Reliability Academy

PM programs are often bloated and ineffective. But optimising them doesn't need to be complicated or expensive. After 20+ years working in maintenance, here is the straightforward 6-step approach I've seen work time and time again— 1️⃣𝐈𝐧-𝐝𝐞𝐩𝐭𝐡 𝐚𝐧𝐚𝐥𝐲𝐬𝐢𝐬 𝐨𝐟 𝐲𝐨𝐮𝐫 𝐜𝐮𝐫𝐫𝐞𝐧𝐭 𝐏𝐌𝐬— Identify your bad actors through your data. And then see where time and costs are being wasted. 2️⃣𝐏𝐫𝐢𝐨𝐫𝐢𝐭𝐢𝐬𝐞 𝐟𝐨𝐜𝐮𝐬 𝐚𝐫𝐞𝐚𝐬 — Pick some quick wins first to build momentum. Then tackle the more complex issues. 3️⃣𝐃𝐞𝐜𝐢𝐝𝐞 𝐨𝐧 𝐦𝐞𝐭𝐡𝐨𝐝𝐨𝐥𝐨𝐠𝐲 — Start simple. Formal RCM or other methodologies come later once the value is proven. But never skimp on the core principles of maintenance engineering (how to treat hidden functions, non-age-related failures, etc.). 4️⃣𝐂𝐨𝐧𝐝𝐮𝐜𝐭 𝐚 𝐩𝐢𝐥𝐨𝐭— Test changes on a small scale. Then quantify your results before expanding. 5️⃣𝐈𝐧𝐢𝐭𝐢𝐚𝐭𝐞 𝐚𝐧𝐝 𝐝𝐞𝐥𝐢𝐯𝐞𝐫 𝐏𝐌 𝐩𝐫𝐨𝐣𝐞𝐜𝐭— Educate your team. Take a phased approach. And celebrate your small wins. 6️⃣𝐁𝐮𝐢𝐥𝐝 𝐜𝐨𝐧𝐭𝐢𝐧𝐮𝐨𝐮𝐬 𝐢𝐦𝐩𝐫𝐨𝐯𝐞𝐦𝐞𝐧𝐭 𝐥𝐨𝐨𝐩𝐬— Monitor data, get feedback, and keep optimising. PM reviews must be ongoing. With discipline, these 6 steps will transform your program. Unnecessary costs will be eliminated while your reliability improves. I discuss each step in greater detail inside our blog—“6 Steps to Dramatically Improve your Preventive Maintenance Program”. Link in the first comment. #maintenance #reliability #ReliabilityAcademy

