January 12, 2006
Root Cause Analysis (RCA) Tips
When conducting real Root Cause Analyses, uncovering the truth, or the Latent Roots, can be a very sensitive subject. Imagine if you conclude in your RCA that your boss’s boss wrote a flawed start-up procedure that an operator followed and resulted in an explosion. How are we going to communicate this to our management in an effort to correct the problem and prevent it from recurring?
Oftentimes. Managements may be the ones who sign the checks to support RCA efforts, but they were never made aware of the methodology that would ensue. Therefore they would not be educated on the concepts of Human Root Causes and Latent Root Causes.
In our above scenario, trying to express the FACTS of our RCA to a group of managers that are not educated in the RCA process can be “career-limiting”. Therefore, we must strategize on how to get what we want without alienating the wrong people. In these cases, we would educate such bosses weeks before our final RCA presentation so that they would know what the terms were and how they were being used. Then we would express our conclusions in an unbiased fashion without giving or insinuating any names of people or groups. For instance, in our case above, the Latent Root might be labeled as “Inadequate Start Up Procedure”. It does not matter who wrote it, what matters is that it is corrected and that the system that allowed it to exist is corrected.
Tip provided by the Reliability Center Inc.
http://www.reliability.com
Tel: 804-458-0645
January 12, 2006
Free Integrated Solutions Seminars
Free — yet rich in ideas and solutions. That’s what maintenance people are saying about the unique one-day PMS2 seminar coming near you. You’ll learn how to best apply early warning technologies — infrared, ultrasound and motor electrical analysis — to your predictive/preventive maintenance programs. Three technology leaders have combined forces in an industry first — a unified team approach to integrating predictive monitoring and analysis technologies. Mikron Infrared, UE Systems, and ALL-TEST Pro are bringing the free PMS2 Seminars — a double dip of Proactive Maintenance Solutions and Process Monitoring Solutions — to various locations in North and South America.
The seminars offer proven solutions … technology presentations, demonstrations, and hands-on opportunities … how-to explanations on application methods … plus free lunch and free prize drawing.
January 12, 2006
Alignment Tip
SAFETY PRIOR TO ALIGNMENT
The number one item that should be taken care of prior to aligning machinery is to ensure that the machines are locked out and tagged accordingly. Isolate machinery from all forms of mechanical and electrical energy. If equipment is accidentally started up while an alignment is being performed, serious injuries can occur. Be sure to close check valves so back pressure from another pump can’t make yours start spinning backwards; tie down fan blades so sudden gusts of wind won’t cause your shafts to turn or expose you to danger from the blades, etc.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
January 12, 2006
Reliability Tip
The Six Criteria for Evaluating Best Practices in Reliability
Everyone seems to be looking for “Best Practices” today - and they are very illusive, almost seeming like a myth or fable. Are there really defined “Best Practices in Reliability”? Yes, there are defined practices in reliability which have been successfully used by many companies.
Best Practices are the standardized activities that:
• enable an organization to maximize efficiency and effectiveness
• are typically employed by the leaders in an industry (lowest cost/highest quality providers)
To define best practices for a given function usually requires that we combine capabilities from multiple companies, as no one company performs best at all things. Since best practices relate to the performance of a function or activity, best practices in reliability must be defined in terms of the elements a proactive business process for reliability. Each element of the process should be evaluated in terms of the following 6 criteria:
1. Current Practices (observable duties, tasks or behavior)
2. Roles and Responsibilities (job descriptions are defined, understood and accepted)
3. Information (information is available, communicated and acted on)
4. Resources (people, tools, materials and facilities)
5. Training (training needs are evaluated and core skills are maintained)
6. Performance Assurance (the quality of work within each element is monitored)
For example, some of best practices for the Work Planning Element of a Reliability Process are:
1. Practices
• All work orders are accurately detailed to the right level
• Work plans include collection of condition data
2. Roles & Responsibilities
• Roles and responsibilities are well defined for Planners
3. Resources
• We have a sufficient number of planners
4. Training
• We have a training program for planners
5. Information
• Planners have access to the required information for their role
6. Assurance
• We measure the effectiveness of our planning function
Tip provided by Ricky Smith, CMRP
Ivara
http://www.ivara.com
January 06, 2006
Reliability and Asset Management Conference in Las Vegas
RCM-2006 & EAM-2006
Orleans Hotel
March 8-10
Las Vegas
Please join us for the Reliability Centered Maintenance Managers’ Forum Co-located with the Enterprise Asset Management Summit in Las Vegas.
• Learn everything you need to build a world class Reliability Centered Maintenance Program and what you need to select, implement and operate a Maintenance Information Management System or Enterprise Asset Management System
• Discover exciting new ideas and learn helpful techniques to jumpstart your Reliability Centered Maintenance program and the productivity of your CMMS/EAM
• Learn how Maintenance & Reliability Professionals just like you are creating results with RCM/CMMS/EAM
• Learn how to track the results of your RCM program
• Meet leading RCM, CMMS and EAM Solution Providers - we have previewed a few of these exhibitors below.
