Think About

Things to

and Do in 2012

Big thoughts and small

actions make a difference.

Heres what were working on and thinking about.

What about you?

Feel free to share this pass it along. Things To Think About (and do) this year.

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Featuring:

Malcolm Jones Henry Ellmann Jeff Shiver Joel Levitt

Doug Plucknette Tom Moriarty Cliff Williams Kim Hunt Brad Peterson

Jeff Smith Steve Thomas Terrence OHanlon Joe Swan George Williams Jim Hall

Winston Ledet John S. Mitchell Chris Colson Kate Kerrigan

Saul Cizek

ONE

One word and only one word holds the key to maintenance successreliability. John S. Mitchell

Improved reliability, locating and eliminating the cause of failures is the only way to move from a reactive to an effective, proactive organization safely meeting every mission requirement. Initiating and or improving planning and scheduling wont do it for you.

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Click on the App icons to read more!

A P P

App
In the world of computers, smart phones and information from everywhere, wouldnt it be great if you could download an app just for maintenance? Something that would help you run a maintenance department? Well, today you can, but its an APP for your mind, not your device.

Cliff Williams

Standards
When faced with problems, we often go into root cause analysis (RCA) mode trying to find the single cause of the problem. However, problems are often the result of multiple causes. In total productive maintenance (TPM), we identify chronic deterioration that eventually combines to cause sporadic failures. A different approach is to ask a simple question: Do we have a standard? If we dont have a standard, the appropriate response is to create one. Lets define a standard as a reliable method that produces the required output from given inputs.

Malcolm Jones

Hover your cursor over the images to see an Infrared view!

International manufacturer and supplier of leading edge, current state of the art, thermal imaging cameras for the predictive maintenance, security and OEM applications

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Connect with Soltec

http://necavioinfrared.com | (800) 423-2344

Responsibility
i
responsibility {ri-spon-suh-bil-i-tee}:

the quality or state of being responsible, taking ownership or accountability of a given act or goal. (Merriam-Webster)

Douglas Plucknette

Green

Looking forward into 2012, I see many reasons for optimism rather than pessimism. I believe the added concern over energy consumption is leading companies towards major sustainability efforts. These efforts have a direct relationship with maintenance reliability. The days of maintenance departments carrying the reputation of simply being a cost adder are quickly becoming obsolete. While companies are being pressured by the market (their investors and consumers), along with regulators to save energy, be more environmentally sensitive, and become green and sustainable, maintenance is being pulled into a much more positive light. Click to read more

Chris Colson

Advantage
The simple reality is that maintenance departments are cost centers. This means maintenance costs the company money and does not provide a value-added service to the end customer. In short, maintenance departments do not create salable product, yet your job exists solely to support salable product.

Direct Labor Material Cost Maintenance Cost

Therefore, maintenance must be managed as a competitive advantage. By changing organizational thinking to view maintenance as a competitive advantage, more innovative ideas are implemented. To affect this shift, maintenance is measured by the value produced. First run output becomes a direct measure of equipment capability, therefore reliability.

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Kate Kerrigan

Des-Case Corporations unique combination of products and expert services help companies around the world achieve a new level of performance in maintenance and reliability.

i
Des-Cases Lubrication TransformationSM Services provide the necessary tools and training to evaluate and develop a first-class lubrication program. Additionally, implementing lubrication best practices is made easier with Des-Cases wide variety of desiccant breathers, lubricant storage, and filtration systems.

Dedicated Filtration

Please call (615) 672-8800 or visit www.descase.com to learn more about how Des-Case can help you transform your lubrication program.

ACCOUNTABILITY
Being accountable requires individuals to look at situations in an unbiased way and execute based on the intent of the requirements.
Accountability can be defined as taking or being assigned responsibility for something you have done or are supposed to do. It cannot be demonstrated by deflecting or rationalizing the things that didnt go the way they should have. Being accountable requires individuals to look at situations in an unbiased way and execute based on the intent of the requirements. Accountability is the basis for process discipline. Process discipline is the basis for consistent performance. Consistent performance is the basis for continuous improvement. No matter your status or function in an organization, you must strive to be accountable.

