Reliability Approach for Maintenance Manager

I was honoured to be a guest speaker at the Maintenance and Reliability 4.0 event in Bangkok a month ago. During my presentation, I had the privilege of sharing my perspective on the concept of the Reliability Approach for Maintenance Managers. I am delighted to take this chance to revisit and share those insights with you once more, hoping that they resonate with you as well.

1, The Reliability Approach encompasses Engineering Design, Operating Processes, and Maintenance Strategies.

In a usual scenario, the majority of maintenance managers tend to concentrate solely on machine maintenance. Their routine often involves traversing the factory, assessing machine statuses, and occasionally getting directly involved in repair tasks. They often take pride in their ability to repair numerous machines and the swiftness with which they can accomplish these tasks.

Within the framework of the Reliability approach, maintenance plays a significant role, but it is not the sole factor contributing to overall reliability. Ramesh Gulati underscores that attaining reliability in production requires the integration of effective design, correct operational practices, and a well-suited maintenance strategy. Consequently, as a maintenance manager, it becomes imperative to expand your perspective beyond the realm of routine maintenance activities. Engaging proactively in offering insights on machine design and evaluating standard operating procedures holds equal importance.

Going beyond conventional perceptions, the role of a maintenance manager extends to ensuring comprehensive training for the operators regarding the equipment they handle. Operators, being in close proximity to the assets, hold a pivotal role in both asset management and potential machine failures. It is of utmost importance to guarantee that operators receive thorough training concerning the assets they are entrusted to operate. While discussions on Total Productive Maintenance (TPM) often emphasize autonomous maintenance, it is essential to recognize that training and education constitute foundational pillars that hold even greater significance.

2, The Reliability Approach focuses on Machine Availability, Performance Capability, and Quality Stability.

Frequently, during my interactions with maintenance managers, I inquire about the ongoing situation, and the response invariably leans towards positivity, highlighting the absence of breakdowns in the previous week. While this is undoubtedly a positive aspect, it leaves me somewhat perplexed. While the absence of breakdowns is commendable, it falls short of being the ultimate benchmark for success.

Reliability entails emphasizing OEE (Overall Equipment Effectiveness), not solely fixating on breakdown occurrences. Maintenance managers should prioritize the comprehensive performance of OEE, which encompasses factors such as machine availability, operational efficiency, product quality, and safety. It's worth noting that a single 12-hour breakdown during a challenging week might impact only a modest 7% of the overall OEE. While such breakdowns tend to command significant attention for subsequent weeks, it's possible that your production line has been experiencing a consistent 30% reduction in speed over the past five years, which is equally significant but often overlooked.

I would go so far as to advise maintenance managers to take a proactive approach by identifying and addressing production line bottlenecks, thereby enhancing line capacity. When a company starts to see improved profits, it becomes more inclined to reinvest in the production line, which could involve upgrades, overhauls, automation, and other enhancements. This initial step sets in motion a positive cycle of continuous improvement.

3, The Reliability Approach involves recognising that each component has its own Failure Mode.

What action typically arises from a root cause analysis (RCA)? For how long has this component been in use? We must schedule periodic replacements for this component. We should consider more frequent replacements for this component. The focus consistently revolves around time-based replacement. Interestingly, statistics reveal that only 11% of component failures are actually linked to age, yet we often treat all component failures as age-related.

In reality, 68% of component failures are due to infant mortality, where the highest risk of damage occurs right after installation. If we opt for blind time-based replacements without comprehending the failure modes of our components, it could lead to increased downtime. Hence, it's paramount to prioritise working smart over working tirelessly in this scenario.

When the concept of reliability was introduced in the airline industry, the overhaul program for the McDonnell Douglas DC-10 led to a significant reduction in the number of mandatory replacement components, from 339 down to just 7. The remaining replacements were determined based on the component's condition. As a result, the aircraft's performance improved and became more reliable, owing to the reduction of unnecessary interventions.

4, The Reliability Approach involves the systematic assessment of Risks.

When inquiring about the main concerns of a maintenance manager, the responses typically revolve around the latest breakdowns, recurring issues, and immediate challenges. However, the reliability approach introduces a more methodical approach to gauging risks, involving an assessment of factors like the severity of failures, the frequency of occurrences, and the detectability of failures.

The benefit of utilizing this approach is that it provides a more accurate representation of the actual risk, allowing the team to allocate their attention to assets based on their priority. Additionally, it offers guidance on identifying the specific areas where risks or opportunities lie. Drawing from past experiences, the aspect of detectability is often underestimated, and there are numerous easily addressable aspects such as vibration analysis, temperature monitoring, or even transparent covers that can significantly contribute.

Risk management is a crucial competency for maintenance managers, yet it is often overlooked in their training. I strongly advocate for maintenance managers to actively participate in specialized training in this area. Gaining a comprehensive understanding of risks and implementing effective control measures constitutes a genuine proactive and preventive strategy. This stands in stark contrast to the common practice of adhering blindly to pre-established preventive maintenance plans that accumulate over time, often without a clear rationale.

5, The Reliability Approach adheres to the principle of "Less is More."

Many times, when a fresh maintenance manager becomes part of a team to assess the maintenance plan, they might introduce extra tasks drawn from their expertise. Yet, how frequently do we witness them actually removing maintenance tasks during the evaluation? The occurrence is rare. There exists a reluctance, stemming from the apprehension of being blamed should problems emerge after certain maintenance tasks have been eliminated. For most of us, the approach to maintenance tends to be an ongoing accumulation, marked by a constant addition of tasks driven by the notion that more tasks equate to better outcomes. This perspective is rooted in the fear of neglecting any possible maintenance need.

In practice, the number of available technicians remains constant. However, the continuous addition of maintenance tasks inevitably results in being understaffed, ultimately leading to the omission of certain tasks. With the team stretched thin, the likelihood of crucial maintenance being overlooked increases, which can subsequently result in unforeseen downtime and repair work, perpetuating a detrimental cycle. The reliability approach emphasises concentrating on essential maintenance tasks, derived from a comprehension of component failure modes analysis and the implementation of rational maintenance strategies to manage risks effectively. This approach advocates for transparency, ensuring that everyone, including technicians, comprehends the rationale behind each maintenance task.

Preventive maintenance is often portrayed positively, yet it involves intervening in a stable system, which could potentially introduce disruptions. Therefore, effective management of preventive maintenance is crucial. A large volume of maintenance tasks can become overly intricate to handle, underscoring the importance of maintaining their effectiveness. From a reliability standpoint, minimizing interventions is preferable; it's better to refrain from maintenance than to engage in ineffective or unnecessary interventions.

6, The essence of the Reliability Approach lies in embracing Effectiveness.

After spending numerous years in the maintenance industry, I've come to realize that many of us perceive maintenance as an immense mountain – unchangeable, constantly accumulating, and seemingly uncontrollable. This colossal task often captures our focus, driving us to explore it tirelessly, yet its true management feels elusive. Gradually, with the passage of time and experience, narrow pathways emerge amid the expanse, and the collective follows these established tracks, eventually considering them the norm. This phenomenon has naturally evolved into a challenge that confronts anyone engaged in modern industrial practices, a complex predicament that serves as an inevitable yet essential aspect of the field.

The Reliability approach presents a valuable avenue for disrupting this cycle, urging maintenance managers to engage in a systematic evaluation of their maintenance strategy. This method encourages the optimization of maintenance tasks, ensuring they remain effective and aligned with the operational needs. It advocates for the removal of redundant and ineffective maintenance practices, thereby enabling the team to channel their efforts towards performing their tasks with precision and accuracy.

By embracing the Reliability approach, organizations can proactively address the challenge of maintenance overload. It empowers maintenance managers to fine-tune their strategies, shedding unnecessary tasks that might be contributing to inefficiencies. This, in turn, allows the team to concentrate on executing their responsibilities with greater efficacy, fostering a work environment where the right tasks are performed at the right time. Consequently, the Reliability approach acts as a catalyst for enhanced operational performance, breaking free from the burdensome cycle and steering the maintenance practices towards a more streamlined and effective path.