Maintenance Management

 When you run machines above design rates that decision goes against all that we know about creating high plant uptime and outstanding equipment reliability—in fatigue situations 10% additional stress will cost you ten breakdowns. 

The dominate factor in machine life and production plant uptime is the stress in your machines’ working parts. The stress developed in a part’s material of construction microstructure is directly linked to the force applied to it. It does not matter where the force comes from or why it is applied, once the stress in your parts go beyond their microstructure limits your machines fail. If you want to run at high production rates first ensure that your working parts cannot become overstressed.

 Is your Maintenance at 100% performance in delivering all the six business purposes shown in Figure 1? 

 It’s easy to lose your way in maintenance, reliability and enterprise asset management. Without a vision you are aimless. Without a map you are lost. To get maintenance, reliability and enterprise asset management success you must have both the right vision and the correct path to it. 

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 Abstract: Do the reliability math on organizational structure design, and in a militaristic silo configuration you’ll see that managers have a huge influence on their departments performance. But what is most surprising is that supervisors in silo groups have more than double their manager’s impact on their group’s success. Managers making poor and wrong choices will cause serious trouble. But supervisors who get decisions wrong cause catastrophe.

An MTBF calculation is often done to generate an indicator of plant and equipment reliability. An MTBF value is the average time between failures. There are serious dangers with the use of MTBF that need to be addressed when you do an MTBF calculation.

Take a look at the diagram below representing a period in the life of an imaginary production line. What is the MTBF formula to use for the period of interest to represent the production line’s reliability over that time? [Read more…]

Guest post by David Finch, MSc, MIEAust, CEng, FSOE, AIMM

Maintenance Work Backlog Management: a Start in Managing Maintenance!  A maintenance manager can commence a maintenance improvement programme by simply creating opportunities for individuals and groups to make high performance contributions. One way to do this is to manage the Maintenance Backlog.

Guest post by B.D. McLaughlin, ScD, MInstrP

 Using a comprehensive and inclusive definition, risk may be defined as the cost of “failure to add value” per unit time. Such failure includes performance deficiencies for employees, equipment, material and method. It includes the types of “failure to add value” comprising traditional waste such as overproduction, wait time, transportation, processing, inventory, motion and defects. It includes the cost of injury, litigation and damage to company reputation. It encompasses the total cost of failure and not just the cost of remediation. You must minimize risk to stay competitive. Risk is consuming the hidden wealth of your enterprise. It is disguised and concealed as the “cost of doing business.”

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 Users of the Plant Wellness Way EAM methodology use accuracy-controlled procedures to turn their company into an Accuracy Controlled Enterprise: a quality driven, “learning organization” effectively using useful technologies.

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