Tom Moriarty, PE, CMRP

Upgrade
Reliability is a journey, not a destination.
Perhaps your maintenance reliability program could use an upgrade. One of the most common phrases I hear when I ask maintenance reliability professionals why they are doing a particular task, the reply is because that is the way we have always done it or things will never change around here. In fact, many organizations are upgrading to new maintenance reliability strategies, new maintenance reliability technologies and new maintenance reliability techniques to create world-class asset operations excellence. Just because you have not seen change at your organization does not mean the world is standing still. It is not. Terrence OHanlon

Predictive
i

Some basic tips on how your organization can get started using predictive maintenance (PdM) and what mistakes to avoid.

Joe Swan, PE, CMRP

Step One
Seek knowledge, learn and network with other reliability professionals. Discuss with them how they are using PdM in their workplace.
Mistakes to avoid:
Reinventing the wheel. Copycat predictive maintenance from an Uptime award-winning program is acceptable and encouraged!

Your productivity experts.

Education for MaintEnancE OPEratiOnS rEliabilty

See what our customers are saying:
i much enjoyed the instructors, delivery and attention during the sessions. ... a lot out of textbook stories, experiences and information.

People and Processes, Inc. is an education and consulting services firm dedicated to Maintenance and Operations enhancement by utilizing industry recognized best practices and processes in a holistic site approach.

robert Medina, craft Supervisor Orange county Sheriffs Department

Upcoming classroom programs:

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A Computerized Maintenance Management System (CMMS) Overview Measuring the Central Hub Planning and Scheduling Metrics

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Phone: 843-814-3795

Storytelling
Are you a storyteller?
The dictionary definition of storytelling is one who relates anecdotes. Are you a storyteller? Storytellers are all around you. You may know a storyteller. It may be someone in your immediate family, such as a parent, aunt, uncle, or a grandparent. Maybe its a co-worker or someone outside your organization whom you have listened to and learned from over the years and is familiar with your instruments, equipment and applications. Regardless of whom he or she is, a storyteller must be able to relate to yesteryears failures, incidents and applications to possibly prevent an incident or failure by relating to applications of today. I for one have made a living telling stories. That is to say, while instructing thousands in the use of ultrasound instruments, ultrasound theory and ultrasound applications as it relates to predictive and preventative maintenance, I relate to my audience by introducing past incidents, failures and applications during the training class.

Jim Hall

CULTURe

We are what we habitually do. Excellence then is a habit, not an act

Aristotle 384 BC 322 BC

Operations Excellence. Back to Basics. Safety, Reliability, SAP. What do these endeavors have in common? Trying to affect the behaviors of their people. Except most of the time, we dont understand that its all about behaviors. What people do every day. Rather, we think its about key performance indicators (KPIs) or improvements or initiatives or change. In the end, however, we want people to work differently. This is work behavior.
Brad Peterson

HigH iMPacT learning THaT ProDuces resulTs

The life Cycle institute is the learning source for Reliability ExcellenceTM. The institute was created by life Cycle Engineering (lCE) to be a lifelong learning resource for people engaged in optimizing asset reliability and performance. Your investment in training with the life Cycle institute is unique because we offer: Facilitators who practice what they teach and teach what they practice Cutting-edge course content, updated with the latest tools and methods Adult learning methods that minimize lecture and emphasize learning by doing Classrooms that facilitate learning Download our Free learning resource: introduction to High impact learning

Training arTicles:

How to Ensure Training Changes Behavior To Kit, or Not to Kit: That is the Question
> MORE ARTiClEs

What Root Cause Analysis Tool is Best for Operators?

Free resources:

FAQ series Planning and scheduling

> MORE REsOuRCEs

Budgeting for Maintenance: A Behavior-based Approach

Asset Maintenance Program self-Assessment Tool

Maintenance Planning & scheduling Materials Management Planning for shutdowns, Turnarounds & Outages Predictive Maintenance Technologies Reliability and Operations Excellence Reliability Engineering Excellence Reliability Excellence Application Reliability Excellence for Managers Risk-Based Asset Management Root Cause Analysis

our reliaBiliTY courses incluDe:

CONNECT WiTH us:

www.lce.com | 800-556-9589

Change

Steve Thomas

Start of the change process - develop the assessment questions and administer the survey

Determination
The process of transformation from reactive to proactive maintenance reliability is a long and arduous journey. First, you need to have a plan, then you must have the rigor to stick to it. Seven years ago, our plant initiated a project to implement a reliability-driven maintenance program. Today, we continue to drive improvement through the relentless application of best practice. Success is built around the culmination of people and processes and a mindset that does not accept good enough.