To get a $200 early bird discount and $60 per night 4-star hotel rooms register before January 31.
Call toll free (888) 575-1245 or…
Learn more about RCM-2006 & EAM-2006
AssetPoint Enterprise Asset Management Software
AssetPoint provides Enterprise Asset Management Software that is Quick, Easy and Effective. We have been helping companies manage facility and plant assets for over 25 years. The latest release of TabWare EFx is Microsoft Certified and conforms to Windows XP standards. We utilize proven project alignment and implementation processes that work and we maintain a 100% implementation success rate. We provide superior customer service that results in high retention rates and we deliver high quality and flexible on-site, hosted or Internet-based solutions.
Please visit AssetPoint in EAM/RCM-2006 Expo booth 11
Learn more about about AssetPoint
January 05, 2006
Root Cause Analysis (RCA) Tip
IS RCA INDUSTRY SPECIFIC?
Many people believe that their choice of RCA methods will vary depending on the industry they are in. These people do not realize that true RCA has nothing to do with the environment, but its common denominator is the human being. The nature of the event is irrelevant. What is important is the logical, deductive discipline of the human thought process. The same thought process will be used whether a person is investigating an explosion of a crude unit in a refinery or an unexpected death in a hospital.
Tip provided by the Reliability Center Inc.
http://www.reliability.com
Tel: 804-458-0645
January 05, 2006
Lubrication and Hydraulic Tip
Starting an oil analysis program?
Even before you analyze your oil you can start to improve your situation. I once experienced a hydraulic system that was cleaned out and two months later the reservoir was half full of contamination. A vendor was only too happy to try and sell us a filtration system to resolve the problem, but we needed to do much better before we tried additional filtration. The root cause of the problem was a lack of training and a domino effect. The system had leaks with an open breather in an area of high contamination. Because of the leaks the covers were left loose and sometimes open to add fluid and additions were made from a hand pump from an open barrel and open pails, barrels and pails left in the same contaminated area. The contamination caused hydraulic problems that interrupted the manufacturing process resulting in blow backs of raw material (wood chips and saw dust) contaminating the area. After a blow back the area was cleaned up with compressed air dislodging covers and adding more contamination.
Reminds me of a commercial, “Midas shows you how not to install a muffler.”
Basic tips:
• Store fluids in sealed containers away from moisture
• Container vents should be filtered
• Clean the area before you open a system
• Keep the equipment clean - Refrain from using compressed air which can induce contamination and damage seals
• Seal all of the system leaks so less fluid needs to be added
• Install raised surfaces where covers fasten
• Install all covers - With gaskets
• Seal all points of ingression - Except for the breather
• Install a desiccant type breather - Especially in temperature / humidity differential applications
• Add filtered fluid only to maintain the proper level
• Fluid should be added below the tank level so air is not entrained
For other ideas on how to start a program contact:
Clifford Spear
January 05, 2006
Alignment Tip
TIGHTEN THOSE BRACKETS!
When using a laser shaft alignment system, always double-check that all brackets and components mounted on the shafts are sufficiently tightened to prevent vibration or just plain gravity from unduly moving them as you rotate the shafts. Also, ensure they are clear of hitting any external obstructions as the shafts are rotated. Also make certain the support posts inserted in the brackets are not only adequately tightened but are burr free. Otherwise, you may be clamping down on a burr rather than the support post itself, and still have mechanical looseness. Any of these factors can affect the measurement accuracy. Performing repeatability checks between alignment readings and corrections is essential in revealing any of these potential pitfalls.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
January 05, 2006
Effective CMMS/EAM For Asset Management at your plant
Please join Reliabilityweb.com and Maintenance-Tips for EAM-2006 the Enterprise Asset Management Summit, March 8-10, 2006 in exciting Las Vegas Nevada.
This year, EAM-2006 is co-located with RCM-2006 - The Reliability Centered Maintenance Managers’ Forum providing twice the value and learning opportunities.
EAM-2006 is the only event dedicated to Enterprise Asset Management and Computerized Maintenance Information Management including Maintenance Inventory, Maintenance Planning & Scheduling and Maintenance Work Management.
You will take away new solutions for maintenance information management that you can put to immediate use as peers and industry experts share knowledge and experience in a non-commercial environment.
January 05, 2006
Happy New Year from Maintenance-Tips
We want to take this opportunity to thank all the Maintenance-Tips subscribers who support our work.
We have more new tips ready to make 2006 the best year ever!
You can continue to support Maintenance Tips and ensure priority delivery:
1) Please click the CONFIRM link at the bottom of this email. This will speed delivery to your inbox in the future.
2) Once you click the CONFIRM link you will also get an email with links to three free downloads:
* The RCM Scorecard
* CMMS Best Practices
* Best Practices Maintenance Benchmark Report
Please click the CONFIRM link now. It is that simple.
3) Once you confirm - you can also include your mailing address so we can send you sample issues for Uptime Magazine and Reliability Magazine.
Remember - we are running the Maintenance-Tip Challenge through January 12 - with 4 EAM-2006 and RCM-2006 Conference Pass winners! Details are available at the link below.
