Getting Started With Reliability

For some reason most companies don't recognize the need for manufacturing equipment reliability until they are overwhelmed with emergency and demand maintenance work. They struggle each day to meet production schedules and then begin to put off scheduled maintenance shutdowns in order to try and meet the production schedule. In attempting to meet the schedule they run harder, faster and longer fighting to make good product and maintain quality standards. In the end they are consumed by failures and are unable to meet production demands. Now is when they understand the importance of equipment reliability, good maintenance practices and spare parts. If you have waited too long, the real problem is it may be too late. Think about it, now that you can no longer meet customer demand and have delivered late orders; is this the time to train people on the importance of equipment reliability?

This essentially is the key difference between managers of failed companies and managers of successful companies. Having worked to help companies train operations and maintenance people in the importance of reliability over the last ten years I could easily make a list of companies who achieved successful reliability efforts, and companies who failed. Instead I will list the signs of success and the signs of failure.

Signs of Success

1. Successful companies understand they need to be reliable before they can become lean
2. Successful companies measure equipment reliability (Overall Equipment Effectiveness OEE) and have OEE listed as a KRA for each manager.
3. Successful companies understand the importance of maintenance and maintenance managers are partners in business decisions.
4. Successful companies train operations, maintenance and engineering people in the importance of equipment reliability, and reliability tools such as RCM Blitz, TPM, and RCA.
5. Successful companies have ranked the criticality of their equipment and have developed a complete maintenance strategy for these assets that includes critical spare parts.
6. Successful companies use RCM Blitz as a proactive reliability tool to develop maintenance for critical assets.

Companies in Danger of Failing

1. Companies in danger of failing believe that the production schedule is more important than equipment reliability and as a result perform more than 60% emergency/demand maintenance.
2. Companies in danger of failing always look for a silver bullet to fix a long term problem. They will often attempt to implement lean manufacturing without equipment reliability and the lean effort will fail.
3. Companies who are in danger of failing will often try tools like RCM or RCA but they will never follow through and implement all of the findings. Instead they will cherry pick the analysis looking for one or two things to fix the present problem.
4. Companies in danger of failing always want to rush through "Lean, RCM, RCA, or TPM" because there must be a faster way!
5. Companies in danger of failing don't engage their operations and maintenance people in important scheduling decisions.
6. Companies in danger of falling change managers and supervisors at about the same rate most people buy a new pair of safety shoes! Managers need time to listen, learn and be effective.
To learn about manufacturing equipment reliability, reliability measures, reliability tools and RCM training, contact Reliability Solutions, Inc. at 585-349-7245.

RCM Blitz - Delivering Results

Someone once told me that you know when you have made it in life when someone tries to copy you or something you invented. I guess I have officially made it. I'm also trying to feel good about the fact that someone has copied material that took me years to develop, and decided to offer it up to companies around the globe without consulting me first.

I guess I should feel honored! For some strange reason I don't.

For my loyal and successful customers over the past seven years I would like to say thank you! Reliability Solutions, Inc. is thankful that customers like Whrilpool, Cargill, Invista, and Newmont Mining took the time to search and research looking for the best RCM Training and mentoring available around the world. Because these companies took the time and invested in Reliability Solutions they now have successful RCM efforts with results that continue to provide return on the money they invested in RCM Facilitator Training.

For companies interested in RCM Training I would encourage you to read the article in the link and contact Reliability Solutions, Inc.

Drive - Determination - Discipline

Drive, determination and discipline. Three traits one must have to successfully implement RCM at their plant site. One of the most difficult things to understand and accept is the fact that you are not going to start a RCM effort and see results over night. While RCM Blitz is fast, efficient and effective it can not be turned on and off like a light switch.

RCM takes time, and because of this you should plan your effort well. Start out by ranking your equipment, measuring OEE on these assets and selecting your first asset for analysis. Set up and hold your RCM Training on-site and select your best people as facilitators and participants. As soon as your RCM analysis is completed begin implementing the tasks identified by your team. The quicker you get your tasks implemented the quicker your company will recognize the results!

For information on RCM Blitz and RCM Training, contact Reliability Solutions at 585-349-7245.