What Ive learned along the way

Focus on the low hanging fruit - measure improvements and ROI.

8 9 10 11 12 13 14 15

Kim Hunt, CMRP, CLS

COMMITMeNT The Will to Make a Change

In our experience with many companies and sites within companies, we find that people have good intentions but fail to get results from their reliability initiatives. Nobel Prize-winning economist Friederich von Hayek argued many years ago that human institutions evolve as a result of human action, not human intention. This reminded me of a quote from The Scottish Himalayan Expedition that Peter Senge said in a presentation on organizational change.

Excellence

Until one is committed there is hesitancy, the

Efficiency

chance to draw back, always ineffectiveness. Concerning all acts of initiative (and creation) there is one elementary truth, the ignorance of which kills countless ideas and splendid plans; that the moment one definitely commits oneself, then providence moves too. All sorts of things occur to help one that would otherwise never have occurred. A whole stream of events issues from the decision, raising in ones favor all manner of unforeseen incidents and meetings and material assistance, which no man could have dreamt would have come his way. I have a deep respect for one of Goethes couplets: whatever you can do, or dream you can - begin it. Boldness has genius, power and magic in it.

Essentials

Winston Ledet

GPAllied is the most diverse reliability and operations consulting and services company in the world. We develop significant value propositions for our clients by delivering solutions across different industries, geographies, and most importantlyacross different aspects of an operation.

1
2 4

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How Do You Measure up?

Follow us

inspired Training

View the GPAllied Events for the whole year.

GPAllied, llC | 4200 Faber Place Drive | Charleston, sC 29405 O. 888.335.8276 | F. 843.414.5779 | www.gpallied.com | training@gpallied.com

Instructional

Definition: The act, practice, or profession of instructing.

A world-class maintenance program includes an ultrasound program. Through my years of instructing thousands in the use of ultrasound for predictive and preventative maintenance, it became obvious that many companies had purchased equipment not from a need, but to have the latest and greatest instrument available. Particularly, as it applies to ultrasound instruments. Companies discover that the ultrasonic instrument is more than just a leak detector or a steam trap diagnostic instrument. They then struggle to learn the other applications, applications that may not be covered in the owners manual.

Jim Hall

Objectives
As we prepare for 2012, remember one golden rule of process improvement: Never have end result metrics as part of your teams objectives. What needs to be in their objectives is this: Follow documented processes with zero unapproved deviations. This will allow you to look at where your processes can be improved as well as guarantee the accuracy of the end result metrics based on the current process. All changes to the process will show their impact to the resultant metrics and provide clarity into how those changes affected your business.
Request Screening Approval

200

160 140 120 100 80 No Noticable Change in Backlog 2007 2008 2009

Planning

Approval

Scheduling

Materials

Assignment

Excecution

Closeout

2010

George Williams

Backlog in Crew Weeks

Total Technicians

180

10 9 8 32% 7 6 5 4 3 2 1 0

Safer

Equipment reliability = Safer workplace

Part of the mission of every maintenance department is to provide reliable equipment in a safe environment. But who knew these issues were so intertwined and one always leads to the other. Lets look at some of the causes of accidents.

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Joel Levitt

learn@MobiusInstitute.com | www.MobiusInstitute.com

Welcome Message

Mobius Institute offers unique and easily understandable vibration analysis training and certification that follows ISO standards to Predictive Maintenance technicians and Reliability Engineers, allowing companies to operate at higher levels of availability and profitability.

Headquarters: 280 Myers Road, Merricks North, Victoria, 3926, AUS Tel: (+61)3-5989-7285 Mobius Live Training Video

North America: Post Office Box 2982, Brentwood, TN 37024 USA Tel: (+1)615-216-4811

Cheerlead
Geese seen flying in a V formation arent being led by one team lead the entire time they fly. One of the team takes the lead and breaks the wind resistance so the others can fly easier. Seemingly, the remainder of the geese in the formation honk to cheer the lead goose to push on. When the leading goose tires, it drifts backward in the formation. Another goose takes up the lead position while the others motivate, again shouting encouragement by honking. Even flying in formation has a purpose as it makes it easier to keep up with each bird for coordination and communication purposes.

Back

Read more

Jeff Shiver

Grow

Attend a conference at the Reliability Performance Institute in SW Florida to learn what other maintenance reliability professionals have done to improve reliability, change cultures, and overcome obstacles.

