Rooted in Reliability: The Plant Performance Podcast: Recent Episodes
James Kovacevic
A weekly Maintenance and Reliability podcast covering common industry challenges and what you can learn from them. Each episode dives deeper into critical issues and explains how you can begin correcting theses maintenance flaws today. Sharing new tips and techniques to help you achieve industry best practice and shining a light on widely debated maintenance topics with special guest experts.
Your host and founder of High Performance Reliability James Kovacevic, will take you on a weekly tour of his 13+ years of shop floor experience, along with special guest that lend an expert look inside your maintenance departments problems and concerns.
Plane, train, or automobile, however you’re traveling to work Rooted In Reliability is compatible for listening on the go.
The Frustrations of Reliability: From Strategy to Synergy with Bob Latino and Ken Latino Welcome Bob and Ken Latino to the Podcast. Bob has been to this Podcast before discussing defect elimination and is an author involved with RCA and other reliability items. Briefly, Ken, can you introduce yourself. I worked with Bob and my […] The post 316-The Frustrations of Reliability: From Strategy to Synergy with Bob Latino and Ken Latino appeared first on Accendo Reliability.
Prioritizing Initiatives with Paul Daoust Welcome Paul to the Podcast. Paul is the founder of Scio Asset Management. Although, briefly, tell us about yourself. I have almost 30 years experience in engineering reliability maintenance and both strategic and holistic asset management. At Scio we are providing frameworks for leadership in asset management that is based […] The post 315 – Prioritizing Initiatives with Paul Daoust appeared first on Accendo Reliability.
Clean Energy with Howard Penrose Welcome back Howard to the Podcast. Howard is the founder of Motordoc and is heavily involved with IEEE and SMRP. Though, briefly, tell us about yourself. My entire career has been about electric machines and systems from my time in the Navy. I later had short stints both in repair […] The post 314 – Clean Energy with Howard Penrose appeared first on Accendo Reliability.
Decarbonization and the Impact on Maintenance with Steven Dobie Welcome Steven to the podcast. Steven is a co-host of another podcast called Maintenance Disrupted. However briefly, tell us more about yourself. I am a maintenance and reliability engineer in the mining industry who has been in tech for a couple of years. Presently working with […] The post 313 – Decarbonization and the Impact on Maintenance with Steven Dobie appeared first on Accendo Reliability.
Cost vs Benefit of Inspection with Dane Boers Welcome Dane back to the podcast. We last talked about asset modelling and factors that influence those assets. Today we will talk about optimising strategies; how we determine cost vs benefit of strategies. But first, give a brief introduction of yourself and Modla. Modla is an asset […] The post 312 – Cost vs Benefit of Inspection with Dane Boers appeared first on Accendo Reliability.
Defect Elimination with Doug Plucknette Welcome Doug back to the podcast. Doug is the Author, President and Owner of Reliability Solutions Inc. Though briefly, give an introduction of yourself. I started my reliability consultancy career back in 1999 after serving in several capacities at different organisations. Although currently semi-retired, I still respond to past clients […] The post 311 – Defect Elimination with Doug Plucknette appeared first on Accendo Reliability.
310 – Name Your Spare Parts Correctly with Conrad Greer It is my pleasure to welcome Conrad Greer to the podcast, the founder of SPCResults. In this episode we covered: What is data cleansing? Why do we want to standardize our material information? Is MPN a saving grace? Why do we want to standardize our […] The post 310 – Name Your Spare Parts Correctly with Conrad Greer appeared first on Accendo Reliability.
Optimizing Energy Efficiency of Rotating Equipment with Simon Jagers It is my pleasure to welcome back Simon Jagers, one of the founders of Samotics, an industrial analytics company that helps clients improve reliability and sustainability, particularly of their rotating equipment. In this episode we covered: Why is energy efficiency so important for organizations? What can […] The post 309 – Optimizing Energy Efficiency of Rotating Equipment with Simon Jagers appeared first on Accendo Reliability.
Determining Training ROI with Lucas Marino It is my pleasure, to welcome back Lucas Marino to the podcast, working at The East Partnership dealing with submarine logistics. In this episode we covered: Why do you need training? How do we calculate that ROI? Why are organizations hesitant to invest in training? There are a lot […] The post 308 – Determining Training ROI with Lucas Marino appeared first on Accendo Reliability.
The Evil Ways of MTBF with Fred Schenkelberg It’s my pleasure to welcome Fred Schenkelberg back to the podcast. He is a reliability engineer and management consultant. In this episode we covered: What is MTBF? Why would people want to calculate what that average time between failure is or where did this come about? What […] The post 307 – The Evil Ways of MTBF with Fred Schenkelberg appeared first on Accendo Reliability.
RCM Implementation with Nancy Regan It is my pleasure to welcome back Nancy Regan to the podcast, the founder of RCMtrainingonline.com. In this episode we covered: What is an RCM implementation? What challenges do you see within organizations as they go to implement the findings from their analysis? What do you believe is the most […] The post 306 – RCM Implementation with Nancy Regan appeared first on Accendo Reliability.
Balancing Short and Long Term in Change with Shon Isenhour It's my pleasure at welcome back, Shon Isenhour to the podcast, the owner of R and D show. In this episode we covered: How do clients get time to move and to start doing some of these proactive things? How do you manage skill traits? […] The post 305 – Balancing Short and Long Term in Change with Shon Isenhour appeared first on Accendo Reliability.
Workforce Survey with Tom Wilk It’s my pleasure to welcome Thomas welcome back to the podcast. In this episode we covered: What was the genesis of this survey? Why do you think the organizations do the workforce training? Why do you think you’re such an increase in our interest in the certification? What was the […] The post 304 – Workforce Survey with Tom Wilk appeared first on Accendo Reliability.
Some Parts are Good, More Must be Better with Andrew Jordan It's my pleasure to welcome back Andrew Jordan to the podcast, the Managing Director and CEO of Extivity. In this episode we covered: Do organisations assume that more parts in stock means reduced downtime and reduced risk? How do organisations strike that balance then […] The post 303 – Some Parts are Good, More Must be Better with Andrew Jordan appeared first on Accendo Reliability.
What is Asset Performance Management with Paul Daoust It is my pleasure to welcome back Paul Daoust to the podcast. In this episode we covered: Does value leakage come in a row for variety of different places? What is asset performance management? When organizations decide to adopt APM, do they just buy the software package […] The post 302 – What is Asset Performance Management with Paul Daoust appeared first on Accendo Reliability.
Bolted Joint Reliability with Jorg Albrecht It is my pleasure to welcome Jorg Albrecht to the podcast, the managing director of Heavy Technologies. In this episode we covered: What do you consider a bolted joint? How do we normally determine if a bolt is 'properly in place'? How do we measure clamping force? What do […] The post 301 – Bolted Joint Reliability with Jorg Albrecht appeared first on Accendo Reliability.
Past and Future Trends in Reliability It is my pleasure to welcome our panelists today, Eric Elder, Maureen Gribble, Jenna Johns, and Shon Isenhour. In this episode we covered: What were the things you were seeing people asking about at that conference? What does the future look like for the reliability industry? 2022 Conference Plans! […] The post 300 – Past and Future Trends in Reliability appeared first on Accendo Reliability.
Ensuring Transformer Reliability with Howard Penrose It is my pleasure to welcome Howard Penrose back to the podcast. In this episode we covered: Why are electrical reliability or electrical assets neglected? What are the major types of transformers? If we detect a high level of moisture in the oil, do we change the oil or […] The post 299 – Ensuring Transformer Reliability with Howard Penrose appeared first on Accendo Reliability.
Risk Based Inspection with Ricardo Santos It is my pleasure to welcome Ricardo Santos to the podcast, a Senior Manager at Deloitte. In this episode we covered: What is RBI – Risk-Based Inspection? When would organizations want to leverage risk-based inspections over RCM or something else? Why do organizations want to go about implementing RBI […] The post 298 – Risk Based Inspection with Ricardo Santos appeared first on Accendo Reliability.
The Silent Killer of Rotating Machinery – Softfoot with Daus Studenberg It is my pleasure to welcome Daus Studenberg to the podcast, the product manager, a national product manager of the alignment with Lu DACA. In this episode we covered: How many ways can we? What is soft foot? If we’re going to perform a […] The post 297 – The Silent Killer of Rotating Machinery – Softfoot with Daus Studenberg appeared first on Accendo Reliability.
Bearing Lubrication Reimagined with Ian Conyers It’s my pleasure to welcome Ian Conyers to the podcast, the Northeast, Mid-Atlantic US regional manager at UIE systems. In this episode we covered: How important is good bearing lubrication to maintaining our assets? What are the current challenges that we face as an industry and why aren’t we […] The post 296 – Bearing Lubrication Reimagined with Ian Conyers appeared first on Accendo Reliability.
Real Life Metrics with Rick Clonan It is my pleasure to welcome back Rick clone into the podcast, the implementation and training manager at era DCO. In this episode we covered: What is a metric to begin with? Why do organizations really use metrics? With all these challenges, how do organizations either pick the […] The post 295 – Real Life Metrics with Rick Clonan appeared first on Accendo Reliability.
Trends in Electrical Reliability with Alan Ross It is my pleasure to welcome Alan Ross to the podcast, currently president of EPRA, the chair of the Tripoli smart grid marketing committee, as well as the editor in chief of transformer technology and women in power systems. In this episode we covered: What’s happening in electrical […] The post 293 – Trends in Electrical Reliability with Alan Ross appeared first on Accendo Reliability.
Diversity & Inclusion in the Maintenance Community with Caitlyn Young-Gilbert It is my pleasure to welcome Caitlin Young Gilbert to the podcast. She is the Chief of Staff at Upkeep. In this episode we covered: What type of trends are you seeing in maintenance lately? The maintenance community’s been going strong for a year now, […] The post 292 – Diversity & Inclusion in the Maintenance Community with Caitlyn Young-Gilbert appeared first on Accendo Reliability.
Putting People At the Center of Work with Jeff Ma & Mohammad Anwar It is my pleasure to welcome Mohammad Anwar (Founder & CEO, Softway) and Jeff Ma (Director, Softway). In this episode we covered: What is the biggest challenge that you have experienced in leading people and teams and developing that culture overall? In […] The post 291 – Putting People At the Center of Work with Jeff Ma & Mohammad Anwar appeared first on Accendo Reliability.
Smooth Transitions from Cooling to Heating with Mark Orlovsky It’s my pleasure to welcome Mark Orlowski to the podcast. He is a quality warranty and service expert at Modine manufacturing company. In this episode we covered: What is an HVAC system? How do you ensure that HVAC systems are operating at optimum efficiency? Now, if […] The post 290- Smooth Transitions from Cooling to Heating with Mark Orlovsky appeared first on Accendo Reliability.
Secrets of CMMS Implementation with Joseph Schmitt It’s my pleasure to welcome Joseph Schmitt to the podcast. He is a VP of customer success at Upkeep. The team focused on deploying and implementing upkeep at new locations. Our customer success team is focused on driving the post onboarding relationship. It’s really honing in on adoption […] The post 289 – Secrets of CMMS Implementation with Joseph Schmitt appeared first on Accendo Reliability.
Facilitating FMEAs with Bobby Lee It’s my pleasure to welcome Bobby Lee back to the podcast. He is a reliability engineer with irritation. He spent quite a bit of time working on FMEA’s equipment, maintenance plans, RCAs, etc. He has spent about 10 years as a maintenance technician and a reliability engineer. In this episode […] The post 288 – Facilitating FMEAs with Bobby Lee appeared first on Accendo Reliability.
Evolution of Technology with Simon Jagers It’s my pleasure to welcome back Simon Jaegers to the podcast. He is one of the founders of Samotics in 2015. His professional career has been spent in technology, usually evolving around either making data, storing it, or processing it. Samotics provides condition monitoring technology based on electrical signature […] The post 287 – Evolution of Technology with Simon Jagers appeared first on Accendo Reliability.
