Reliabilityweb.com just released the Asset Condition Monitoring (ACM) Project Manager’s Guide and, based on its contents, it’s a resource no organization should be without. For several years, I have been involved in asset management and managing condition based asset teams, but never have I seen a more complete project plan than what is presented in this guide. Not everything in the ACM Project Manager’s Guide will work for everybody, but there are sections in the guide that will adapt to every situation. No matter where you are on your asset condition monitoring journey, at the beginning or with a mature program, this guide contains information that will help to grow and sustain every ACM program.
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?
Engineer and management consultant Joseph M. Juran said, “If you don’t measure it, you don’t manage it.” It’s a fairly accurate statement. But, another question might be: “If you do measure it, does that help you manage it?” Far too often, experience shows that it does not, for a host of reasons. Some of these include: having too many measures leading to complexity and confusion about what’s important; a lack of focus; measuring the wrong things; not measuring things that are truly important to the business; having measures that are in conflict across functional boundaries; or not displaying the measures prominently or, if displayed, not keeping measures current, resulting in employees considering them unimportant (after all, if you don’t keep the measures current, how important could they be?).
In Part 1 of this article (Dec/Jan 2017), we talked of how good managers must always try to keep their organizations energized, moving forward and upward. To do this, they must find ways to constantly disrupt complacent, status quo thinking and behavior.
In less than 10 years, the consumer digital camera essentially completely replaced film cameras, which had been in the market for over 100 years. In an even shorter period of time, the smartphone has, in turn, sent the consumer digital camera the way of its film based cousin.
Operator driven reliability (ODR) is a process that involves operators in the maintenance and reliability of their equipment. ODR selects tasks previously performed by maintenance technicians and reassigns these tasks to operators. However, ODR is only effective when operators are focused on specific tasks. Operators must be properly trained and coached in the performance of each task.
Determining the proper maintenance strategy for a site’s assets can be a daunting undertaking. There’s a fine line between profitability and reliability, and frequently, a facility’s strategy usually favors one or the other. When weighted toward running equipment past its design or capabilities, it can lead to frequent, unplanned interventions and associated costs of labor, material and lost production. When the arc of the pendulum swings too far to over maintaining an asset, the availability can be seriously hindered and impact profitability. It’s important to find that “sweet spot” between these two approaches to ensure there’s an appropriate amount of maintenance that still drives profitability. The question is how to find it.
The Oct/Nov 2016 Uptime article, “An Asset Manager’s Guide to Building a Meaningful Company Vision,” explained why it’s essential to have a company vision at the department level in order to gain collaboration and create excitement among department level managers. Next, this article explains why it is crucial for the enterprise asset manager to guide department level managers toward an understanding of how to translate their vision into a top level, order of magnitude for change. In other words, a company vision is only good if it can be sold to the executive level team of your organization.
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.