15 Most Common Obstacles to World-Class Reliability - A by Don Nyman

By Don Nyman

Reliability depends on shared realizing and ideology. Managers in any respect degrees needs to know how their judgements and instructions frequently influence adversely the facility in their association to accomplish and perpetuate Reliability…thereby undermining cognizance of huge company ambitions. This booklet identifies and explores fifteen cultural hindrances in most cases encountered through such a lot companies of their pursuit of world-class reliability. The motive is to supply senior administration with a warning call. they have to tackle the pointed out stumbling blocks the folks they've got charged with pursuit of reliability (middle managers, engineers and useful experts) could be profitable. another way, senior administration is its' personal worst enemy. it's a must-read for senior managers in any respect degrees (corporate to plant and inside of plant at departmental levels).

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Yet, those same organizations wonder why they live in a constant state of reaction to urgent demands (real or exaggerated). The answer begins with the fact that they have essentially organized for reactive response by decentralizing a disproportional amount of labor resources to 29 30 Chapter 2 fixed-designated assignments within narrow areas of the facility. As a result, technicians spend a significant portion of their day in standby mode, waiting for the next failure to occur. Consequently, few resources remain for performance of important scheduled work aimed at elimination of failures that inhibit asset reliability.

The total calculation provides the average situation, which might indicate sufficient resources. However, individual calculations may indicate poor distribution of the resources relative to where specific work- 52 Chapter 4 loads lie. The reason the average backlog looks okay may be due to one group being out of control on the high side of control limits, while another group is out of control on the low side. The real situation may be a chronic shortage of specific skill-sets and skill-levels required to address specific workloads essential to asset reliability (see next chapter on skills training).

Clarify the current status regarding reasons for delay. Capture any work that needs to be performed, but has not been committed to a work order (see Step 17). 17. Aggressively Inspect the Facility and Equipment. Identify all additional work required to bring equipment and the facility to maintainability. 18. Bootstrap All Assets Back to Reliability. This step involves working off any deferred backlog to bring it into control limits (4–8 weeks, see Appendix J — Work Program) and bring equipment to a state of maintainability.

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