Current Trends in Reliability with Fred Schenkelberg It’s my pleasure to welcome back Fred Schenkel Berg to the podcast. In this episode we covered: I see a lot of people working remote, maybe not full-time, but part-time as reliability engineers, is this the new normal and can they effectively do their job working remote? Is […] The post 286 – Current Trends in Reliability with Fred Schenkelberg appeared first on Accendo Reliability.
Conserving Water through Proper Sealing Selection with David Brewer It’s my pleasure to welcome David Brewer to the podcast. He is Atlantic regional manager for SEPCO sealing equipment. I spend most of my time in paper mills, chemical plants, food processing wastewater treatment plants. I work with distributors and solve problems when it comes to […] The post 285 – Conserving Water through Proper Sealing Selection with David Brewer appeared first on Accendo Reliability.
A Systems Engineering Approach to Reliability with Andrew Kelleher It is my pleasure to welcome Andrew Keller to the podcast. He is the Managing Director for Rams Men Taught in Germany. I’ve trained as a materials engineer, having spent approximately 20 years working in different aspects of reliability engineering from failure analysis to risk-based inspection, […] The post 284 – A Systems Engineering Approach to Reliability with Andrew Kelleher appeared first on Accendo Reliability.
Habit #4: Decide with Data with Peter Horsburgh It’s my pleasure to welcome back Peter Horsburgh. He is the author of the 'Five Habits of Extraordinary Reliability Engineers.' He has a long history within reliability engineering. He essentially started in manufacturing, then moved to mining, then to power generation, and to aluminum smelting. In this […] The post 283 – Habit #4: Decide with Data with Peter Horsburgh appeared first on Accendo Reliability.
The Low Hanging Fruit of Lubrication Improvements with Devin Jarrett It’s my pleasure to welcome Devin Jared to the podcast. Devin is a success manager at Noria. He has worked as a processes guy, made a transition over into the technical team, managing projects, then I stepped into the technical consultant role, then now a […] The post 282- The Low Hanging Fruit of Lubrication Improvements with Devin Jarrett appeared first on Accendo Reliability.
281 – Asset Criticality with Gregory Perry Welcome Gregory Perry to the Podcast. Gregory is a Capacity Assurance Consultant at Fluke Reliability. Today we will discuss asset criticality. In this episode we covered: What is asset criticality? Why is it important to organizations? How do organizations determine asset criticalness? What about the ranking system within […] The post 281 – Asset Criticality with Gregory Perry appeared first on Accendo Reliability.
280 – Healthy Buildings with Brian Turner Buildings IOT is a: - System integrator - Software developer - Services provider for the built environment: Work spaces, play, and industrial buildings except housing. In this episode we covered: What is a healthy building? Is it more than custodial work? Prior to COVID-19 people rarely talked about […] The post 280 – Healthy Buildings with Brian Turner appeared first on Accendo Reliability.
279 – Learning from Metrics with Dan Miller Welcome Dan Miller to the podcast. Our topic will be metrics; how to pick the right KPIs and we will also discuss cornerstone metrics. But first, about Dan: Dan is a maintenance reliability engineer at Global Water Resources. The guest worked as a consultant but currently is […] The post 279 – Learning from Metrics with Dan Miller appeared first on Accendo Reliability.
278 – Maintenance Task Analysis with Lucas Marino Welcome Lucas Marino to the podcast. Lucas is the founder of East Partnership and initially spent a lot of time as an engineer with Coast Guard starting off as a diesel engineer and rising through the ranks. Today's topic is maintenance task analysis. But first: In this […] The post 278 – Maintenance Task Analysis with Lucas Marino appeared first on Accendo Reliability.
277 – Adoption of Mobility with Ryan Chan Welcome Ryan Chan back to the podcast. Today we will discuss mobile work solutions. In this episode we covered: What are mobile work solutions? Why would organizations want to leverage mobile work solutions? Why haven't many organizations implemented mobile solutions? What are mobile work solutions? As it […] The post 277 – Adoption of Mobility with Ryan Chan appeared first on Accendo Reliability.
Driving Asset Answers with Suspect Data with Manjish and Yanpei Welcome our guests to the podcast. We are going to discuss Asset Answers in today's episode. However, briefly about our guests: Yanpei has a background in telecom and smart grid. Currently is working as a product leader at Asset Answers. Manjish is the service lead […] The post 276 – Driving Asset Answers with Suspect Data with Manjish and Yanpei appeared first on Accendo Reliability.
275 – Decoding Mechanical Failures: A class experience with Shane Turcott Welcome Shane who is the author of Decoding Mechanical Failures. More about Shane and Steel Image: Shane is a mechanical engineer who founded Steel Image, whose primary business is analyzing information on broken parts: how it failed, mechanisms of failure, and whether the part […] The post 275 – Decoding Mechanical Failures: A class experience with Shane Turcott appeared first on Accendo Reliability.
274 – Dealing with Ramp Up and Degraded Assets with James Reyes-Picknell Welcome James Reyes who is the author of Uptime and many other books, also a principal consultant at Conscious Asset. More about James: Having a career that spans for 44 years, James has worked in different organizations and industries some of which include […] The post 274 – Dealing with Ramp Up and Degraded Assets with James Reyes-Picknell appeared first on Accendo Reliability.
273 – Understanding and Leveraging OEE with Ron Moore Welcome Ron back to the podcast. Ron is an author and the founder of RM Group. In this episode we covered: What is OEE? Do companies use OEE simply because it is strategic and tactical? Why does maintenance get blamed for poor OEE? What is OEE? […] The post 273 – Understanding and Leveraging OEE with Ron Moore appeared first on Accendo Reliability.
272 – Operator Care: A Thought Out Approach with Cliff Williams Welcome Cliff Williams back to the Podcast. Cliff is a principal advisor with People and Process as well as TMS Asset Management. The guest has also worked as an asset manager for many years. In this episode we covered: What is operator care? Where […] The post 272 – Operator Care: A Thought Out Approach with Cliff Williams appeared first on Accendo Reliability.
271 – Developing Operational Standards with George Williams and Joe Anderson Welcome Joe Anderson and George Williams back to the podcast. They are the founders of ReliabilityX and are consultants as well as trainers. Briefly about them and Reliability X: Reliability X covers all aspects of reliability; both operational and maintenance, coaching and currently creating […] The post 271 – Developing Operational Standards with George Williams and Joe Anderson appeared first on Accendo Reliability.
270 – Where to Start with DfM & DfR with Fred Schenkelberg Welcome Fred back to the podcast. Clients are starting to realize that they have to design their systems properly while paying attention to certain tradeoffs. However, tell us where they should start; whether to design for reliability or maintainability. Before starting, the team […] The post 270 – Where to Start with DfM & DfR with Fred Schenkelberg appeared first on Accendo Reliability.
The Capabilities Trap with Simon Jagers Welcome Simon back to the podcast. Simon is the founder of Samotics and has been involved in technology throughout his Career. Today we will talk about capabilities trap. Although briefly, tell us more about you: Involved with technology, our guest focuses on: machine learning, and the conversion of data […] The post 269 – The Capabilities Trap with Simon Jagers appeared first on Accendo Reliability.
Understanding & Communicating the Value of PMs with Rick Clonan Welcome Rick Clonan who has been in maintenance for 30 years working both in defense and industry. More about Rick: Currently at SMRP working as implementation and training manager. In this episode we covered: How do we communicate the value of PdM and PM? What […] The post 268- Understanding & Communicating the Value of PMs with Rick Clonan appeared first on Accendo Reliability.
Managing Up with Bobby Lee Welcome Bobby Lee who has been involved in maintenance engineering working for different companies in various capacities. Bobby Lee started out as a maintenance apprentice and has risen through the ranks as a maintenance engineer for over 9 years. In this episode we covered: What does it mean to manage […] The post 267 – Managing Up with Bobby Lee appeared first on Accendo Reliability.
Asset Modeling with Dane Boers Welcome Dane Boers who is the founder of Modeler. Our topic will be asset modelling. More about Dane: Dane started his career in mining then moved to consultancy before starting Modeler. The company was started to make reliability more efficient and automated because of the repetitive work he had observed. […] The post 266 – Asset Modeling with Dane Boers appeared first on Accendo Reliability.
Moving from Paper to a CMMS with Jeff O’Brien Welcome Jeff O'brien who is the cofounder of Zoidii CMMS Jeff has worked with CMMS in manufacturing and consultancy for years and has currently launched their own application. In this episode we covered: What prompted you to start your own CMMS? Why would organizations transition from […] The post 265 – Moving from Paper to a CMMS with Jeff O’Brien appeared first on Accendo Reliability.
Crucial Decision with Ryan Sitton Welcome Ryan Sitton to the podcast. Ryan is the founder and CEO of Pinnacle Engineering and has spent a lot of time around reliability and production engineering. Notably, he is the author of "Crucial Decisions"; a book that we will discuss in the episode and how it applies to maintenance […] The post 264 – Crucial Decision with Ryan Sitton appeared first on Accendo Reliability.
Leadership with Rob Kalwarowsky Welcome Rob back to the Podcast. You were the founder of Rob's Reliability Project and later started working as a co-host of the Leadership Launchpad Podcast and Dismantling the High Performance Narrative. Although, tell us more about yourself. Rob- Having worked in reliability for ten years- transitioning across manufacturing, mining, and […] The post 263 – Leadership with Rob Kalwarowsky appeared first on Accendo Reliability.
Why AI Fails with Matt Kirchner Matt is the Chief Product Officer at Atonix Digital and is involved with AI, works on software packages, analytics etc. More about Matt: He has a background in mechanical engineering and started off in a large firm where they offered remote monitoring services to power generating customers. They oversaw […] The post 262 – Why AI Fails with Matt Kirchner appeared first on Accendo Reliability.
Why is it so hard to get Lubrication right with Bennett Fitch Welcome Bennett who is the Director of Product Development at Noria Corporation. Bennet has a background in Mechanical Engineering and worked in an oil analysis laboratory. Currently focuses on lubrication product development and has consulted for many plants enough to notice the common […] The post 261 – Why is it so hard to get Lubrication right with Bennett Fitch appeared first on Accendo Reliability.
Practical Implementation of Technology with Simon Jagers Welcome Simon back to the podcast. He is the founder of Semiotic Lab; a company involved in predictive technology maintenance. Previously, he talked about monitoring electrical systems using online monitoring and wireless sensors. Our podcast today is about the practical implementation methods to optimize the benefits of these […] The post 260 – Practical Implementation of Technology with Simon Jagers appeared first on Accendo Reliability.
Learning in COVID Times with Bill Leahy Welcome Bill to the Podcast. He has held different talks and training sessions around leadership, change management, PMs and many others. Today, we’re tackling important points such as: Should companies be investing in training during COVID-19 pandemic? What are some of the topics that are being grasped quicker […] The post 259 – Learning in COVID Times with Bill Leahy appeared first on Accendo Reliability.
Remove Wasted Time and Frustration from the Maintenance with Zachary Yost Let's welcome Zachary Yost who is an integration lead at CNS. Our main topic will be the removal of wastage in the maintenance work process. Zachary will give us insight on: What were the goals in trying to streamline the work process? How did […] The post 258 – Remove Wasted Time and Frustration from the Maintenance with Zachary Yost appeared first on Accendo Reliability.
Reliability Misconceptions with Fred Schenkelberg Welcome Fred to today's episode. Our topic will be the misconceptions surrounding reliability. What is reliability? The English dictionary defines reliability as the characteristic of trustworthiness or being able to adhere to a schedule and deliver as needed. On the other hand, reliability in engineering encompasses functionality, probability of success, […] The post 257 – Reliability Misconceptions with Fred Schenkelberg appeared first on Accendo Reliability.
Learning Communities with Ryan Chan It is my pleasure to welcome Ryan Chan who is the founder of Upkeep. Ryan has done a lot of work in building online maintenance communities.. He went to University of California Berkeley and graduated as a chemical engineer. His first job was at a manufacturing company where he noticed […] The post 256 – Learning Communities with Ryan Chan appeared first on Accendo Reliability.
255 – Forecasting the Future with Frank Emery & Stuart Fergusson Welcome Stewart and Frank to the podcast. Briefly tell us about yourselves Stewart has a background in Big Data and Applied Mathematics and currently specializes in AI at Fiix. Frank on the other hand has a background in manufacturing of consumer products. In this […] The post 255 – Forecasting the Future with Frank Emery & Stuart Fergusson appeared first on Accendo Reliability.
Defining Subsystems in an RCM Analysis with Doug Plucknette We’re excited to be joined again by Doug Plucknette, an author, consultant, and instructor around maintenance and reliability, to talk about RCM analysis. This topic relates to a previous episode on failure curves. In this episode, we covered: What is an RCM analysis? Why break down […] The post 254 – Defining Subsystems in an RCM Analysis with Doug Plucknette appeared first on Accendo Reliability.
Using WO Data in a Well Rounded PdM Strategy with Frank Emery We’re excited to have Frank Emery, the product manager of AI at Fiix Software, with us to talk about how to make the Work Order data work. Fiix Software is a CMMS that was initially called Maintenance Assistant. He’s been in the software […] The post 253 – Using WO Data in a Well Rounded PdM Strategy with Frank Emery appeared first on Accendo Reliability.
How to Avoid Becoming a Prisoner of Your Own Process with Brandon Weil We’re excited to be joined by Brandon Weil, the operations director at Eruditio. He was also the chair at the 2020 SMRP conference. Brandon will be giving us an in-depth look into becoming a prisoner of your process. Key highlights from this […] The post 252 – How to Avoid Becoming a Prisoner of Your Own Process with Brandon Weil appeared first on Accendo Reliability.
How to Make a Good Request with Fred Schenkelberg We’re glad to have Fred Schenkelberg back to help us understand how to make a complete request. A lot of times, emails circulate through the organization requesting tasks to get completed. However, they don’t define the: Who When How Fred will give us insight on: Elements […] The post 251 – How to Make a Good Request with Fred Schenkelberg appeared first on Accendo Reliability.
Decoding Mechanical Failures with Shane Turcott We’re glad to have Shane Turcott to helps us understand more about decoding mechanical failures. He’s a principal metallurgist from Steel Image and is heavily involved in a lot of professional societies. Shane’s previously worked at a steel mill, a turbine company, and a failure analysis lab specializing in […] The post 250 – Decoding Mechanical Failures with Shane Turcott appeared first on Accendo Reliability.
Understanding the Failure Curves with Doug Plucknette & Ron Moore Were excited to have Ron Moore and Doug Plucknette get into the topic of age and random failure patterns. Ron’s been involved with maintenance and reliability for a long time. Doug’s from RCM Blitz and is a big advocate for understanding failure modes, reliability centered […] The post 249 – Understanding the Failure Curves with Doug Plucknette & Ron Moore appeared first on Accendo Reliability.
Leading FMEAs with Bill Leahy We’re honored to have Bill Leahy back to talk about Failure Mode Effect Analysis. He’s a principal instructor with Eruditio, having a background in manufacturing and the military. He’s been involved with maintenance and reliability for several years. Today, we’re tackling important points such as: What is an FMEA Why […] The post 248 – Leading FMEAs with Bill Leahy appeared first on Accendo Reliability.
Global Asset Management Certifications with Susan Lubell We’re excited to have Susan Lubell, the PEMAC Asset Management Association of Canada President, with us. She’s also the chairperson at World Partners in Asset Management and the principal consultant at Steppe Consulting. Susan presents at conferences, instructs, and has been heavily involved in maintenance and reliability and […] The post 247 – Global Asset Management Certifications with Susan Lubell appeared first on Accendo Reliability.
Where Did Procedure Based Maintenance Come From with Jack Nicholas We’re excited to have Jack Nicholas with us. He started as a naval officer before becoming a senior service engineer and reserve naval officer. He’s founded companies, authored books, and helped with driving forward maintenance and reliability programs, predictive maintenance, and the other aspects that […] The post 246 – Where Did Procedure Based Maintenance Come From with Jack Nicholas appeared first on Accendo Reliability.
The Role of Steering Committees in an M&R Implementation with Shon Isenhour We’re glad to have Shon Isenhour, a founding partner at Eruditio, back with us. He was heavily involved in maintenance and reliability, industry, consulting and finally started Eruditio. He’ll help us know more about the role of a steering committee in maintenance and […] The post 245 – The Role of Steering Committees in an M&R Implementation with Shon Isenhour appeared first on Accendo Reliability.
RAM Modeling with Fred Schenkelberg We’re pleased to have Fred Schenkelberg back with us. He’s a reliability engineering and management consultant with a background in product development. He’s also been a manufacturing engineer and shift supervisor working in a factory and helped found AccendoReliabilty.com. Fred will give us more insight into RAM Modeling. Fred will […] The post 244 – RAM Modeling with Fred Schenkelberg appeared first on Accendo Reliability.
The Role of Project Management in M&R with Lucas Marino We’re excited to have Lucas Marino back. He works at Amentum and is the owner of the East Partnership. He’s also working on the book Level of Repair Analysis. In the past, he spent many years in logistics engineering and the coast guard. Lucas will […] The post 243 – The Role of Project Management in M&R with Lucas Marino appeared first on Accendo Reliability.
Am I ready for AI with Geraldo Signorini We’re pleased to have Geraldo, the principal consultant at Eruditio. He spends a lot of time doing reliability activities like instructing and consulting, among others. He started his engineering career in 2008 and spent more than ten years in oil and gas in roles related to reliability […] The post 242 – Am I ready for AI with Geraldo Signorini appeared first on Accendo Reliability.
The Role of the EAM in Improving Reliability with Steve Richmond It’s our pleasure to welcome Steve Richmond, the founder, and CEO of Projetech, a company providing IBM Maximo as a service. He has a degree in mechanical engineering and is also on the Forbes Technology Council. Projetech started by building automation systems, energy management, […] The post 241 – The Role of the EAM in Improving Reliability with Steve Richmond appeared first on Accendo Reliability.
Manage All Failures or Else with James Reyes-Picknell We’re excited to have James Reyes-Picknell, the author of Uptime, Strategies for Excellence in Maintenance Management, back with us. He’s also written Reliability Centered Maintenance - Re-engineered and Paying Your Way which is his latest book. James also trains and consults in maintenance, reliability and asset management […] The post 240 – Manage All Failures or Else with James Reyes-Picknell appeared first on Accendo Reliability.
The Soft Side of Planning with Rick Clonan We’re excited to have Rick Clonan back with us to talk about planning. He currently serves as an Implementation and Training Manager at Eruditio and as the Best Practices Chair for the SMRP. He’s been in the industry for close to 30 years as a technician, planner/scheduler, […] The post 239 – The Soft Side of Planning with Rick Clonan appeared first on Accendo Reliability.
Marketing with Ashley Larrimore We're excited to be joined by Ashley, a marketing expert at Eruditio. She has been there for 2 years and handles all the marketing e.g., emails, products, websites, conferences, etc. Overall, she has amassed a wealthy 8 years of experience in marketing. She'll be our guide on discussing the common themes […] The post 238 – Marketing with Ashley Larrimore appeared first on Accendo Reliability.
Bringing Ultrasound to iIoT with Blair Fraser We’re glad to have Blair Fraser, the Global Director for IIoT Solutions at UE Systems. He’s been our guest on topics like Artificial Intelligence, IIoT, and other areas relating to tech and maintenance and reliability. Blair previously worked at Quartic and Lakeside Process Controls, getting involved in the […] The post 237 – Bringing Ultrasound to iIoT with Blair Fraser appeared first on Accendo Reliability.
Machinery Installation: Planning with Roman Megela It's a pleasure to have Roman Megela from Easy-Laser join us on this deep dive into Machinery Installation. He’s worked with rotating equipment for over 20 years, particularly in service, installation, assembly, and commissioning for gas compression, glass production, and stainless steel. So far, we’ve looked into how strategy […] The post 236 – Machinery Installation: Planning with Roman Megela appeared first on Accendo Reliability.
Preparing for the CMRP with Bobby Lee We’re excited to welcome Bobby Lee on this episode. He started in the maintenance field in his early twenties. He got a two-year degree in Industrial Systems Technologies, after which he worked at Baxter Healthcare. He then proceeded to work for American Zinc Products as a reliability engineer […] The post 235 – Preparing for the CMRP with Bobby Lee appeared first on Accendo Reliability.
In-House or Contracted Oil Analysis with Bryan Johnson We’re thrilled to have the chairman of ICML, Bryan Johnson, with us. He’s worked at the Palo Verde Generating Station for 30 nearly years as a lubrication engineer. Bryan’s also involved with ASTM, starting about three decades ago. That was due to the creation of an on-site […] The post 234 – In-House or Contracted Oil Analysis with Bryan Johnson appeared first on Accendo Reliability.
Learning from Failure with Jim Fitch We’re excited to have Jim Fitch, the CEO of Noria Corporation and the director of ICML, back. He previously explored ICML 55, the standard around lubrication programs. ICML was founded about 18 years ago as a non-profit. It was to provide certification resources for organizations and individuals who needed […] The post 233 – Learning from Failure with Jim Fitch appeared first on Accendo Reliability.
Machinery Installation: Strategy with Roman Megela We’re glad to have Roman Megela, a reliability engineer with Easy-Laser. With over 20 years of experience, he’s been a service manager, assembly manager, and commissioner for gas compression systems. Roman’s also worked in steel and glass production, as well as oil and gas. He’s joined us before, shedding […] The post 232 – Machinery Installation: Strategy with Roman Megela appeared first on Accendo Reliability.
231 – Process Safety Management with Paul Daoust We’re proud to have the Scio Asset Management founder and MD, Paul Daoust with us. He has extensive experience in the energy, oil, and gas sectors. Paul’s also on the Board of Directors at PEMAC. His more than 25 years of experience have helped in the development […] The post 231 – Process Safety Management with Paul Daoust appeared first on Accendo Reliability.
Ensuring Effective Remote Training with Chris Christenson We’re excited to have Chris Christenson, the director of education at Noria. He’s been there for seven years and has been in the adult learning and education field for about 16 years. That involved building curriculum courses and programs. He also did training in classrooms for adult learners. […] The post 230 – Ensuring Effective Remote Training with Chris Christenson appeared first on Accendo Reliability.
Building Support for FMEA with Fred Schenkelberg We’re glad to have Fred Schenkelberg from the Accendo Reliability website joining us. He hosts the Speaking of Reliability podcast and even does reliability webinars. Fred also has articles and helps create online courses on Accendo. He’s well versed in the product development space of reliability engineering. But […] The post 229 – Building Support for FMEA with Fred Schenkelberg appeared first on Accendo Reliability.
Reliability Career with Tim Holmes We’re excited to have Tim Holmes joining us. Tim’s presented at conferences and worked with SMRPs. He’s also DuPont Operations’ principal internal corporate consultant for reliability and maintenance engineering. Before that, he was involved in maintenance and reliability as well as Six Sigma. He’s actively involved in SMRP since 2011. […] The post 228 – Reliability Career with Tim Holmes appeared first on Accendo Reliability.
Machinery Installation: Integrity with Roman Megela We’re excited to have Roman Megela joining us. He’s a senior reliability engineer with Easy-Laser. Before that, he was a service manager, and he also worked in the service engineering field. Roman’s primarily worked with rotating equipment for over 20 years. He’s dealt with glass production and stainless-steel production. […] The post 227 – Machinery Installation: Integrity with Roman Megela appeared first on Accendo Reliability.
Easy RCA with Bob Latino Bob Latino, an expert on root cause analysis with 36 years of experience, joined us on this episode to discuss Root Cause Analysis and the Easy Root Cause Analysis program that he and his team have developed. We'll go into the nuances of: Defining RCA Features of the programme Hurdles […] The post 226 – Easy RCA with Bob Latino appeared first on Accendo Reliability.
Maintenance is a Marathon, Not a Sprint with Michael Mazur We’re glad to have Michael Mazur from Schwan’s Global Supply Chain. With 10 years at that plant, he currently holds the role of a maintenance technician. He’s previously worked as a trainer and supervisor at Schwan’s. Michael started as an electronics maintenance technician in the […] The post 225-Maintenance is a Marathon, Not a Sprint with Michael Mazur appeared first on Accendo Reliability.
Crossing the Chasm with Patrick Parker Patrick Parker works for Rockwell and prior to that he worked with the US Navy. In the Navy he started as a technician and climbed all the way up. His experience is well rounded in that he touches base with everything. He has been involved in maintenance and reliability […] The post 224-Crossing the Chasm with Patrick Parker appeared first on Accendo Reliability.
Asset Investment Planning with Paul Daoust Back with us is Paul Daoust, the founder of Scio Asset Management. He’s also a member of the PEMAC board of directors. Paul’s helped us tackle different topics on several previous shows. That’s due to his extensive experience in the oil, gas, and energy sectors. He’s also gotten life […] The post 223-Asset Investment Planning with Paul Daoust appeared first on Accendo Reliability.
Spare Parts Optimization with Rob Kalwarowsky Today, we’re welcoming Rob Kalwarowsky from Rob’s Reliability project. He’s currently an asset manager at Enbridge, handling their mechanical assets. Rob was previously a reliability consultant for five years, as well as a reliability engineer at Teck Resources. He’s been on a few of our previous podcasts. But today, […] The post 222-Spare Parts Optimization with Rob Kalwarowsky appeared first on Accendo Reliability.
Should I Hire or Build an RE with Bill Leahy I’m excited to have Bill Leahy with us for a deep dive into whether organizations should build an RE internally, or they should hire externally to fill those roles. Bill has worked at Eruditio for the past three years and is currently a senior instructor […] The post 221-Should I Hire or Build an RE with Bill Leahy appeared first on Accendo Reliability.
How to Sell Reliability with George Williams and Joe Anderson Joe Anderson and George Williams started Reliability X. Joe Anderson is the COO and George is the CEO. Reliability X is a consulting organization that offers the implementation of holistic reliability for manufacturing sites. They also offer coaching, mentoring and teaching in a variety of […] The post 220-How to Sell Reliability with George Williams and Joe Anderson appeared first on Accendo Reliability.
How Detailed Should a Job Plan Be with Jeff Shiver Jeff Shiver works with People and Processes. He is heavily involved with maintenance and reliability. He has made presentations for years. He started out in Procter and Gamble doing controls and engineering. He has also worked with Mars in four different plants and also held […] The post 219-How Detailed Should a Job Plan Be with Jeff Shiver appeared first on Accendo Reliability.
OEE Modeling with Brad McCully We’re delighted to have Brad McCully joining us. He’s a business development executive at Advanced Technology Services and has been a part of the company since its founding in 1985. But, he got involved in the manufacturing field much earlier in his career, working at various levels for Caterpillar. Brad […] The post 218-OEE Modeling with Brad McCully appeared first on Accendo Reliability.
Life Cycle Costing with Paul Daoust It’s a pleasure for me to have Paul Daoust back again to talk about life cycle costing. Paul is the founder of Scio Asset Management, with over 25 years of experience in the asset management field. He also sits on the board of directors at PEMAC. Together, we’ll be […] The post 217-Life Cycle Costing with Paul Daoust appeared first on Accendo Reliability.
Proper Greasing with Wesley Cash We're excited to have Wesley Cash to shed light on proper greasing techniques. He’s been at Noria Corporation for nine years now and is currently their director of technical services. However, his professional experience in fields relating to reliability, lubrication, and maintenance spans over 16 years, enabling him to acquire […] The post 216-Proper Greasing with Wesley Cash appeared first on Accendo Reliability.
Remote Working with Patrick Parker Patrick has been with Rockwell Automation 7 years now but previously served in the US Navy. He started out as an electronics technician then moved on to dealing with nuclear systems in aircraft. He is now a reliability professional and has 13 years work experience in his field. Patrick works […] The post 215-Remote Working with Patrick Parker appeared first on Accendo Reliability.
Sealing in Pulp & Paper with Chuck Tanner Today we’re joined by Chuck Tanner, the director of market development at SEPCO. With over 25 years in the industry, he’s been helping with sealing challenges. In this episode: What is sealing Why are pulp and paper sealing hard How do we overcome contamination Do successful […] The post 214 – Sealing in Pulp & Paper with Chuck Tanner appeared first on Accendo Reliability.
Scheduling for All with John Reeve We welcome John Reeve back to tell us all about scheduling for all. He has three decades in the industry. John is going to guide us through: What scheduling for all is Its benefits How automation can help The struggles The solutions There are a lot of authors and […] The post 213 – Scheduling for All with John Reeve appeared first on Accendo Reliability.
Asset Integrity with Ali Bashir Our guest today is Ali, who is a reliability and asset management consultant. He’s going to be touching on: What asset integrity management is Regulatory requirements in place How do we develop an asset integrity management system How to make an organization successful through asset integrity management What is asset […] The post 212 – Asset Integrity with Ali Bashir appeared first on Accendo Reliability.
Fleet Maintenance Software vs CMMS with Sean Eckersley Sean Eckersley from Assetminder is today’s guest. He’s talking about fleet maintenance software versus the use of traditional CMMS’s.
Various assets can have different maintenance schedules. Fleet software is like CMMS but focuses on fleets of vehicles. These include trucks, trailers, and even plant machinery. A Computerized Maintenance Management System, or CMMS, focuses on assets like manufacturing equipment.
We will tackle:
- Differences between a fleet software and CMMS
- How does a CMMS fail to support fleets
- Can you also add third-party vendors into the system
- And much more!
Differences between a fleet software and CMMS
Since they’re similar, you’ll come across a lot of similarities. In the UK, the DVSA regulates road-going assets and the maintenance schedules. It also checks how often these schedules get inspected, maintained or taken off the road to get work done. The maintenance planning side of a fleet system is harder to track. That’s because you don’t know where the asset is at all times. Scheduling repairs or inspections on those assets need mobile engineers. They can then go to inspect and repair them wherever they are. So, the main difference is that a fleet system requires a very userfriendly and connected app. It should also have a database to store asset information. You may have mobile technicians that you need to connect with through your fleet system. That wouldn’t be as typical in a CMMS.
Can an asset’s past usage help create predictability?
For servicing an asset, you can set a reminder through, for instance, Assetminder. It has a maintenance planner for you to set up events associated with the mileage of the asset. Then when the asset gets to that timeframe, you know that a service is necessary. There are also a lot of routine inspections that need to get done, either weekly or monthly. Based on a vehicle’s schedule, you may need to combine events to cut downtimes.
How does a CMMS fail to support fleets?
Fleet systems come with a lot of aspects. These include details such as:
- The driver’s details
- Training to operate specific machinery
- Driver license checking
- Reporting on defects or a maintenance event occurrence
With a fleet system, you’d have all these aspects and more. The app would be userfriendly enough that even non-technical staff can use them.
Can CMMS support fleets?
They can. You can set an asset maintenance schedule, repair, and manage a maintenance plan for an asset in a CMMS. But, in the UK, a fleet system would work best. That’s because they get built for that environment rather than a broad asset environment.
Significant features and functions when getting a fleet management system?
The UK has two fleet levels. You would have:
- A maintenance bookshop to repair your assets
- An asset on a repair and maintenance route
When picking an asset for your business, you would choose based on cost. Once you select a course, you need to decide on that exact system, the features you need. For instance, for drivers, you would need a system that can manage all aspects of your fleet. Also, the driver information should fit into that one system.
Can you also add third-party vendors into the system?
It’s hard to get buy-ins from third-parties in the UK. These would make it possible for the data to feed into the fleet system. It would also make it more visible for the business. The data can come from the third-party, the repair, or the workshop using the fleet system at the point of repair. Or, the fleet would have to take that data if they couldn’t get the buy-in. They’d then input the data into the fleet system after the event, which isn’t the preferred method.
The less human contact in getting data into the system, the fewer errors possible. Correct data helps with knowing asset costs and the likelihood of a breakdown. It serves to save the business more money while keeping the asset on the road.
Does fleet software look into evaluating the life cycle cost?
Fleet systems these days provide graphs, piecharts, and reports of the captured data. It then goes to a reporting suite before being presented in the many forms mentioned above. These give an ongoing review of what an asset or asset type costs the fleet. That’s the data the fleet manager would need for meetings that check the fleet’s assets. That information is necessary from the capture phase to the repair, reporting the defect, and the occurring event phases.
Can fleet systems integrated with OEM sites to get billing materials, parts lists, etc.?
Several fleet systems can manage stock, purchasing of parts, and manage third-party stocks. By integrating and implementing the system, you can bring fleet parts in bulk based on the data. Then when you’re adding spare parts for a particular work order, the system picks them from the stock. The levels of what’s used and the asset repair cost can then get reported.
How does dedicated fleet software contribute to driving primary metrics?
It would be best if you were proactive in understanding the data before an event. For instance, you can plan when an asset’s service will be due. Keeping track of that ensures you have the assets, parts, and workforce needed for the repairs. That’s a crucial phase in maintenance planning to ensure the downtime is minimal.
How can you be successful with fleet management systems?
For your organization to be successful with managing fleets include:
-
Knowing the costings of the fleet
-
Having the ability to analyze the collected data
-
Being able to make decisions at the backend
-
Linking data captured within the management system across other departments
What could you change to make fleet management programs better?
There are a lot of fleet systems in the UK. But, these systems get created by what a software engineer feels that the system would need. They aren’t userfriendly enough for the technicians or fitters doing the work. For you to make it better, the complex workflows and processes need to go. The fleet systems need to be easier to use to manage maintenance.
Adoption is also vital. You need to pick a system you can follow throughout its implementation phases.
Fleet management, in a nutshell
Connect with someone that understands your requirements and the challenges you face. They can help you work through the journey together. You’ll then establish the benefits you’re trying to get from the fleet system. From there, it becomes a journey to pick the right solution, through to its implementation and going live. So making sure that if you’re in the market for a fleet system, that you get the right people involved in the business.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
Sean Eckersley Links:
- Sean Eckersley LinkedIn
- Asset Minder Solutions
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 211-Fleet Maintenance Software vs CMMS with Sean Eckersley appeared first on Accendo Reliability.
Inherent Availability and Reliability with Greg Perry We're privileged to have the Capacity Assurance Consultant for Fluke Reliability Solutions, Greg Perry. He has two decades worth of experience in the industry. So he will be talking about what availability and reliability are.
We will tackle:
- What are availability and reliability
- What are the inherent availability and inherent reliability
- Do companies confuse inherent versus the actual values
- And much more!
What is availability?
Availability is the capacity for which the equipment or system can perform its original function when needed. Also, the percentage of its availability is essential. There are different definitions of availability, such as:
- Inherent availability
- Achieved availability
- Operational availability
What is reliability?
Reliability is somewhat like availability. It also measures whether a system can perform its function. But, reliability has a broader scope. It plays a more significant role in impacting the business’s performance. Reliability ensures all aspects, other than assets, are functional.
What are inherent availability and inherent reliability?
Inherent reliability is to the left of the potential failure (PF) curve. Meanwhile, inherent availability is to the right of the PF. That’s because you inherited the demerited new value. It’s also referred to as the maintainability state. You cannot do anything within the inherent availability realm to restore what you lost in the inherent reliability space. You’re never going to build to increase it. So, you need to improve failure modes rather than mitigate them, as is the case with inherent availability.
Even if you believe you have the perfect system, some failures would still occur. You have to take into account design for reliability and maintainability. These two work in balance to create capacity assurance.
Do companies confuse inherent versus the actual values?
Most companies do not know that there is even a difference. That could be due to them not understanding what the term inherent means. But once you use the curve to explain the concept, then they start to see it.
How does understanding the inherent versus achieved or operational availability relate to reliability?
For reliability, you need to understand what you can do from a holistic process. You need to ensure you address safety with the inherent reliability. From a capacity assurance angle, a safer scenario is more reliable. It doesn’t mean it’s available.
Do organizations need to measure availability and reliability?
For this, organizations look at the mean time between failures. As a result, you’ll be referring to failure modes rather than failure codes. Reliability lies more on code than a modal approach. Measuring availability relies on corrective. Keep in mind that everything on the PF curve is corrective. So all PMs, all PM routes, all condition monitoring, among others, are corrective.
You can’t derive a reactive work order categorization from a known maintenance strategy. You can also call a maintenance strategy a preventive action plan. Let’s say you’re looking to find out the total downtime, or repair time. With a system that can identify a work request, there’s the time the work request came in until it got approved. From there, it becomes a work order ticket. That request time created the ticket to start the clock. You’ll then get timed on how long it takes you to mitigate or end the failure. From start to finish, you should include processes like triaging, staging, and scheduling. Documenting all these stages falls under rent time. Add that to total response time, and you have the entire repair time. For this example, you’re only looking for full repair time on correctives.
Reactive work types include issues classified as a random bathtub curve. It’s both the before and after functional failures. By finding out the number of hours an asset should function, you’ll have a baseline. Total repair time then becomes a percentage of that full availability time. From there, you can get the percentage availability of that asset. It can get recorded daily, weekly, monthly, or even quarterly. You then get a better picture of how healthy your preventative actions are.
How do you calculate inherent availability or reliability?
That calculation is more of an asset design activity. Designers can use maintainability predictions, reliability predictions, and such. They’ll also use allocations to divide what they want. It could be more or less maintainability on reliability aspects. It’s not a manageable number to calculate. The higher the percentage of the capacity on the left of the DIPF curve, the longer the PF curve becomes. That will impact your PF interval.
What drives success when dealing with inherent measures?
The most significant success piece is understanding that there’s hope. You have to understand what the job entails and accept it. If you don’t believe it, you’ll create a different cultural behavior. These will have metrics that drive instead of guide specific actions. Going back to the basics will show you that it’s not as bad as you think. From there, you can look for ways to change the situation. Look at opportunities to the left of the PF to help you move.
How to change how people measure availability and reliability
Try and focus on what matters. Ensure you understand the business, the foundation, and its fundamentals. Most companies believe technology will bring about reliability and even capacity assurance. That won’t be possible without a foundational understanding of how things work. It would be best if you first learned the foundational tools.
In summary
It would help if you challenged the assumption. Get out there and find out for yourself what the actual standards could be. Don’t rely on what others say, especially when you doubt the outcomes based on what you see. It will surprise you how much you already know.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
Greg Perry Links:
- Greg Perry Linkedin
- Fluke Reliability Services
- Accelix.com
- RCM Blitz
- SMRP.org
- CMRP Certification from SMRP
- ISO 55000
- Accelix LinkedIn Group
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 210-Inherent Availability and Reliability with Greg Perry appeared first on Accendo Reliability.
The Productive Leadership System with Tom Moriarty With us, today, to talk about the Productive Leadership System (PLS) is Tom Moriarty. PLS is essential in getting maintenance and reliability principles to work.
We will tackle:
- What leadership is
- What is PLS
- How to improve leadership within the organization
- How to begin the journey to having good productive leadership in your organization
What is leadership?
Leadership is getting things done through other people. It is the ability to communicate the desired results. Besides that, it’s also setting missions, visions, values, and objectives. It’s making the necessary assets available, while also authorizing and implementing the methodologies. These help in the deployment of assets to achieve that end state. Providing guidance relies on:
- Policies
- Process
- Plans
- Procedures
- Measures
People in leadership positions need to be accountable to execute. Good leaders get things done by encouraging team members. It brings about good morale, low turnover, and better safety awareness. Weak leaders, on the flip side, do not manage to complete their tasks. Their team members suffer from lower morale. That leads to more turnover and problems with quality and safety.
What is PLS?
PLS is a system that creates a framework within which proper leadership can get enabled. The organizational reliability and productive leadership model generate part of this system. The productive leadership development program then completes this framework. Thus, allowing you to train and execute leadership.
What is the organizational reliability model?
The organizational reliability model assigns accountability within each level of an organization. It’s an asset management system. The top half of the model is the Proactive Improvement Realm. With this, the senior person is accountable for proactive improvement. They assess internal strengths, weaknesses, external opportunities, and threats (SWOT). These get assessed against the organization’s mission, vision, values, and objectives.
Next comes the Define Phase. Here, you apply things like Reliability Centered Maintenance (RCM), root cause, or defect elimination to develop a response to the SWOT. It’s also where a solution gets vetted. It’s then written down into a policy, plan, process, procedure, and measure. Training then occurs, resources get procured for easy availability. You then move to the lower half of the model called the Control And Stability Realm. The aim here is to have compliance or adherence to guidance.
At the bottom half of the model, accountability shifts to a subordinate. The senior person is no longer in charge. They then become accountable for executing current guidance with current assets. It differentiates between authorized guidance and access and current guidance and access. Thus, the subordinate now communicates matters on the ground to their seniors. This keeps the company productive.
As a subordinate, how do you get your seniors to react?
There are ways that a subordinate can influence their seniors to make decisions. One way is by taking the initiative and informing your seniors of the available options. If they do not respond, use the phrase, “Unless otherwise directed.” It forces them to either reply or not. Even by not responding, the addition of that phrase means that they have agreed to your terms.
To use this phrase, you must first gauge the amount of responsiveness the senior person has. You also need to be aware of the amount of trust and respect between the two parties. Higher trust and respect levels are likely to make the senior more responsive to the request. To create that trust and respect, explain yourself with clarity. Thus, helping the seniors relate to what you’re recommending.
What is the productive leadership model?
Productive leadership refers to how a leader executes their control and stability accountabilities. It applies to both senior and subordinate leaders. A leader must want responsibilities that allow them to lead others. They must also have personal missions, visions, values, and objectives. These should get satisfied through them becoming leaders. When it comes to leadership roles, attributes, and skills, there are five of each.
- Leadership Roles
These refer to where a leader spends their time throughout the day. They are:
- Expert technician
- Manager administrator
- Coach
- Systems thinker
- Visionary
Leaders should also spend their time on personal development and having free time.
- Leadership Attributes
These refer to the leader’s characteristics. They help your subordinates know how to act during different situations. These attributes include being:
- Consistent
- Attentive
- Respectful
- Motivational
-
Assertive
-
Leadership Skills
These are the leadership skills you’ll come across often with leadership training sessions. They include:
- Time management
- Communication
- Empowerment
- Giving and receiving feedback
- Conflict management
Power Bases
There are two bases of power, that is personal power and position power. Position power refers to authority delegated to you from your seniors. Personal power is how you interact with other people. It’s given to you by your seniors as well as your peers and subordinates. It’s based on how virtuous and truthful you are, as well as how you conduct yourself.
The preference is in having personal power. But, position power becomes necessary in situations where you need to compel compliance. That is, especially when people don’t want to do something.
How to influence others
Maslow’s hierarchy of needs gets applied here. It implies that you can’t meet higher-level needs before meeting lower-level needs. You can only influence others by knowing the needs that motivate them to do something. There are three different needs theories:
- Maslow’s
- McClelland’s needs theory
- Herzberg’s motivation-hygiene theory
Setting Goals
You need to be able to motivate team members to progress towards a goal.
Leadership development programs
Organizations need to think about their structure as well as:
- How to assign accountability
- How to deal with proactive improvement
- How to make sure they have control and stability in what they do
To apply these, you need productive leaders. That’s where productive leadership programs come into play. Elements within the program include:
- A policy statement signed by the senior-most individual in the organization. It’ll outline how they’ll promote leadership. It should also specify the criteria for when you onboard people.
- Using the organizational reliability model.
- Setting productive leadership standards.
- Having ongoing training programs to train people. That will be on the organizational reliability model and leadership that’s consistent.
- Surveys to identify how leaders view they’re doing. That is versus how their team members see they’re doing.
Leadership training within your organization should be every two to three years. You’ll start noticing average to above-average motivation scores among your employees.
What improves leadership within an organization?
There are three points in the leadership process. The first focuses on accountability, which guides the organization’s leadership. The second looks at organizational reliability. Finally, the inner circle is productive leadership.
Without accountability, you can’t execute the systems you have in place. It’s essential to foster accountability on all levels.
How can you start to make a change in your organization?
The key to improving your organization is to start learning more about leadership. And not only for yourself, but for your team members as well. Get different leadership materials to guide you through the various processes. Learn your craft as a leader to enable you to adapt to different situations faster.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
- Eruditio Supports: www.help.eruditio.com
Tom Moriarty Links:
- Tom Moriarty LinkedIn
- The Productive Leadership System: Maximizing Organizational Reliability
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 209-The Productive Leadership System with Tom Moriarty appeared first on Accendo Reliability.
Pros and Cons of Different RCA Methods with Shon Isenhour Shon has been on our past episodes. He is the founder of Eruditio LLC, a co-author of several books, a conference presenter, and he has been in maintenance and reliability for quite a while. He has been in the reliability sector for 20 years.
This episode focuses on:
- What is root cause analysis
- What are the Different Tools of RCA
- How do You Pick a Tool to Use
So, what is root cause analysis?
Root cause analysis is a problem-solving strategy. It involves dissecting a problem thoroughly and understanding how to address not just the surface issue but every aspect. We look at what is to be eliminated or reduced to ensure that the problem does not occur again. You reduce the risk to a level that you can manage and afford.
What are the Different Tools of RCA?
There are a lot of tools and these are just some of them
- Pre-analysis tools
- Time tools
- Tree tools
- Transparency tools- for big problems like performance gaps
The Tree Tools
Why should we use them?
Where should we use them and what are the shortfalls?
Tree tools are the most common tools available.
One of the Tree tools is 5Ys
5Ys- ask why 5 times how something contributes to an issue. Adding ANDs' and ORs' to all branches to have the ability to see where things come together and what could be the problem factor. This is great in a root cause investigation where evidence was destroyed or lost.
The tree tools best fit where you have one specific problem. Fault trees are also used with other tools such as the time tools.
Where do tree tools fall short? Can they be used for short or complex problems?
If the problem is very large or has very broad amounts of forcing functions coming in, the tree is too broad even for the surface you are working on. It will become inefficient. Being visual is a pro but the amount of intensity might be problematic. You will overrun the sides of your whiteboard.
Tree tools don't allow you to see risks and potential probability in the grand scheme of things. So, if you are mapping out potential causes, there are some that are very likely to have occurred while others are very unlikely to have occurred, so you do not have a good way of evaluating the risk associated. That means switching over to transparency tools.
Transparency Tools
This is a set of three tools but the most popular is the fishbone.
Fishbones. A way of understanding contributing factors and causes. They only deliver higher-level causes in most cases.
Time Tools
Time tools are often neglected but are the most powerful tools in problem-solving. The tools are then narrowed down to two steps:
- Sequence of events
- Expansion of the sequence of the events. It branches into an event and causal factor and is a bit complex. You use the branching mechanism to understand problems when you cannot put things in sequence.
The limitations? You may need extra tools such as a fault tree. In this situation, it is not a tool enough for the job. It is great for understanding what happened in the past and what will happen in the future.
What other tools are used in the field?
The ones we have mentioned are already common but there is the barrier analysis where we look at all the different systems that could stop something from occurring.
Most of the other tools are a take on one of the tools like change analysis. Change analysis is the idea where you check what is different today from what was working perfectly. You look at what changed when it changed and how did it change. This is seen in a root cause methodology.
How do You Pick a Tool to Use?
We have to be comfortable with transitioning as a situation changes. This is because as a situation changes, the tool might change. So, in most cases, the best fit is the tree tool. But if there are a lot of changes that call for flexibility then transition tools will do. If you have no idea of what happened then time tools will be suitable.
Transparency tools are for big problems.
Tree tools are for specific failures
Time tools help us get an understanding of all the contributing factors where there is a lot of missing data.
What is needed?
Stick to the basis of root cause analysis and do them well. There is a huge ROI. Don’t be scared of root causes, start small and have a process that informs you of what you should and should not do. Make sure you communicate your RCAs. A 50-page document will never be read as much as you need the data, package it right even in one page.
Just go and do some RCAs. You will take longer but it will get better. There is no silver bullet but as you put other things in play, more value will be added.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
- Eruditio Supports: www.help.eruditio.com
Shon Isenhour Links:
- Shon Isenhour LinkedIn
- Shon Isenhour Twitter
- Eruditio.com
- Eruditio Linkedin
- Nasa Fault Tree Handbook
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 208-Pros and Cons of Different RCA Methods with Shon Isenhour appeared first on Accendo Reliability.
Hand Safety With Joe Geng In maintenance and reliability practices, physical risks are always present. The most common injuries are hand injuries. Today, we have Joe Geng telling us all about the importance of hand safety.
He has a book out aimed at helping workers understand:
- Why hand safety is important
- How we can prevent hand injuries
- The levels of ensuring work safety
- The measures you can take to ensure hand safety
Why hand safety is important
People in the workplace usually don’t give hand injuries the seriousness they deserve. When someone gets a cut, they should either report it or get help. But instead, they bandage it up, or add some crazy glue and keep on working. But, these injuries could lead to more significant issues. These include infections or even losing your fingers. You may also have to take time off work, reducing productivity and even morale at the workplace. Severe issues such as losing a hand may also force you to leave work, affecting your quality of life.
How can we prevent hand injuries
Hand injuries in the workplace are preventable. But it requires all workers and their superiors to get committed to safety practices. Most companies have safety managers. But, these managers need support from upper management. Without help, the safety measures implemented will likely fail. So, the top management needs to:
- set aside budgets for safety enhancement purposes.
- get more involved in the safety procedures undertaken.
- have regular safety meetings to create a culture in it.
- encourage workers on the importance of working in a safe environment.
- ensure safety managers and workers can communicate in case of any issues.
The levels of work safety
Safety at the workplace can get broken up into the following elements:
- Personal Protective Equipment (PPE)
- Policy
- Training
- Procedures
-
Cultures
-
Personal Protective Equipment PPE
For hand safety, one of the first safety measures is offering protective gloves to the workers. Companies should have a hierarchy of safety practices to help end hazards on the work floor. These help to cut the prevalence of injuries. That way, gloves only come in to create an extra barrier, where necessary, to help prevent injuries. Gloves help reduce or prevent injuries such as cuts, burns, Vibrations, impact on the back of the hands and exposure to chemicals
It’s important to note that gloves can also expose workers to injuries in some cases. That is, especially around circulating equipment like a drill press. Even with well-fitting gloves, the material could get caught in the machine. If that happens, your hand will get pulled in the process. Such incidents result in extreme injuries. It's advisable to avoid gloves around circulating equipment.
There are, nowadays, tear away gloves, created for working with circulating equipment. They come off fast when caught, decreasing the chance of getting injured.
- Safety Training
To get the best training, you need to have tailored safety exercises per plant operation. You would also need a trainer who understands how the plant floor operates. Such a person would be able to relate to the issues experienced on the work floor. Being relatable means, they wouldn’t be giving generic safety advice during training sessions.
Mindfulness training is also essential as workers tend to lose attention. That could be at the end of the day, or when gearing up to a long weekend.
- Cultural Issues
These are one of the leading causes of injuries in the workplace due to:
- Language barriers – Non-English speakers miss information from safety training sessions. The same applies to safety signs in the workplace.
- Non-native workers are too submissive – Such workers do not speak up about any issues on the work floor. They will continue to work even when they have injuries.
Measures you can take to reduce hand injuries
A lot of elements come into play when you’re looking to reduce hand injuries. The hierarchy of safety controls is the first component. It helps workers cut hazards by having:
- guards in place
- signs in many languages to cater to your entire workforce
- the right PPE available
To improve behavior-based safety, you need to observe the injuries occurring. This is even after the safety controls have gotten implemented. From there, plan a strategy to reduce the casualties. That could be by holding meetings with the workers in those injury-prone areas.
Another way to promote safe work practices is by making injuries personal to them. Expose the workers to the reality of the injuries they’re likely to come across. It could be by either showing pictures or videos of injuries. You could also hold real simulations to act out the accidents that may occur.
Positive peer pressure can also get applied to create awareness of hand safety. Get some workers to commit to safety procedures, and other workers will likely join in. Other options include rotating safety signs across the work floor. You can also make sure that PPE is easy to come by in the workplace.
In a Nutshell
It’s important to understand that hand-related injuries can reduce. These aren’t like other work-related injuries, such as back injuries. Back injuries occur in a variety of ways, making them harder to avoid. Companies need to understand what hand safety best practices are. These include having the right procedures, training, PPE, among other safety practices implemented. Strategic approaches are the best move. They enhance safety practices, bringing about a longlasting effect at the workplace.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
- Eruditio Supports: www.help.eruditio.com
*Joe Geng* Links:
- Joe Geng Linkedin
- Superior Gloves
- Superior Gloves Blog
- Safety Function
- Rethinking Hand Safety: Myths, Truths, and Proven Practices by Joe Geng
- 7 Insights into Safety Leadership by Thomas R. Krause & Kristen J. Bell
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 207-Hand Safety With Joe Geng appeared first on Accendo Reliability.
Reliability Basics and AI with Fred Schenkelberg Artificial Intelligence has become a hot topic today with organisations attempting to find ways of applying it. The fact is, however, that a good number haven't found a compelling case for the adaption. Fred of Accendo Reliability joins us on this episode to break down what AI means for the reliability industry.
Key highlights from this interaction are:
- How reliability is influenced by AI
- Why people are jumping on the trend' without looking at the relevance
- Considerations to make before adopting AI for reliability
Today, more assets are becoming smarter and in the process generating large quantities of data. Ironically, even with countless data points flowing into databases, there is yet to be sufficient information that generates value.
With regards to AI, tools for performing analytics are a step in harnessing insights. However, the underlying logic of AI algorithms comes from having a good understanding of the systems as well as the basic principles of mathematics. Just because the competition is embracing AI does not mean you should also buy the next plug-and-play solution.
How is reliability influenced by AI?
In the competitive world today, maintenance and reliability teams are discovering ways in which AI can help them:
- Optimize maintenance schedules and predict abnormal performance
- Select appropriate conditions for equipment performance
- Increase process efficiency
The technology revolution is only just building momentum, and those who embrace it dynamically are the ones poised to lead their industries.
Why some people without AI experience are still jumping in?
Because of its seemingly trendy nature, AI has attracted many teams to start tinkering with it. The industry is facing something similar to the shiny object syndrome'
A fraction of those who try implementing AI strategies without a fundamental understanding of the need end up with a model that produces inconsistent results. The wrong approach is staring off with an AI solution' and looking for the problem. It is therefore critical for personnel in charge of reliability to have a good understanding of their existing operational difficulties, before figuring out where AI can plug into it.
Key considerations to make before diving into AI for reliability
Having the fundamentals down means that from a design point, both intrinsic and extrinsic influences get factored into the performance consideration. When going through designing an AI solution, you can then take a procedural getting ideas like:
- Identify the existing problem
- Interrogate ways in which AI can improve it in comparison to the existing state
- Consider the influence of intrinsic and extrinsic factors like seasonality, product mix etc, and how they would affect the AI model
- Gather sufficient historical data that will be used to train the model. Ensure it covers as many performance scenarios as possible
- Once trained with historical data, try testing the AI model using appropriate methods e.g supervised learning, unsupervised learning etc
Other important considerations are that you should have a skilled data scientist or statistician working with domain experts, so as to adapt these algorithms to your facilities day-to-day scenarios.
Key takeaway
Understanding the problem is a key component for successful deployment of AI. You need to ask yourself:
- What problem are we trying to solve?
- Why is the existing infrastructure not fast enough or powerful enough, to require AI?
After this problem definition phase, you need to come up with a pilot test case. The pilot will give a better picture of the expected output after scaling.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
- Eruditio Supports: www.help.eruditio.com
*Fred Schenkelberg* Links:
- Fred Schenkelberg s LinkedIn
- FMS Reliability
- Speaking of Reliability Podcast
- Accendo Reliability
- Soft Skills for Reliability Engineers
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 206-Reliability Basics and AI with Fred Schenkelberg appeared first on Accendo Reliability.
Ultrasound Remote Monitoring with Doug Waetjen Today we host Doug, the Vice President of Global operations, UE Systems. He has been with the organization since the 80s. He has spent a lot of time working with ultrasound technology.
Key highlights from this episode are:
- Overview of Ultrasound Remote Monitoring
- What technology is available to monitor remotely with ultrasound
- What should be done that is not being done
This is a technology that was used to listen to problems but when conditioning reliability evolved, this had to change to dig into the nuts and bolts of figuring out problems.
The disadvantage of the old device using the point and shoot method is that it takes a lot of time to do something. As companies over the years have shifted to safety aspects, a lot of equipment is covered and shrouded and there are access issues.
What technology is available to monitor remotely with ultrasound
There is still a place for handheld monitoring technology but there is also the option of going full blast. There is also a blended program. Most of the companies want to take the critical aspects and put that on a permanent monitoring system.
How do organizations choose
First, there is a need to understand what assets are available and how they fail. Map out their failures and what is the best technology to apply to them. Then do asset criticality exercises, what is the impact on the organization and safety if the asset goes down. The data should be stored for future analysis. See if you can avoid such failures in the future by doing something differently.
You do not want failure to happen within monthly checks.
What applications are best for remote monitoring for ultrasound
- Motor bearings
Safety advantages
The best thing is that nobody has to go near that asset. Just set the system up. It’s all about removing interaction between people and the asset. Eliminate human interaction with a looming hazard. This applies to both full time and handheld data collection.
These sensors are mounted right on the actual housing. The outboard will do.
Where do organizations start looking
They start with the route-based approach then depending on the data they are getting back; they choose a suitable technology. In short, do homework before you dive in.
There are so many different options but people focus on only two. There is an in-between system and that is simply looking at mounting a sensor that sets off an alarm. Having that in a control room ensures its working all the time. It is also a low-cost option.
Triage and figure out what you need to do next.
The homework portion, criticality analysis ensures that you do not just monitor for the sake of it. Take it slow and look at the assets that you have and work out your bugs. Find out what action you have to take and how fast should you take it. After all this, slowly expand the program. Start slow and learn as you go.
What should be done that is not being done
The biggest thing to change is committing to a tremendous amount of training. Trust what the information says to be able to make the call. most organizations buy ultrasound equipment but do not have sufficient training on how to analyze and collect data.