🎓 Master Maintenance Planning & Scheduling in 10 Weeks or Less! 🎓 PS100: Implementing Maintenance Planning & Scheduling Online Training Course! Learn our 6-step maintenance planning & scheduling process to get your team out of the reactive maintenance cycle, increase productivity, demonstrate your value as a true maintenance professional, and finally secure that promotion. Through the course, you will… ✅ 𝐆𝐞𝐭 𝐦𝐨𝐫𝐞 𝐰𝐨𝐫𝐤 𝐝𝐨𝐧𝐞 𝐢𝐧 𝐥𝐞𝐬𝐬 𝐭𝐢𝐦𝐞. Eliminate backlog, stress, and overtime in your working environment by addressing key issues in your existing Maintenance Planning and Scheduling process. ✅ 𝐈𝐧𝐜𝐫𝐞𝐚𝐬𝐞 𝐲𝐨𝐮𝐫 𝐭𝐞𝐚𝐦’𝐬 𝐩𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐯𝐢𝐭𝐲 𝐛𝐲 𝟑𝟓% 𝐖𝐈𝐓𝐇𝐎𝐔𝐓 𝐡𝐢𝐫𝐢𝐧𝐠 𝐧𝐞𝐰 𝐩𝐞𝐨𝐩𝐥𝐞. Learn how to implement simple but effective practices to eliminate a lot of the fire-fighting that is so typical of many maintenance environments. ✅ 𝐋𝐞𝐯𝐞𝐥 𝐮𝐩 𝐲𝐨𝐮𝐫 𝐜𝐚𝐫𝐞𝐞𝐫. Gain a deeper understanding of how Planning & Scheduling works in an industrial organisation so you become more impactful and valuable as a professional… and increase your chances of getting a promotion or pay raise (like some of our students have done). Within 10 weeks or less, you’ll learn the Maintenance Planning & Scheduling process that took me 20 years to master and develop. 👉 𝐌𝐚𝐬𝐭𝐞𝐫 𝐭𝐡𝐞 𝐟𝐮𝐧𝐝𝐚𝐦𝐞𝐧𝐭𝐚𝐥𝐬 𝐨𝐟 𝐌𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞 𝐏𝐥𝐚𝐧𝐧𝐢𝐧𝐠 & 𝐒𝐜𝐡𝐞𝐝𝐮𝐥𝐢𝐧𝐠 which are necessary for you to stay competitive and up to date in the maintenance industry 👉 𝐃𝐢𝐬𝐜𝐨𝐯𝐞𝐫 𝐭𝐡𝐞 𝐩𝐫𝐨𝐯𝐞𝐧 𝐈𝐦𝐩𝐥𝐞𝐦𝐞𝐧𝐭𝐚𝐭𝐢𝐨𝐧 𝐅𝐫𝐚𝐦𝐞𝐰𝐨𝐫𝐤 that will help you successfully execute Maintenance Planning & Scheduling in your organisation. 👉 𝐋𝐞𝐚𝐫𝐧 𝐏𝐫𝐨𝐣𝐞𝐜𝐭 𝐌𝐚𝐧𝐚𝐠𝐞𝐦𝐞𝐧𝐭 𝐚𝐧𝐝 𝐂𝐡𝐚𝐧𝐠𝐞 𝐌𝐚𝐧𝐚𝐠𝐞𝐦𝐞𝐧𝐭 𝐏𝐫𝐢𝐧𝐜𝐢𝐩𝐥𝐞𝐬 so you can create long-lasting results from your Planning & Scheduling. Want to know more about the course? Link in the first comment. #maintenance #

If Chat GPT was your Reliability Engineer... You would have fired it a long time ago. Now, unless you have been living in a cave, you will have seen and read plenty about ChatGPT. And chances are, you’ve already used it. About 100 million people have apparently. Including me, and I was, and still am, impressed with what it can do. There is also a lot of angst out there about AI taking over jobs. I guess that is happening in some fields already. And in our space of maintenance & reliability it will also happen... eventually But ChatGPT is a long way off from being your next hire for the role of Reliability Engineer or Maintenance Engineer. And if you had hired it, you would have fired it pretty soon after (or at least you should have). You see, ChatGPT is pretty good at generating convincing sounding responses when it comes to maintenance and & reliability topics... ... it can give you a list of failure modes for certain types of equipment ... I have seen some people use it to generate PM check lists But all too often, what it writes is flawed. Just wrong or completely invented (apparently it is normal that AI's suffer from so-called 'hallucinations', we call it something else when humans do it) The problem is that ChatGPT perpetuates our own bad practices. For example, if you look at the check lists it generates, these are full of statements like "inspect and clean fuel pump" Inspect for what? I know most checklists in industry are full of phrases like these, but they shouldn't be. If you ask a technician to inspect a piece of equipment, be specific about: -what they should inspect for -what the acceptable limits are -and what they should do if the limits are exceeded You see similar issues with failure modes, or when you ask it to explain certain maintenance and reliability concepts. In short, ChatGPT and AI are going to change the way we work. No doubt. They will be massively helpful to analyse huge amounts of data whether that ...

Reliability culture... how’s yours? Leadership drives change. But culture sustains it. Without the right culture, your hard-won improvements will simply erode over time. And before you know it, you’ll be back in that vicious cycle of reactive maintenance and low reliability. So ask yourself... how’s your reliability culture? To help you answer that question, I created the Reliability Culture Ladder. It’s a model to help you assess your reliability culture based on 5 levels of maturity: - Toxic - Reactive - Effective - Proactive - Enlightened This model leverages Professor Patrick Hudson’s Safety Culture Ladder. Throughout my own career I found the Safety Culture Ladder useful, practical, easy to understand, and easy to use. And its widespread use around the globe suggests that I am not the only one who thinks that. Reliability and its improvement have many similarities to safety, and we can learn a lot from analysing the advances in safety across industries. So, the Safety Culture Ladder formed a great basis for a reliability maturity model. But that begs the question: What makes up a reliability culture? That’s where the 4 Elements of a Reliability Culture come in, which I’ll talk more about in my next post. But first... Let us know in the comments what you think your reliability culture is and why. #maintenance #reliability #ReliabilityAcademy PS if you don't want to wait and want to read more about the Reliability Culture Ladder and the 4 Elements of Reliability Culture then check out the link in the first comment.

