Your Reliability Engineering Professional Development Site
When engineers design a machinery part, they begin by defining the operating load range it will experience during its service life. This range will include the loads when the machine part is not working through to the maximum stress that it will operate under. Examples of high stress situations include operating overload events, or when starting up under a large load. How great the imposed stress reaches and how often those events occur changes a part’s reliability.
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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.
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Human error causes 80% of plant and equipment failures. It is the single factor, which if controlled, makes the most difference to achieving world class equipment reliability and operational success. With the introduction of low cost communication and visual devices it is now possible to assist maintenance workers proactively prevent human error. By using interactive audio-visual devices workers can be coached through a job error-free to get right-first-time quality every time.
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.”
Let a Plant Wellness Way EAM System-of-Reliability halve your Annual Maintenance Costs
A Plant Wellness Way enterprise asset management system is a powerful solution for world class enterprise asset management (EAM) success. There are three scenarios when it is justifiable for a business to adopt PWW EAM as your company’s EAM methodology.
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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.
Estimating the money for commissioning spares allowance of a capital project using the maintenance cost in the RAV ratio is probably wrong, but it is often done. The allowance also depends on the life cycle asset management processes and practices in use.
Risk is probabilistic—a risk event may happen or it may not. The human mind struggles to understand probability until you make a picture.
Here is a simple visual management tool to let you see the impact of changing risk. Combine it with a risk cost calculator and you have an effective way to see how your risk changes with risk management plans and risk abatements
We are blind to risk. Most of us have to suffer a risk event before we know we are in one. We first experience pain and then we realise that we need to stop doing what is causing the pain.
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UNLIKE LEAN AND SIX SIGMA, THE PLANT WELLNESS WAY DIFFERENCE IS IT PREVENTS OPERATING RISKS FROM STARTING WITH A SYSTEM THAT IS BUSINESS-WIDE AND GOES END-TO-END OF THE WHOLE ASSET LIFE CYCLE
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Lean and Six Sigma are point-in-time problem focused methodologies, where as PWW EAM System-of-Reliability uses the whole life cycle to build business and operational systems with processes that continually optimize productivity, minimize risk, and generate maximum operating profits.
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Maintenance Planning and Scheduling can be learnt on the job, but to become a very good maintenance planner and maintenance scheduler you still need to know the reasons behind why you do things in certain ways when you plan and schedule maintenance work orders.
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First parts fail, then machines stop! If its parts don’t break your machines and equipment will always be reliable
Physics-of-Failure microstructure science explains why components fail, and why they get failed during service life. Understanding Physics-of-Failure is foundational to the Plant Wellness Way EAM methodology
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The very best monitoring and measuring analysis you can do for your company’s maintenance success is to develop the distribution curves of your range of maintenance KPI’s.
At least they will be useful in the honest decision-making you need to do to continually become a better and better maintenance performer.
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A business management system needs a quality management system built to make customers happy.
Every company already has a business management system they use to deliver products or services. If you want to be a more profitable business, you need to continually create a better management system.
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It took a long time to understand why a business in the same market did better than other businesses. Every one thought it was due to better marketing, or access to more capital. But it was not. It was simply that one business had products that better suited customer needs. The best product always gains most market share and makes the biggest profits. Which is why a business management system needs a quality management system that improves their products.
Behaviour Based Safety (BBS) programs address safety culture barriers with effective solutions for changing safety culture and securing a positive safety behaviour change.
Behaviour Based Safety passively and positively changes existing unsafe workplace behaviours by identifying and reinforcing the use of the right behaviours that protect people in real-world safety problems.
In workplaces that want high safety performance, behaviour based safety programs, when properly implemented, significantly improve personal safe performance and greatly reduce workplace injury and illness.
Behavioral Observation Programs using behavior based safety management reduce safety incidents by bringing beneficial workforce safety behavior change.
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A risk management risk matrix can trick you into leaving high consequences uncontrolled and convince you it is fine to do nothing to reduce the impacts of failure. Whether you think a bad event cannot happen has no standing in Law. The likelihood of an adverse event is unimportant; only the resultant severity is how the Law will gauge your risk abatement efforts. Did you do ‘reasonably practicable’ risk control?
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