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The Institute of Internal Auditors (IIA) just issued “On Risk: A guide to Understanding, Aligning, and Optimizing Risk 2020”. This is the first risk assessment survey conducted by IIA. It is also the first survey which includes responses from board members, the C-suit and the Chief Audit Executive (CAE). This article looks at the results of the survey and its implications. [Read more…]
Despite its well-documented successes, Reliability Centered Maintenance has always drawn a lot of discussion and controversy. Much of it is because of a lack of understanding and ‘myths’ generated to discredit RCM as a viable business solution. Here I will fill in some of those gaps in understanding and debunk some of the myths. [Read more…]
Over the last few decades, advancements in technology have dramatically changed the maintenance and reliability industry. Organizations have invested heavily in automation and technology to reduce staff overhead, improve product quality and increase safety. One thing that hasn’t changed much in the last few decades is preventive maintenance, or PM. PM is all about performing routine maintenance to improve equipment reliability, performance and cost-effectiveness. If applied correctly, PM has the capacity to transform an organization’s maintenance approach and lead to significant improvements in equipment reliability. However, there are many mistakes that can ruin an organization’s PM program.
The following are seven preventive maintenance mistakes to avoid: [Read more…]
This episode revolves around the book titled as Reliability Centered Asset Management by Richard Overman. It is based on using the principles of reliability centered maintenance to manage your assets. It helps you understand the processes involved in managing your assets effectively by finding answers to questions such as; how or why your assets are failing? What are the consequences of those failures? And how to take actions to prevent those failures from occurring in the first place. It is based on the application of RCM principles to ensure reliability through-out the lifecycle of the asset.
The points addressed in this podcast highlight:
If a methodology or a program isn’t producing desired value for an organization even after putting all the necessary resources into it, the root cause might be the culture of that organization. The culture of an organization consists of its practices, common goals, and shared values. If people aren’t putting efforts into securing the goals that an organization values, there’s definitely something wrong with the organization’s culture. That’s why culture is so important for managing assets and the overall success of the organization. A good culture is formed when the organization has set some standard procedures and values in place to ensure certain practices.
The points addressed in this podcast highlight:
The awareness gap results from management having limited or no knowledge of the maintenance function and its ability to contribute to the manufacturing process; and maintenance personnel, managers included, having a limited understanding of the business side of manufacturing. The result is that management and maintenance are often unsure about how they together contribute to the company’s success. [Read more…]
By Guest Blogger Wesley Suplit, product manager, SDMyers
After my first year in college, I discovered my favorite curriculum – economics. This surprises my friends and family because that discipline is known for its dry content and difficult math concepts. However, I had a completely different and inspiring experience. The course, and, really, my professor, opened my eyes to the beauty of observing how people make decisions.
What rocked my world was how simple economics could be. Conclusions could be inferred simply by observing phenomena and then performing thought experiments related to the observations. The goal of a thought experiment is to explore the potential consequences of the principle in question. Surprisingly, no mathematical formulas or complex equations were needed. [Read more…]
Coronavirus seems to be spreading quicker than previous pandemic potential viruses, i.e., H5N1, H7N1, SARS, Ebola, MERS, etc. Could this be the long awaited/anticipated threat realization, or is it becoming a media driven phenomenon? Needless to say, planners should be implementing some assessment analysis regarding the potential for impacting business operations. Here is a brief look back at one of my articles from 2006, entitled, “Pre-Pandemic Planning: Business Continuity Perspectives“, when Bird Flu (H5N1) was the hot topic:
The business community is “not adequately prepared” for a possible avian flu pandemic, says Secretary of Health & Human Services Michael Leavitt. As of July 24, 2006, there have been 231 confirmed cases in humans resulting in 133 deaths (a mortality rate of 57%). The virus has spread to 33 countries through wild migratory birds that have now infected domestic poultry (source World Organization for Animal Health). [Read more…]
Reliability Centered Maintenance methods compliant with the SAE standard JA-1011 (“Evaluation Criteria for RCM Processes”) all have common features – they must, or they won’t comply with the standard. Those requirements are “minimum” requirements, as they are with any standard. RCM-R complies. But what makes it different and why?
The RCM standard and most, if not all, of the established RCM methods are firmly rooted in the past as it was defined by those few individuals who wrote the SAE standard. The standard and those methods have stood the test of time because they work, but we asked, “Can they work better?” Answer – yes. [Read more…]
“Science is the process that takes us from confusion to understanding…” – B
Properly done, Process FMEAs should improve manufacturing and assembly processes and corresponding process controls. This article describes how PFMEAs can be used to improve process controls, which are embodied in the Process Control Plan (PCP).
The buzzword, “continual improvement,” is a hard one to miss. No matter how it’s worded, the notion of making changes that positively affect your business isn’t new. If you’re exploring ways to continually improve your maintenance operations, consider the benefits of integrating your computerized maintenance management software (CMMS) with other business applications. Software integrations can vastly increase the efficiency of your everyday operations and processes. Read on to learn our top CMMS integrations for your business.
Combining CMMS software with other relevant components of your organization helps eliminate duplicate or redundant processes. For example, critical information that is typically only found in a CMMS can be utilized by additional departments to improve the accuracy of their operations. The likelihood of errors decreases dramatically when systems communicate directly with one another. [Read more…]
Not all risks the same. Some are minor with little consequence, while others are not. Every organization or reliability program facings a plethora of risks and being able to communicate the range of identified risks is helped by using a risk matrix.
The risk matrix is a simple two-dimensional grid that lays out on one access the expected consequence of risk, from minor to catastrophic. The other axis has the likelihood or occurrence of the risk becoming realized, ranging from rare too certain.
The boxes within the grid then contain classifications ranging from low to extreme, which provide a prioritization to address the risk in some fashion. Low-risk items are those with rare occurrences and insignificant consequences. The other end of the spectrum are extreme risks that are almost certain to occur and have catastrophic results. [Read more…]
Getting experts to agree on most things is challenging at best, and often,downright impossible. Getting transformer experts to agree might be even more challenging. Despite the fact that transformers have been around for nearly a century—and with varying opinions on transformer design and maintenance—most experts agree that not all transformer failures are alike. Also widely recognized is that the life of the insulation or paper is the primary limiting factor towards the life of the transformer. [Read more…]
A title like this is supposed to make you curious about two things: First is whether you are aware of these myths and second is if you are aware of them but wrongly believe them. They are myths after all.
Working in the reliability field with a focus on electrical systems, I have become increasingly aware of how many people believe in one or more of these myths and, more strikingly, stake their production uptime and even their career on them. I am not over-exaggerating. It is a big problem we seldom hear about because following these myths has led to a significant increase in the number of transformer failures with a corresponding dramatic increase in the cost of those failures.
So let’s get started. Be honest about it. If you know these are myths and are thinking the right way, then you will no doubt have just verified your prowess. On the other hand, if you believe some or all of these myths, then now is the time to recalibrate and set the record straight. [Read more…]
Supportability entails matching the design and logistics requirements of an asset to its operational needs. When buying equipment, decision-makers are usually quick to base their decision on the upfront capital investment without weighing in the effects of continuous operational expenses. Other foregone considerations in valuing an asset can touch on areas like supply chain requirements, equipment obsolescence, personnel training, configuration management and environmental impacts. Lucas joins us on this episode to help create an understanding of supportability.
Some of the important insights include:
