Things to Think About and Do in 2011: Needs

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Needs

Maslow’s Silver Hammer? When you’re used to using a hammer, every problem looks like a nail.

Asset owners are too often told that new technology, upgrades or training will address failures and improve reliability. A decision process follows, then procurement, implementation, and much later, measurable success.

Machinery continues to fail for various reasons. Often the most basic conditions, actions or omissions cause or accelerate these underlying failures. We live with the underlying failure-friendly conditions for many reasons, including:

• They’ve been around so long we develop a natural tolerance and don’t see them anymore.
• People believe they’re taken care of by operating procedures. The maintenance management systems, craft procedures or technicians’ skills.
•  Time is spent on other concerns which have higher profiles.
• Fortunately, fixes are typically simple and rarely require a large budget. They can be implemented by technicians and supervisors. For example, I’ve seen failure rates drop significantly after:
• Producing (and following) checklists for key activities. AN example would be a systematic approach when returning major machines to service after overhaul.
• Identifying daily ‘quick codes’ on machine operation envelopes. For instance, gas turbines should be checked regularly to be sure they are not over-firing.
• Applying disciplined duty and standby operation procedures.
•  Updating condition monitoring and verification procedures.
• Identifying and removing conditions that cause or accelerate failures works. In 2011, when it comes to failure friendly conditions, stop doing what comes naturally and do what works.

—Frank Sutcliffe