Plant Hexcellence™ – Plant

Plant Hexcellence™ – Plant

In the previous article describing the Plant Hexcellence™ model, we started with people and just as we said that all change starts with the people, the purpose of that change revolves around the plant or assets themselves. Inherent with having a manufacturing company has a manufacturing site and equipment to create the widget or product you are selling. Without the plant, there is no need for the people or any change.

The Plant Cell encompasses more than just physical assets–it also includes the methods, risk evaluation and mitigation strategies you’ll employ […]

Linking Failure Codes To A Proactive Maintenance Strategy

Using Failure Data to Drive Sustainable Improvements

If you are lucky enough to have good failure data history in your CMMS, you are one of the few.  But even if you have the data, can you use it to make a difference to your organization?  Obviously, the data can be used to perform certain reliability engineering analyses, but what can those without reliability engineering experience do with the data?

Bad Actor / Pareto Analysis

Two simple analysis that anyone can use with their failure history are;

  • A Bad Actor analysis is identifying equipment that is […]

Collecting Failure Data: A Practical Approach

How to collect the failure data needed to drive improved plant performance.

The first step to any reliability improvement program is to define what data or information will be required to drive defect elimination.  In the previous posts, the following topics were discussed;

All of the topics discussed what data is required and how to structure the data to implement a reliability engineering program or defect elimination process.   Understanding the what, when and why set up and is required to setup a reliability engineering […]

Understanding ISO 14224: You Guide to Sustainable Defect Elimination

Capture The Right Failure Data to Power Your Defect Elimination Activities

In the petroleum, natural gas and petrochemical industries, great attention is being paid to safety, reliability, and maintainability of equipment.  This is true in any industry and as such the learnings and information found within ISO 14224 can be applied to any industry.

While ISO 14224 was developed for the Petroleum, Natural Gas and Petrochemical industries, the same process can and should be applied in any organization.   When implemented, the right data can be gathered to not only eliminate defects from […]

How to Setup An Asset Hierarchy

Ensuring the Failure Data Collected Can Be Used To Drive Improvements In Any Organization

ISO 14224 – Equipment Taxonomy

If you were to go into your CMMS and look at the hierarchy and equipment, would it be well laid out and organized?   Would you be able to drill down the to the lowest level of components to know what failures have occurred?  Can you see how pumps are performing across a specific area or the entire plant?  The chances are that for many organizations, this is not possible.   Why is that?  The asset […]

Failure Reporting And Corrective Action System (FRACAS)

Using a System to Record, Report And Eliminate Defects

Why is that some organization seem to break the reactive cycle and others don’t?  After all most organizations have a PM program and some form of a planning and scheduling program right?   The key difference between those that do is their ability to use their failure data and systematically eliminate defects and issues from the processes and equipment.  This doesn’t mean adding a new PM everytime some fails, which just won’t work.

To eliminate the defects and issues, the organization needs to collect meaningful data to […]

Using Simplified Technical English to Write Effective Maintenance Procedures

Reduce the Variability in Your Work Routines and Procedures

Based on our understanding of the six failure patterns, we can see that there is a large probability of failure when the equipment is first installed and started up.   One of the Englisch causes of this increase in probability is the fact that the equipment was not installed or maintained correctly.  This may be due to the installer or maintainer not using or following procedures.  Having procedures is the first step to reducing these failures, but the procedures must be written in a clear, […]

The Importance of Master Data in Spare Parts Management

Enabling Storeroom Success Through Data

DataHow often does your facility run out of raw materials?  Chances are it is not very often, if ever.  Why is this?  It may be because the organization has invested heavily in gathering the right data, analyzing and developing contracts for the materials.  This prior work ensures a steady supply of materials.

So why is it that within the same organization there is virtually no data to support the spare parts?  Not having a spare part can dramatically impact an organization in the same way as not having raw […]

Standards? We Don’t Need No Stinking Standards

How Your Organization Can Benefit from Standardization

qtq80-zXIPOWImagine if every day you had to relearn a process or use a different CMMS.  Chances are you would get virtually nothing accomplished, leaving your plant operating poorly.   Now we all know that we having to relearn a process every day or using a new CMMS is not practical nor is it rooted in reality (not to be confused with the Rooted in Reliability podcast).  But this type of thing happens more often than you may think.

When people change positions in an organization, the […]

The Next Step in Your Failure Data

Improve your failure data to improve the speed and accuracy of your failure & reliability analysis.

24254846213_6b6950bbbd_mA few years into your reliability journey, you start to struggle to make the improvements you were able to when you first started.  Why is this?  You were able to systematically eliminate all of the low hanging fruit using the existing data in your CMMS.  But now you have to dig deeper to realize the improvements and that requires better data.

As Fred discussed in the previous post, A Mean Cumulative Failure Analysis can be another powerful tool […]