Struggling to get your leaders to support your improvements? Here are 5 steps to convince your top management to invest in and love maintenance planning & scheduling. 1️⃣ 𝐇𝐢𝐠𝐡𝐥𝐢𝐠𝐡𝐭 𝐭𝐡𝐞 𝐩𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐯𝐢𝐭𝐲 𝐩𝐫𝐨𝐛𝐥𝐞𝐦 - Calculate your current wrench time using our simple wrench time calculator (download link in the first comment). Show how much time (and money) is lost as waste. 2️⃣ 𝐄𝐱𝐩𝐥𝐚𝐢𝐧 𝐡𝐨𝐰 𝐩𝐥𝐚𝐧𝐧𝐢𝐧𝐠 & 𝐬𝐜𝐡𝐞𝐝𝐮𝐥𝐢𝐧𝐠 𝐟𝐢𝐱𝐞𝐬 𝐢𝐭 - Walk through how dedicated planners & schedulers optimise work. Show how it increases wrench time. 3️⃣ 𝐂𝐚𝐥𝐜𝐮𝐥𝐚𝐭𝐞 𝐭𝐡𝐞 𝐡𝐚𝐫𝐝 𝐑𝐎𝐈 - Use your wrench time figures to calculate the yearly value gained in hours. Translate hours saved to dollars saved/earned. 4️⃣ 𝐒𝐮𝐦𝐦𝐚𝐫𝐢s𝐞 𝐜𝐨𝐬𝐭𝐬 𝐯𝐬. 𝐛𝐞𝐧𝐞𝐟𝐢𝐭𝐬 - Add up implementation costs. Compare to the calculated ROI of implementing planning & scheduling. Show the massive value compared to the small investment. 5️⃣ 𝐂𝐥𝐨𝐬𝐞 𝐭𝐡𝐞 𝐬𝐚𝐥𝐞 - With all the groundwork done, prepare a simple presentation using the graphs and data you generated using the wrench time calculator. You only have a few minutes to pitch this and only one chance, so you need to get it right. Keep the message simple, effective, and short. Focus on the bottom-line benefits. Avoid jargon and enjoy the opportunity. Sow the seed with your CEO and other stakeholders that this is a permanent change – not just a once-off program. …that planning and scheduling is an essential step on the Road to Reliability. Good luck and let us know how it goes! #maintenance #reliability #ReliabilityAcademy

Make sure your Maintenance Planner is not buried in admin and gets enough time out in the plant. #planning #scheduling #planningandscheduling #workmanagement #maintenance

I repeat. Maintenance is NOT just a cost centre. In fact, there are HUGE opportunities to increase plant profitability, hidden in the maintenance department of most organisations. That's why if you're a Plant Manager or a Senior Executive... then don't just treat maintenance as just a cost centre to be controlled or to be reduced to a minimum. Dig deep and you will find opportunities to... 1. Increase uptime 2. Reduce scheduled downtime 3. Systematically reduce costs by doing less work 4. Increase productivity 5. Make your workplace a better place to work These opportunities ultimately increase your plant's profitability. Start looking at maintenance & reliability as a new opportunity, rather than a 'necessary evil'. Do you need help looking for these opportunities in your organisation? Send us a message here on Linkedin, and let's have a productive discussion about it. #maintenance #reliability #planningandscheduling

