing sector has seen a rise in competitiveness because of the introduction of Industry 4.0 technologies over the last decade. It has become important for manufacturers to stand out in the industry by optimizing their systems to be as perfect as possible. One of the factors that make a factory competitive is its reliability, and a smart factory has great opportunities to improve it using the failure data from its assets.

The smart factories created using these technologies have greater efficiency and provide valuable data about the assets which can be used to further improve plant performance. The asset failure data gathered from different assets can provide insights into the reliability of assets and how to improve it. [Read more…]

by Robert (Bob) J. Latino Leave a Comment

Electronic Data Collection: The Bridge to the Connected Plant

Guest post by Ken Latino

The Industrial Internet of Things (IIoT) has created immense excitement and promise for industrial facilities. Having connected assets that continuously monitor their own health and feed that information back in a way that is timely and actionable will drive business outcomes and help organizations achieve loftier goals. The challenge today is that many of our assets are not yet “connected” or “intelligent,” meaning that they are not yet outfitted with the health monitoring instrumentation that provides the live, automated data feed directly to a centralized repository of data. Yes, critical assets like turbine generators, boiler feed water pumps, highly critical motors and the like are indeed outfitted with modern instrumentation and fail-safe solutions. However, in most industrial facilities throughout the world, this is a very small population of assets.

[Read more…]

by Greg Hutchins Leave a Comment

World Economic 2021 Forum Global Risk Report

Guest Post by Michael Keer, Founder & Managing Partner, Product Realization Group

The World Economic Forum has conducted a Global Risk Survey since 2006. This is the fifteenth survey. The responses are from 650 members of the World Economic Forum. In the preface to the 2021 Global Risk Report it is noted that: “In 2006, the Global Risks Report sounded the alarm on pandemics and other health-related risks.” (1) With this context in mind, the 2021 risk analysis “centers on the risks and consequences of widening inequalities and societal fragmentation. In some cases, disparities in health outcomes, technology, or workforce opportunities are the direct result of the dynamics the pandemic created.” (2)

This piece will review the results of the 2021 Global Risk Survey. It will also discuss some of the issues surrounding the survey.

[Read more…]

by Larry George Leave a Comment

Forecast Parts’ Demands, Without Life Data, for a Nonstationary Process

In the 1960s, my ex-wife’s father set safety stock levels and order quantities for Pep Boys. He used part sales rates and the Wilson square-root formula to set order quantities.

Why not use the ages of the cars into which those parts go, to forecast part sales and recommend stock levels? Imagine you had vehicle counts (year, make, model, and engine) in the neighborhoods of parts stores, catalogs of which parts and how many go into which cars, and store sales by part number.

[Read more…]

by Greg Hutchins Leave a Comment

SOR 775 Manager and Leader

Manager and Leader

Abstract

Greg and Fred discuss the importance of management and leadership. They cover the similarities and differences between the two.
ᐅ Play Episode

by Alex Williams Leave a Comment

Effectively Integrating Your CMMS with Current Systems

Maintenance management software increases uptime and productivity, lowers maintenance costs and extends the life of equipment and optimizes inventory usage—provided that it integrates seamlessly with existing systems. One of the toughest aspects of managing this software is CMMS integration. If your CMMS doesn’t communicate smoothly and easily with your accounting, inventory, human resources, purchasing, and other systems, it can reduce response times and lead to an increased chance of error. [Read more…]

by Karl Burnett Leave a Comment

Road Maintenance: McAdam, Mud, Major Generals, and the French Influence

British writers often marvelled at the quality and longevity of Roman roads, wondering how modern engineers and governments could hope to imitate their success. The fascination with Roman roads continues, and an excellent overview by Richard Brushi is available on Medium.com.

[Read more…]

by James Reyes-Picknell 1 Comment

Unfit for Purpose – revised

I approach problems with computer systems in a fairly critical way, but I am not anti-CMMS/EAM technology. I am, however, anti-waste. All too often I see a lot of time, effort, and money going into technology that simply doesn’t provide a return on the investment. When it comes to Maintenance data – it is often problematic and unfit for many of its intended purposes. Aside from helping to administer work orders, these systems often provide little business value. Does a small saving in administrative cost and time really justify the millions often spent on these systems?

[Read more…]

by Mike Sondalini Leave a Comment

Design a Maintenance Planning and Scheduling Process for Both Reactive and Planned Maintenance

Divide maintenance crews so a few skilled artisans do reactive jobs, and the remainder do planned and scheduled work orders

A robust Maintenance Planning and Scheduling Process uses a Scheduled Work Crew capacity planned days ahead with planned jobs. And it has a small Quick Response Crew of people capable to handle any random job.