Find out more at www.maintenanceconference.com

PM

PReCISION
CBM

Umbrella of Precision Maintenance

PdM

How many people, when they think of maintenance, think of it as something someone else does? The reason I ask this question is to explore the nature of failures in a complex modern society. We live in an amazing time where automobiles run tens of thousands of miles on their first set of sparkplugs. Less than a century ago motorcycles required multiples daily manual oiling of the rocker arms to keep running.

Saul Cizek

PROFITS
When we address RELIABILITY, of course.. we think of safety first, we think of the environment, we think of uptime, we think of correct resource utilization,

Henry Ellmann

Depending on the specific figures of each company (which can and must be known!), the correlation can be established when the maintenance budget is decided.

% Increase in Maintenance Investment

More Uptime

Higher Capacity

Higher Sales Volume

5
5% 10% 15% 20%

Pro t Growth

As compared with the base year, all other conditions being equal

PLUS improved Safety and Environment, Higher Quality better Resource Utilization,
more satisfaction for all.
40%

we think of product quality and quality of service,

Prot improvement as % over base year

30%

5% incr. in Maint. 10% incr. in Maint. 15% incr. in Maint. 20% incr. in Maint.

we think of customer satisfaction. In fact, we think of satisfaction to all stakeholders. But with all the above, we must keep in mind the bottom line!

20%

10%

0% 1 -10% 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Increase of Sales Volume as % of base year

-20%

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COMPeTe
The Latin word for compete is competere, meaning come together. The root words of competere are com = with/together and petere = search/seek/aim/desire. In later Latin, the term developed the sense strive together, which is the basis for the English term compete, meaning to coincide, to come together, agree, be suitable. When one thinks of compete, what comes to mind? Is it the dictionary version or rivalry, winning, on par, near the top of the game, or striving for the championship? If we were to take to the streets like Jay Leno does in his

The Latin word for compete is competere, meaning come together.

Are maintenance reliability professionals and organizations competing?

shows Jaywalking sketch and ask the public, What is the definition of compete, what would our culture tell us? If we were to perform the same exercise within our maintenance organizations, plants and mines, what would their response be? Maintenance reliability organizations that understand, adopt and work together both internally and externally to aim, agree, strive together, be suitable, or come together will succeed in a competitive global economy. The symbolism of unity in the Latin definition provides a clear understanding of how we should truly compete.

Joe Swan, PE, CMRP

Sustainable

Jeff Smith

The equipment failure loop is as follows: 1. Function failures are utilized as failure codes; 2. Failure modes are used as defect codes; 3. The data is feedback to living Weibull plots, enabling clear understanding of the success or failure of mitigating strategies; 4. Data enables measurement of the value of the deferred spend (component life extension); 5. Clearly understanding the success/value of mitigating strategy to failure mode with a clear understanding of the deferred spend derives optimized return on net asset (RONA). This enables sustainable continuous improvement for one unit of effort.

4
Jeff Smith

Read

Welcome to the MRO-Zone Bookstore!

We understand effective maintenance reliability professionals require continuous training and updated materials to acquire new knowledge and skill sets in a competitive marketplace. We offer a body of knowledge encompassing the latest in publications, multi-media and full-length distance learning courses, allowing our customers to prosper in todays world of increased performance requirements. Our top priority is to provide the highest level of customer service to the professionals we serve, by providing one-stop shopping for valuable resources at a reasonable price. Start shopping here

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Credits
All author contributions generously given by their creators. Conceived by Terrence OHanlon, CMRP, Publisher, Reliabilityweb.com. Designed by Justine Lavoie, Nicola Behr and Sara Soto. Produced by Reliabilityweb.com and Uptime Magazine.

Make something happen. We need your help.

(Post this, e-mail it, tweet itshare it anyway you can.) Spread it freely. Add your own idea. But please dont sell this content or change any of the entries.

Do work that matters.

Join many of the contributors at an upcoming conference. Visit www.maintenanceconference.com for details.
2012 Reliabilityweb.com. This document may be freely distributed by e-mail (no spamming, please) or posted on the web with NO registration required. Must be presented in its entirety. For those interested in contributing to 2012s e-Book publication and for special permissions, please send your request to tohanlon@reliabilityweb.com.

Think About

Things to

and Do in 2012