📌 𝐓𝐡𝐞 𝟒-𝐬𝐭𝐞𝐩 𝐟𝐫𝐚𝐦𝐞𝐰𝐨𝐫𝐤 𝐭𝐨 𝐞𝐬𝐜𝐚𝐩𝐢𝐧𝐠 𝐭𝐡𝐞 𝐯𝐢𝐜𝐢𝐨𝐮𝐬 𝐜𝐲𝐜𝐥𝐞 𝐨𝐟 𝐫𝐞𝐚𝐜𝐭𝐢𝐯𝐞 𝐦𝐚𝐢𝐧𝐭𝐞𝐧𝐚𝐧𝐜𝐞. If you want to improve reliability, escape reactive maintenance, and reduce stress... ...WITHOUT spending so much money ...WITHOUT hiring expensive contractors ...WITHOUT implementing complicated frameworks And all you have is your own maintenance team to depend on... 👉𝐓𝐡𝐞𝐧 𝐭𝐡𝐢𝐬 𝐢𝐬 𝐟𝐨𝐫 𝐲𝐨𝐮! On July 3 and 8, I'm inviting you to a FREE live webinar titled— The Road to Reliability: Moving From Reactive To Proactive In Just 4 Steps In this webinar, you'll discover: →The 4-step framework to escaping the vicious cycle of reactive maintenance. Learn what processes you need to have in place to escape your reactive environment. And discover what makes this framework actually work even in the most reactive environments. →The step-by-step Roadmap to creating a Reliable Plant. Learn the sequence of steps you need to take to effectively implement the framework. You no longer have to be lost on what steps to take to achieving higher reliability. →How to implement this with your own team. There's no need to hire expensive consultants to do this for you. And much more! If you’re still experiencing... Big backlogs, Low reliability, Low productivity, High stress levels, High maintenance costs, And you have a LOT of questions when it comes to maintenance and reliability... Then this might be the most important webinar that you can attend for free in 2024. Not only will we reveal how and why the framework works... 🟢We will also have a Q&A at the end of the webinar where I'll answer any of your questions. You can register for this webinar by clicking on one of the links below for your desired date. Links in the first comment. #livewebinar #maintenance #reliability #ReliabilityAcademy

How do most organisations deal with repeat failures? They plan for these failures. They write job plans. They hold extra spares. And when the failure happens (again), they can fix it fast. They get better and better at fixing failures. That’s great, right? Maybe. Chances are you could be a lot greater… if instead of fixing that failure over and over again… …you actually fixed the SOURCE of the failure. Research done by Winston Ledet whilst working for Dupont in the 1990s has shown that when you implement Planning & Scheduling, Preventive Maintenance, and Defect Elimination--you can reduce your downtime by 90%. About 30% of that reduction in downtime is because of Planning & Scheduling and Preventive Maintenance. And about 60% is the result of Defect Elimination. Simply put, you’ll NEVER become a Reliable Plant if you don’t get rid of those defects that keep generating failures. You will always be fighting fires and working in a reactive environment unless you get rid of those defects. Implementing Planning & Scheduling on its own is not enough. Implementing Preventive Maintenance on its own is not enough. Even implementing both is not enough. You need to start applying Root Cause Analysis and establish a Defect Elimination culture to make big strides in improving your reliability. #maintenance #reliability #defectelimination #ReliabilityAcademy

Sure, Preventive Maintenance is important… But is your PM program really adding the value that it should be? John Moubray wrote in his book RCMII that 40% to 60% of PMs are ineffective. And industry experience aligns with that. Too many PM Programs waste resources and inflate maintenance costs without improving reliability. Here’s a simple way to reduce costs by optimising your PM program and removing useless work: 𝐒𝐭𝐞𝐩 𝟏: Use a Pareto Chart to reveal your bad actors. Start your analysis there. 𝐒𝐭𝐞𝐩 𝟐: For each major PM task, evaluate the failure mode it addresses and ask: - Is the failure mode credible based on history? - Are the consequences significant enough to warrant PM? - Is the task effective in dealing with the failure mode? - Is the frequency optimal? - Are the work instructions clear and concise? 𝐒𝐭𝐞𝐩 𝟑: Eliminate or refine the tasks that fail this assessment. They likely waste your PM resources. And because you’re doing this based on your Pareto chart, you’re tackling the ones that are going to give you the biggest benefit 𝐒𝐭𝐞𝐩 𝟒: Update your process with the optimised PM program. Now, you need to make sure that when you develop your new PMs or optimise your existing PMs, you’re basing them on basic reliability practices. If not, you’ll end up making simple mistakes like using time-based replacements for random failure modes. Following this simple analysis process can help you uncover significant PM waste. Cutting these useless tasks reduces your costs while maintaining uptime. Want to know more strategies on how to reduce maintenance costs? Check out our article: “How to Reduce Maintenance Costs Sustainably in 4 Simple Steps”. Link is in the first comment. #maintenance #reliability #ReliabilityAcademy