If you are currently using ultrasound, go and look at the after-failure actions that took place. Do not get on the reliability problem treadmill where you just find problems and solve, get to the root cause. See what other people have done, don't reinvent the wheel.
Ultrasound is not the only game in town. There are other technologies and communities online that will share their best practices.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
- Eruditio Supports: www.help.eruditio.com
Doug Waetjen Links:
- UE World
- UE Systems
- Doug Waetjen Linkedin
- SMRP.org
- Making Common Sense Common Practice by Ron Moore
- The 7 Habits of Highly Effective People: Powerful Lessons in Personal Change by Stephen R. Covey
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 205-Ultrasound Remote Monitoring with Doug Waetjen appeared first on Accendo Reliability.
Data Quality Issues with Manjish Naik & Sarah Lukens Manjish Naik and Sarah Lukens join us to discuss how to overcome data quality issues with KPIs.
They’ll help us understand:
- What a KPI is
- How to get started with data
- How to establish KPIs
- Factors hindering the accuracy of data quality
- How to overcome data quality issues
What is a KPI?
A Key Performance Indicator (KPI) measures the performance of an asset in either a process or manufacturing plant. The metrics can be high-level, for instance Overall Equipment Effectiveness (OEE), or granular like corrective or reactive count.
KPI metrics can fall into two categories – leading or lagging. Leading metrics give you a forecast of what’s to come. An example is PM compliance. By meeting your PM schedule, it would allow you to find issues in advance, making you more proactive towards fixing arising issues. Lagging indicators like reactive count, take into account something that’s already happened, to analyze and improve future processes.
Having a varied system of KPIs to work with helps you to better understand your asset performance in the field.
How to get started with data
KPIs have been known to bring about issues such as inconsistent measurements and inconsistent data. So, how do we get past these? It all starts with the quality of the data. These are a few questions you need to answer:
- What is the importance of good quality data?
- What is good quality data?
Data quality refers to its fitness to a given purpose. It needs to be complete enough to allow you to measure and understand critical indicators.
How to establish KPIs
KPIs get calculated from the maintenance work done physically. It can also be calculated from your Computerized Maintenance Management System (CMMS), like SAP or Maximo. The process starts with you understanding how many failures happened within a specific period. You could establish this by talking to floor technicians (which isn’t very scalable), or relying on data from CMMS
The data quality from a CMMS is preferred as it helps understand how metrics get calculated, and what insights come out. A CMMS has predefined fields for cost, parts, labor, skill type, activity type, among others. However, these still don’t guarantee quality of the collected data.
Factors hindering the accuracy of data quality
There are three main factors:
- People – Humans manage the data collected throughout the work order on the CMMS. If they’re unaware of the intended use of the data, they may not give accurate input.
- Processes – Rarely are there well-defined processes for people to input data into the CMMS. As such, everyone comes with their own processes to complete the task, with some resorting to ways of circumventing the entire process.
- Technology – A CMMS may not be designed with reliability in mind. It may not take into account the particular analytics of the given plant, missing the necessary fields to calculate certain metrics. Codes relating to work order types may not be clear, or the taxonomy may be ambiguous.
There are organizations trying to streamline data quality issues. These include:
- ISO 14224 – They offer information on how to set up a data collection system for maintenance.
- SMRP – They offer guides on availability in metrics.
However, even with these organizations, we still can’t measure data correctly. That’s because:
- These organizations offer theoretical solutions without practical recommendations.
- The CMMS might not be effective in capturing the information that’s necessary for calculating metrics.
- Without having a way to define the dates of when assets go down or when they got fixed, you can’t have consistency in your availability evaluations.
How to overcome data quality issues
- Improve historical data already in the system
Rather than storing the CMMS data you need to be able to extract this information in a scalable way. Natural Language Processing (NLP) approaches, responsible for programming computers and algorithms, can be used to extract and refine historical data.
Is it worth it to go back and clean the data, or should the organization move forward collecting new data?
The answer depends on whether you can afford the cost, and if you’ll get value at the end of the process.Fundamentally, it’s worth it if you can go at least five years or a decade in the past, and no more. So, rather than paying to create and store data, organizations should unlock historical data. It’s necessary to focus on unlocking valuable assets rather than every stored asset to get the most value.
- Applying industry best practice
Take a holistic approach on aspects like:
- People – Hold training to show how the data recorded in the CMMS gets used
- Processes – Have standardized definitions for all the maintenance terms, with practical examples on how to get these into the CMMS
- Technology – Design CMMS with KPIs in mind to have all the required fields. The picklist should also be clear enough for anyone to use
How can you improve your current data quality?
Start by measuring your data quality to separate the good data from the bad. For the not so good data, find out what makes it substandard. You can also start implementing best practices at your organization. As for your historical data, start using NLP processes to extract and make use of what you already have.
How to become successful with data quality
You need the correct mindset to start getting good quality data. Also, don’t get overwhelmed and don’t procrastinate. This will help you to sustain your improvements through regular monitoring and tracking of the system.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
- Eruditio Supports: www.help.eruditio.com
Manjish Naik & Sarah Lukens Links:
- Manjish Naik Linkedin
- Sarah Lukens Linkedin
- PHM Society
- SMRP.org
- SMRP Best Practices Guide
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 204-Data Quality Issues with Manjish Naik & Sarah Lukens appeared first on Accendo Reliability.
Digital Transformation with Dave Drerup Data is the single most important parameter that helps you define the rest of the parameters in asset management. That's why it is very important to capture the right data in the most efficient manner possible capturing it using digital means rather than traditional ways. Some organizations struggle with digital transformation because they have been doing things the traditional way for the longest of time period and they have difficulty understanding the benefits digital transformation brings to a company. Digital transformation starts with asking the right questions and getting answers by using reliable data, analyzing it, and then, utilizing it to bring value to the organization.
The points addressed in this podcast highlight:
- Why is Data such an important parameter?
- What does Digital Transformation mean?
- What are the positive effects of Digital Transformation if done correctly?
Digital transformation doesn't mean just better tools and advanced technology, it relies heavily on the quality of data and standard processes that will help you use that data to bring effectiveness in the ways you perform asset management and have necessary corrective measures in place in case of failures. The results of digital transformation heavily depend on the culture of an organization, right segregation of data, and smart decision-making skills shown by the personnel running the asset management programs of that facility. They also have to make sure that everyone has access to the right information in a real-time manner using mobile devices to empower them to make risk-based decisions. Change management also plays a huge role to make the digital transformation as smooth as possible so that the work feel a sense of safety and become resilient towards achieving set performance goals.
This will not also result in improved productivity and higher profitability but also, the organization will have an informed task force and overall equipment effectiveness throughout the facilities. So, digital transformation helps frontline personnel to make smart, informed, and thus, more confident decisions which means stronger and retained workforce with passage of time for the organization. Higher and middle level management also benefit from digital transformation because of the increased wrench-time, increased ROI, and availability of performance analytics at all times. It allows you to have integrated processes across the entire organization and that helps you perform analysis in the actual operating context of the asset.
It provides you improved and comprehensive asset management strategy to go about transforming the culture of the organization with time. A lot of organizations struggle with implementing the digital transformation because they have the technology in place but fail to design robust processes to integrate with their systems which makes the biggest difference. They need to understand the value of having something to build upon when they start their journey with digital transformation. Having good libraries for failure management can really help you build a strong baseline to implement digital tools for enhanced data capturing and analysis techniques. The successful outcome is obtained by making the right information available at the right time. The organizations need to know what they are doing and why they are doing it. Having an intelligent operation management to ensure cross-functional adhesiveness towards common goals is the key for a successful digital transformation.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
- Eruditio Supports: www.help.eruditio.com
Dave Drerup Links:
- Dave Drerup LinkedIn
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 203-Digital Transformation with Dave Drerup appeared first on Accendo Reliability.
RCAM with Richard Overman This episode revolves around the book titled as Reliability Centered Asset Management by Richard Overman. It is based on using the principles of reliability centered maintenance to manage your assets. It helps you understand the processes involved in managing your assets effectively by finding answers to questions such as; how or why your assets are failing? What are the consequences of those failures? And how to take actions to prevent those failures from occurring in the first place. It is based on the application of RCM principles to ensure reliability through-out the lifecycle of the asset.
The points addressed in this podcast highlight:
- How or why are your assets are failing?
- What are the consequences of those failures?
- How do you take actions to prevent those failures from occurring in the first place?
So with RCAM, you are not just doing maintenance. You are applying RCM principles to get what you need from your assets at every stage of their life span. The level of reliability can be defined by taking into account the room of unreliability at every stage. Unreliability in stages such as asset design will help you to account for the additional unit production within that facility to compensate for the design flaws of that particular asset. This idea can be applied to set goals for other stages such as installation and operation. Once that's done, you can put guidelines in place to ensure the achievement of those set goals.
With this, you can also put accountability procedures in place to do what needs to be done to stay ahead in terms of cost management and controlling other aspects of the asset management in the long run. As you advance from the design phase towards installation and so on, you need to set standards for acceptability tolerances within that particular phase and then make sure that you put efforts into making sure that tolerances are met while applying those set procedures and standards every step of the way. In this fashion, you will always be prepared to mitigate any failures and always stay ahead of the curve in the process.
Having good processes and effective procedures is always helpful but successful enforcement of those policies is what makes the real difference. This can be made sure by making it the part of the managers' job descriptions to uphold set goals within every department so that the unreliability is managed properly at all times. That way, you will have accountability in the system if the set goals aren't met or policies and procedures are violated. Another thing that needs to be managed is individual goals within the organization and you will have to use needs analysis to identify those.
You can ensure this by providing training and having the right people at the right places. It would be the responsibility of the reliability managers to accomplish the set goals while making sure that everyone understands those goals. They are the champions who have to look at everything from a reliability centered perspective and develop a culture to have a sustainable asset management program. It always starts from the willingness to learn and improve, and the small changes in the thought process of the organization make all the difference in the end.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
Richard Overman Links:
- Reliability Centered Asset Management by Richard Overman
- Richard Overman’s eMail richo@coreprinciplesllc.com
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 202-RCAM with Richard Overman appeared first on Accendo Reliability.
Culture with Patrick Parker If a methodology or a program isn't producing desired value for an organization even after putting all the necessary resources into it, the root cause might be the culture of that organization. The culture of an organization consists of its practices, common goals, and shared values. If people aren't putting efforts into securing the goals that an organization values, there's definitely something wrong with the organization's culture. That's why culture is so important for managing assets and the overall success of the organization. A good culture is formed when the organization has set some standard procedures and values in place to ensure certain practices.
The points addressed in this podcast highlight:
- What does the culture of an organization consist of?
- Why is culture important in managing assets?
- How do we improve the cultire of an organization?
It starts with open communication and accountability but clear consequences and sometimes, enforcing certain practices makes a huge difference in the culture of the organization. While culture is very important for successful asset management programs, the organizations should treat the culture itself as an asset. When there are well thought-out general practices and planned processes in place within the organization, it becomes easier to have the personnel follow the set guidelines and invoke certain practices to ensure the successful application of the organizational culture. There are a few exceptions here and there but they can be mitigated by taking suitable actions in the best interest of everyone involved.
When it comes to changing or improving the culture of a certain organization, there isn't a comprehensive understanding of what that means but there are frameworks out there that will help you change your internal process values and controlling information flow in the facilities. It will also help you manage new talent, channel culture guidelines, and manage overall progress towards improvement. There are always competing values in the organization, so this framework can work as a base for keeping the things up and running while mitigating failures from time to time.
