With the advances that science, technology and regulation have brought, many companies today have excellent engineering capabilities, a fantastic technical framework and good governance. In theory, these companies should function reliably and also achieve great value. But often, that is not the case. What is going wrong? DuPont took a cultural journey to find the “missing link.”
When the RCM standard was published in 19991 it laid to rest many of the more contentious issues regarding what RCM is and what it isn't. Finally there is a standard that companies can use to determine which process could legitimately call itself RCM, and therefore were more likely to represent the original intentions and focus contained within the RCM methodology. This was a crucial step in the evolution of the RCM method particularly as setting minimum criteria eliminates methods that are either counter-productive, with respect to the original RCM report, or even dangerous.
Going from vision to reality in a reliability journey - and how the process grows and changes as the culture transforms from the complacency of run to failure, to the accountability of continuous improvement - is an experience that anyone in the maintenance and reliability profession should get excited about. In this article, we will take a look at a reliability centered effort still in the midst of this journey.
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Let's face it, we all face tough challenges. Competitive pressures continue unabated. Prices are too low, and costs are too high. Companies strive to reduce costs. Some look to improve technology. Some reduce headcount. Too few have become operationally excellent.
Sponsor Case Study: ArcelorMittal Tubular Products Increases Asset Availability with Ivara EXP Enterprise Asset Performance Management Software
ArcelorMittal Tubular Products is one of the largest most diversified mechanical tube manufacturers in the world, with 21 plants operating in 11 countries with a capacity of more than 3 million MT annually. The company's product portfolio spans the entire range of steel tube products - seamless, DOM & ERW.
The most pressing issue in North American manufacturing does not involve competition from overseas. The critical issue involves the short supply of qualified technical labor available to get the work done.
Uptime is named after the single most important topic in process manufacturing. Uptime is a result of doing all the right things. Even safety is a byproduct of doing all the things necessary to get uptime.
In his new book Secrets of Success With Procedures, Jack Nicholas, Jr., BS, MBA, P.E., CMRP, CRL, internationally recognized expert in business operations and maintenance reliability and a decorated US Navy veteran and naval engineer, shares his experiences on the importance of written procedures to operations success. Nicholas describes and discusses many management attributes centered on written procedures and includes a sample procedure found in COMPROSE Inc’s Zavanta Policies and Procedures Management Software.
Sterling Steel produces 450,000 tons of wire rod for its parent company, Leggett & Platt. The long products mini mill utilizes a 415 ton Electric Arc Furnace; two Ladle Metallurgy Facilities; an eight strand Billet Caster and a single strand Rod Mill to produce the wire rod for Leggett & Platt's Wire Mills.
Maintenance Skills Training for industry is a hot subject right now. In many areas of the country, companies are competing for skilled maintenance personnel.
Tammy Bodack with Charlotte's Central Piedmont Community College states that the city's total unemployment rate is less than 2% and the skilled unemployment rate is lower than that.
The skill level of the maintenance personnel in most companies is well below what industry would say is acceptable.
Many times, maintenance professionals have been involved in changes to processes or systems where they have relied on seat of the pants knowledge to determine whether or not they were successful. More often than not, the initiative flounders once their attention has been turned to other endeavors.
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