Why are organizations leaving money on the table by not investigating failures that cost them money? One would venture to say that all manufacturing companies have failures each year that cut into their profit. The prevailing question is: What do you do when that failure occurs? Do you simply fix the equipment, get back up and running, and return to whatever you were working on at the time? Or, do you stop what you are doing and diligently try to understand why the failure occurred and put measures in place to prevent recurrence? Is the culture at your facility one that seeks to understand why something failed or is it in a mode where you need to get back up and running as fast as possible? How about your commercial team and management external to your facility? Is there perceived pressure and a lack of understanding that have driven your organization to a place where failures are not fully understood?
The challenges facing any industry sector today are the same that existed decades ago and were delineated at many conferences and meetings. They are still the same challenges because acting on preexisting ones would have added to the workload.
Defect elimination may be the most significant initiative within a maintenance reliability program. It may also provide the largest return on investment in terms of asset reliability and plant uptime. From a computerized maintenance management system (CMMS) perspective, defect elimination can be used to focus on recurring failures and significant events, and also to address potential failures.
At The RELIABILITY Conference 2016 in Las Vegas, world-renowned author and maintenance expert, Terry Wireman, announced his retirement. Wireman is the very definition of a prolific writer, authoring numerous textbooks, white papers, and articles. Following his announcement, Wireman received Reliabilityweb.com’s Lifetime Achievement Award. Take a trip down memory lane as we revisit some highlights from Wireman’s storied career.
Leaders. They used to be represented at almost every maintenance reliability conference around the world. They were seen as the best in asset management with a seemingly limitless number of case studies that clearly showed the benefits of root cause analysis (RCA), condition monitoring, reliability-centered maintenance (RCM), planning and scheduling. Their people gave presentations that clearly showed the value of the foundational elements of walking down your assets, developing an accurate equipment hierarchy and performing a thorough criticality analysis.
System modification is an economically viable option to restore mechanical integrity, achieve optimum operation and reduce maintenance costs. This is realized through the development of a system modification program for a reciprocating pump with recurring leakage failures.
The SAE International standard for reliability-centered maintenance (RCM)1 says an inspection2 should be done if it is technically feasible and worth doing. The hard part is identifying when a task is technically feasible.