Managing goals and expectations is the key to a successful implementation of the organizational culture and it can be controlled by effectiveness and sustainability of the organization. The sustainability is driven through beliefs and values of the organization. On the other hand, effectiveness of the organization is defined by its goals and objectives. Also, attitude leads to successful achievement of both effectiveness and sustainability within the organization. Maslow's Hierarchy also helps you understand all the things that are going on towards improvement of the culture to contribute to the success of the organization.
There are frameworks and models out there such as ADKAR and Leading change model to help you successfully align the individual goals with the organizational goals. These two models work great when combined together. Cultural change sometimes starts with the efforts of an individual because he stands for his or organization's beliefs and decides to do what's right. So, anybody can be a leader to change the culture of an organization but support of the management and having shared values adds effectiveness to doing the things the right way. All it takes is believing in taking the right action and making sure that it is standardized over the period of time.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
Patrick Parker Links:
- Patrick Parker LinkedIn
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 201-Culture with Patrick Parker appeared first on Accendo Reliability.
Special 200th Episode of Rooted in Reliability Podcast
Joining us for this special episode are some of our past guests. In no particular order:
- Shon Isenhour from Eruditio
- Fred Schenkelberg from Accendo Reliability
- Rob Kalwarowsky from Rob’s Reliability Project
- Brandon Weil from Eruditio
- Lucas Marino from Marino Consulting
- Blair Fraser from Quartic.ai
They’re going to help answer questions from the audience.
1. Tyler is a maintenance supervisor with interests in reliability, leadership, and continuous improvement. He listens and reads a lot on things within different plants and industries. He’s heard about functions like planners, schedulers, reliability engineers, among others. His work environment is tough because there are only small people and small groups. There are also teams on back to back rotations. These individuals don’t get a lot of facetime with the different areas. Thus, he only works with half his crew. So, how does he put in place some of these practices? Keep in mind there are no specific roles or round the clock support for people on the front lines.
Brandon – He’s got a burden of knowledge as he has a good idea of how things should get done. But, facilities with these roles and responsibilities aren’t always doing them well. Having dedicated resources to do a job doesn’t guarantee results. Concentrate on your pain points. That could be issues such as the communication between groups, or even scheduling. From there, focus on the roles and responsibilities that would solve the pain point. You can institute little pieces without having them full time. But you’ll need to pick the parts that give the best results.
Shon – Understand what you’re trying to face or correct, and address them.
Fred – Your ROIs link to your pain points. So, reward efforts by team members who try using these tools, techniques, or practices. Encourage the move by putting more material out there. You can also ask questions that prompt people to do a more in-depth root cause analysis. Classes aren’t enough. Foster the culture of implementing these tools.
Lucas – Drive knowledge sharing through building expectations for standards. Involve team members in the development of the packages to give them a little ownership.
Brandon – You should foster adherence to the process and create the watch team mentality. Be disciplined enough to follow the schedule to help enhance communication between teams.
Rob – Build momentum with a culture. With a team, building momentum can take a short time. You’ll be reinforcing your wins and pushing people forward. Also, have positivity to build positivity as negativity breeds negativity.
2. With IoT being such a big topic, someone is looking into IIoT for their maintenance program. But they still rely on OEM and manufacturer recommendations for PMs. They have some planning in place, but it’s not too developed. Will IoT help them move out of that reactive maintenance realm? Or are there other things they need to consider first to make it possible?
Blair – Studies show that 97% of data generated by our machines don’t get used. And when used, it’s for reactive or forensic purposes when something’s happened. To get the most benefit out of IIoT, pair it with analytics. That way, you get insights into what can change your reliability program. Moving from the reactive to plan domain is about managing risks to that asset. The application of maintenance and reliability still features, regardless of the technology used. You need a foundation in place before looking into AI and IoT measures. Have discipline around understanding which failures you’re trying to tackle. Focus on one asset at a time before moving to an IoT AI strategy to complement that.
Fred – You have to have a decent program from the start. Much of the data we have isn’t going to good use. So adding more data won’t solve the issue. Understand what you’re trying to catch and the physics of failure model well enough to get ahead of it.
Rob – Start small with high value, well-understood assets. Then build it up as you start to see success.
Lucas – Engineers that see the benefits of new technologies often have difficulties conveying the selling points. And, unfortunately, this impedes getting the budgets approved. So there should be ways to show the learning curve isn’t very severe once the tools become available.
3. Someone using IoT is struggling to sell the improvements that come with reliability. So, how do they get their leaders to buy the idea?
Shon – First, ensure you speak their language. Reliability is an answer to a problem they have. Figuring out what that is, gives you the ability to meet a need with something that you desire to create. Keep your pitch short but positive and informative. Use words and body language that shows you believe in the outcome of reliability. Use the hook, story, ask method. The hook refers to the risk. The story relates to the present situation or what you plan to achieve in the future. The ask is what you need.
Fred – Always use three significant digits for your pitch. It’s more believable than a rounded-off amount.
Lucas – Use reliability metrics that resonate with senior leadership.
Blair – Check the language you use. Link your pitch to terms they find familiar.
Fred – Find a friend in finance. They can help you convert your pitch to a financial format. That will make it easier for senior executives to understand.
a) Maintenance task analysis. What is it? How does it apply to an industrial setting other than large government projects? How do they use that to drive improvements in their industrial maintenance program? That’s whether it’s from before the asset shows up, or while the asset’s on site.
Lucas – Maintenance task analysis is something that’s in existence in different forms. It’s how you define detailed maintenance task requirements. Then create a procedure for the maintainer to use. By analyzing all task requirements, you can determine the steps needed. You’ll also know who should perform them and the level of expertise necessary. There’s also the number of technicians and the equipment required. You’ll even know where it happens, be it the factory or at the asset. Aggregating the information will prove useful to the entire organization. Failure to do this in advance could lead to extra costs.
b) Who does the maintenance task analysis?
Lucas – You need a team with a maintenance engineer and, or a maintenance planner. A maintenance engineer with a worldly view on supporting things would be ideal. A planner is an excellent option because they understand time differently. Primarily when referring to the execution of maintenance. After documenting tasks, you need a review process. That includes working with senior engineers and reliability engineers. You need maintainers to perform the job, to capture accurate task durations. You need maintainers at the skill level. You need an analyst to understand the different elements. You also need a technician to handle it and the leadership to oversee it. They’ll decide whether it’s a complete package worth supporting.
c) Is this for PMs, or is it corrective maintenance too?
Lucas – You may consider these as the same thing. If doing condition-based maintenance, then you’ll likely have something that’s post-condition-based. Based on the condition, you may have to take down equipment without scheduling it first. It then starts to look like unscheduled preventative planning. The same can happen for wholly corrective maintenance. But be careful about the resources you divide into forecasts. For these, OEMs become necessary. That’s because they have experience with determining the cascading effects of a failure.
4. Someone is struggling with spare parts. The storeroom has too many of the wrong parts. Where do they start with spares optimization? Which tools and formulas do they need? How do they begin to sort out their spare parts?
Rob – Are you using any formulas at the moment? You need to forecast demands that make sense. Find data at your site that helps you predict usage. Your warehousing, purchasing, and downtime costs also play a part in spares optimization. Also, what’s your warehouse situation? Are parts stored well, or by the time you install them, they’re already defective? The expensive, important parts found on critical equipment should be where you start. To forecast your parts, pick the things that add more value.
Lucas – When dealing with software, include your team when validating the results.
5. How do we know which tools to use to improve reliability, and in which order do we use them?
Fred – If possible, you should hire an expert to look at your system. An alternative is to get more familiar with the field. That’s by attending conferences and training classes or talking to your peers. But, these tools will only work when used well. Specialize in particular areas and include your team to get the best results. Knowing the different tools will help you to install them.
Shon – As you’re applying tools, stick with them to get the results you desire.
Closing thoughts
If you’re looking to install maintenance and reliability measures, how do you proceed? Also, if you’re struggling with its challenges, what do you do?
Shon – Have a plan and stick with it.
Brandon – Don’t forget that it’s about the people involved. Work to change behaviors so that you get the desired results. Look for those interested in these topics and engage them. Give them more exposure through mentoring and seminars to build their passion.
Fred – Stay curious and interested to continue to learn.
Rob – The maintenance and reliability field comes with a lot of frustrations. But remember that your health and happiness matter more than your facility’s reliability. Seek help when you need to.
Blair – When it comes to technology, IoT, and AI, you’re likely more ready for them than you realize. Link everything to failure modes. Know why you’re collecting data, and what you’re going to try to do with it. Start with the data you have, then complement it with more data if needed.
Lucas – There’s a fantastic community out there with lots of knowledge, talent, and support. Become multifaceted and seek to try and maximize value in everything you’re doing. Whenever you hear about great tools and ideas, always remember the fundamentals. Mastering these makes you better.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
Episode 200 Links:
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 200-Special 200th Episode of Rooted in Reliability Podcast appeared first on Accendo Reliability.
Oil Mist Lubrication with Heinz Bloch Lubrication is one of the most important aspects in asset management and having a sophisticated tool for this purpose makes a real difference to facilitate an organization's lubrication program. This is where oil mist lubrication helps to achieve your lubrication goals. Its mechanism is based on creating a slightly pressured area that prevents moisture and other contaminants to enter into the bearing itself which also preserves the integrity of any vulnerable components as well as your lubricant. That's how oil mist lubrication differs greatly from the traditional lubrication as it effectively keeps your lubricant pure from contaminants in the air outside.
The points addressed in this podcast highlight:
- Why is lubrication one of the most important aspects in asset management?
- What are the benefits of this method?
- What are the issues associated with lubrication?
Other benefits of this method include reduction in labor hours because you don't have to replace lubricant consistently and less failures due to intact bearing integrity which saves you a lot of time and money in the long run. It also results in better operating conditions for your machine and that greatly supports your reliability program throughout the facilities. The machinery uptime record for oil mist lubrication alone shows incredible results along with certain advantages that allow you to monitor condition of your machines and take preventive actions before a bearing or a pump failure occurs.
The only issue with this lubrication method is the cost associated with it usually because of the rewards you have to pay to the people working on this program. That cost can be adjusted if the organizations also implement this method for their electric motors that will save them countless labor hours over the period of time. It is a common practice in the organizations to bring in reliability engineers for their expertise when a program is well underway and something goes wrong or doesn't fit in the allocated resources for that specific program. When something like that occurs, a lot of time and resources are already wasted in the early stages.
A better practice would be to seek the advice and help of reliability engineers before the header systems are put in place and then organize the program properly within the budget limits. Letting the corporate politics in the way wouldn't help anyone and the program would become a messy and expensive endeavor after resources have been put into it without a detailed and well thought-out, strategic plan. There are a lot of resources out there to get you started with oil mist lubrication. Heinz Bloch himself has been associated with the program for a long time and has authored a couple of books on the topic.
He also has an upcoming book that would be more focused on strategic side of things for oil mist lubrication. He has great many resources to help you understand the basic as well advanced subject matter for the program. He along with his colleague, provides valuable coaching to help engineers get better at oil mist lubrication based on his extensive experience and proven record in the field. In the end, it all comes down to covering all the basics while designing and installing the system along with the expertise that an organization brings along with it.
Eruditio Links:
- Eruditio
- HP Reliability
- James Kovacevic's LinkedIn
- Reliability Report
*Heinz* Bloch:
- Heinz Block LinkedIn
- Heinz P. Bloch: Reliability Focussed Engineering
Download RSS iTunesStitcher Rooted In Reliability podcast is a proud member of Reliability.fm network. We encourage you to please rate and review this podcast on iTunes and Stitcher. It ensures the podcast stays relevant and is easy to find by like-minded professionals. It is only with your ratings and reviews that the Rooted In Reliability podcast can continue to grow. Thank you for providing the small but critical support for the Rooted In Reliability podcast!
The post 199-Oil Mist Lubrication with Heinz Bloch appeared first on Accendo Reliability.