FREE copy of the Uptime Elements Implementation Guide once you subscribe to Reliability Weekly

Using the Business Level FMEA approach to better understand and prioritize production losses and extraordinary costs, companies can now do a better job selecting the appropriate tool and approach to solve or mitigate the problem. What’s more, this strategy will be based on a system level review of the production process. For example:

  1. If supplier quality and/or quantity is the top opportunity for improvement, supply chain principles and perhaps even Six Sigma can be applied to reduce the variability in quality and quantity of the supply.
  2. If the next biggest opportunity is inconsistency in the production process due to a lack of training of operators, a request can be made to human resources or training to develop a plan to address this need.
  3. If the next biggest opportunity is related to a specific machine and its unreliability, the 5S methodology might be applied first to get the machine in reasonable order. Remember, the purpose of 5S is defect detection and elimination, along with workplace discipline, not housekeeping. Doing a 5S exercise will eliminate many small defects in the machinery. Next, certain Total Productive Maintenance (TPM) principles, such as operator care, or better preventive maintenance (PM) and predictive maintenance (PdM) may be applied to better manage these failure modes. Then, reliability centered maintenance (RCM) may be used to better understand the machine’s functional requirements and the failure modes that are resulting in loss of functionality in an effort to optimize PM and PdM tasks. If the problem with the machine was particularly difficult, root cause analysis (RCA) may be used.
  4. If the next biggest opportunity is to reduce the erratic nature of production planning and frequent changeovers, the approach might be to work with sales and marketing to analyze product mix, sales and gross profit by product and key customers, with a view to better understand and rationalize product mix and sometimes even customers. The company would probably want to implement a quick changeover capability and work to level its production flow, even at the risk of modestly increasing inventory in the short term.
  5. If the next biggest opportunity is to reduce spares unavailability, RCM methods would be applied to understand the most common failure modes or the highest consequence failure modes. Then, certain supply chain principles would be used to make sure the needed spares are on hand, but no more than is needed.

In some cases a company will want to develop a so-called A3, a one-page action plan that contains in very simple terms the current state, future state, business case and action plan. An illustration of a high level A3 that could be used to develop a more detailed and specific one is shown in Figure 4.

A3 Action Plan

Figure 4: A3 action plan

Tip from Where Do We Start Our Improvement Program? by Ron Moore

Upcoming Events

August 8 - August 10, 2023

Maximo World 2023

View all Events
80% of newsletter subscribers report finding something used to improve their jobs on a regular basis.
Subscribers get exclusive content. Just released...MRO Best Practices Special Report - a $399 value!
Internet of Things Vendors Disrupting the Asset Condition Management Domain at IMC-2022

Internet of Things Vendors Disrupting the Asset Condition Management Domain at IMC-2022 The 36th International Maintenance Conference collocated with the RELIABILITY 4.0 Digital Transformation Conference [East]

Asset Management Technology

The aim of the Asset Management technology domain is to assure that IT/OT systems are focused on creating the value from the assets and that the business can deliver to achieve organizational objectives as informed by risk.


TRIRIGAWORLD AWARDS honors excellence in space optimization and facility management, A event to further advance asset management

IMC-2022 Who's Who: The World's Best Run Companies

The International Maintenance Conference (IMC) provides a fresh, positive community-based curated experience to gain knowledge and a positive perspective for advancing reliability and asset management through people, their managers, the strategy, the processes, the data and the technology. The world’s best-run companies are connecting the workforce, management, assets and data to automate asset knowledge that can be leveraged for huge beneficial decisions.

Uptime Elements Root Cause Analysis

Root Cause Analysis is a problem solving method. Professionals who are competent in Root Cause Analysis for problem solving are in high demand.

Reliability Risk Meter

The asset is not concerned with the management decision. The asset responds to physics

Why Reliability Leadership?

If you do not manage reliability culture, it manages you, and you may not even be aware of the extent to which this is happening!

Asset Condition Management versus Asset Health Index

Confusion abounds in language. Have you thought through the constraints of using the language of Asset Health?

Seven Chakras of Asset Management by Terrence O'Hanlon

The seven major asset management chakras run cross-functionally from the specification and design of assets through the asset lifecycle to the decommissioning and disposal of the asset connected through technology

Reliability Leader Fluid Cleanliness Pledge

Fluid Cleanliness is a Reliability Achievement Strategy as well as an asset life extension strategy