A great Maintenance Planning and Scheduling Process design separates reactive work from jobs that can be planned and scheduled. This article explains how to re-engineer a maintenance planning and scheduling process to handle reactive and planned jobs.

Leveraging Foresight via Root Cause Analysis & Defect Elimination

Most associate the traditional application of RCA, with some type of undesirable outcome, that has exceeded a set threshold or trigger. It is at this point that a formal RCA process will be set into motion. Because of its serious nature, it will likely have the attention and support of leadership. It may also have the attention of external stakeholders like OEM’s, insurance companies and regulators. As a career ‘RCA’ professional, I must say that this traditional perception unfortunately is the norm, and not the exception in my 35+ years in this space. This is unfortunate because it suppresses the methodology’s potential, and the capability of applying a more holistic approach to preventing such undesirable outcomes in the first place. In this article my intent is to provide a different perspective of how to view ‘RCA’ in a much broader and meaningful context and coupling its use with an effective Defect Elimination (DE) strategy. While most are familiar with hindsight-based RCA, we will explore the emergence of foresight approaches as well. We will also contrast these perspectives in an effort to truly understand WHY we even do RCA, and is it worthwhile?

[Read more…]

by Mike Sondalini 1 Comment

The Difference between Critical Spare Parts and Strategic Spare Parts

WHAT IS THE DIFFERENCE BETWEEN A CRITICAL SPARE AND A STRATEGIC SPARE, AS WE NORMALLY COMBINE BOTH AS ONE. IS THIS RIGHT OR NOT?

—

We are facing difficulty in developing a definition of Critical Spare Part Inventory. No one is able to define it in its true essence. The situation is further confused with the difference to strategic spare parts. Any guideline or standard where we can find it ?
In the past, every Plant Manager had their own definition of Critical Inventory which changed with time. In optimization of Inventory, the first step is to establish a definition of Inventory considering all factors like production loss, redundancy, safety hazard, failure frequency, and of course, the lead time? Still I am stuck in this phase. I cannot progress, and don’t know what to do 1st, 2nd, and so forth to proceed further in this journey?

[Read more…]

by Greg Hutchins Leave a Comment

Greg Carroll: Future of Work – ERM – Interviewed by James Kline

Guest Post by Michael Keer, Founder & Managing Partner, Product Realization Group

Greg Carroll has a graduate degree in Operations Research from Swinburne University. He has a certificate in Machine Learning from Stanford University and in Data Science from the University of Michigan. He has over thirty years’ experience in Enterprise Risk Management. He has applied risk management techniques to IT and Artificial Intelligence systems in mission critical environments like the Department of Defense and Victorian Infectious Disease Reference Laboratories.

[Read more…]

by Mike Sondalini Leave a Comment

How Much Reliability have You Lost from Your Asset Wellness Curve?

AN ASSET LIFE CYCLE WELLNESS CURVE SHOWS HOW PLANT AND EQUIPMENT RELIABILITY IS LOST AT EACH PHASE ALONG AN OPERATING ASSET’S LIFE CYCLE

—

In some industries, 40% of maintenance repairs result from original equipment manufacturing failures. And up to 35% of maintenance is traceable to design engineering mistakes. That totals 75% of maintenance costs during operation can be from prior life cycle process blunders

To get utmost operating plant and equipment reliability, you need to purposefully design and build your business processes to guarantee maximum reliability from each and every phase of the asset life cycle

[Read more…]

by Greg Hutchins Leave a Comment

Educational Industrial Complex and the Future of Work

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

In a previous article I explored how workers and employers should approach the future and opined that both would be better off if they each understood the motivations and tactics that the other would employ to further their interests. Workers are concerned about achieving and maintaining marketability to employers and companies are concerned about acquiring the workforce they need to compete in the markets in which they do business. I assert that understanding what’s driving the approach each side will take to achieve its aims will be crucial to competing.

[Read more…]

by Larry George Leave a Comment

Dependence in Production Lines

As I rode, I thought, how could I use reliability statistics to optimize a solar-tube production line? Then I noticed a brass glint in the scrub brush. It didn’t look like trash, so I stopped and found an old brass oil lamp like Aladdin’s. Naturally, I rubbed it. There was a flash and a puff of smoke, and out popped the genie who said, “Yes master, by the powers vested in me, I grant you three wishes.”

[Read more…]