Cogito Reliability’s Post

Beat The Breakdown https://lnkd.in/g2nYhqXq In the realm of operational excellence, two acronyms stand as pillars of reliability and maintenance strategy: #MTBF (Mean Time Between Failure) and #MTTR (Mean Time To Repair). Grasping these concepts is crucial for any professional looking to enhance system uptime and efficiency. 🚀 MTBF is the average time our systems operate smoothly between breakdowns. It's calculated by dividing the total operating time by the number of failures over a period. A high MTBF is a trophy, showcasing the reliability of our systems. 🛠️ On the flip side, MTTR measures the average time we take to diagnose and repair a system when it falters. It's the total downtime divided by the total number of repairs. A shorter MTTR indicates a spry and effective maintenance process. So, how do we optimize these metrics? Predict & Prevent: Don't just wait for failures; anticipate them. Regular maintenance can avert crises and improve MTBF. Sharpen Skills: Ensure your team has the know-how to diagnose quickly. A well-trained crew slashes MTTR significantly. Tool Up: Invest in the right tools for diagnosis and repair. The proper wrench can turn hours into minutes. Remember, the goal is not to eliminate failures but to manage and mitigate them efficiently. Our systems learn from each hiccup, and so do we. 🌟 Every minute saved in downtime is a minute gained in productivity. Aim for high MTBF and low MTTR to keep the wheels of progress spinning! #OperationalExcellence #Reliability #Maintenance #Productivity #ContinuousImprovement #LeanSixSigma #BusinessOptimization Source: Vinay Dahiya

To monitor a machine optimization, MTTR is the indicator to monitor for reducing and MTBF is to improving. A measurement of machine mileage to breaking down.

If this saying applies at your place and ticks you off: "We NEVER have the time and budget to do things right, but we ALWAYS seem to have the time and budget to them again!" Then you should do something about it!! This workshop is directed at those frustrated with having to fix the same things over-and-over again. It's mind-numbing, especially the fact that no one seems to care these things happen repeatedly (even after reported). If we could just focus our energies on those chronic failures that are eating our lunch, the financial skeptics would hop on board the ROI train. Average ROI's for an effective RCA effort are in excess of 600% (that's not a typo, and it's conservative). Experience also tells me that once you funnel that energy and identify these chronic issues with the help of field engagement...they are not difficult to solve at all!! Looking forward to meeting you in Atlanta and having some FUN! #rootcauseanalysis #reliability #rca Ken Latino

Top recommended book for Maintenance & Reliability Engineers 1. Maintenance & Reliability Best Practices 3rd Edition by Ramesh Gulati 2. Rules of Thumb for Maintenance and Reliability Engineers by Ricky Smith, & R. Keith Mobley 3. RCM 3 by Marius Basson 4. 10 Rights of Asset Management - by Ramesh Gulati and Terrence O'Hanlon 5. Practical Reliability Engineering Textbook by Patrick D. T. O'Connor 6. Physical Asset Management: With an Introduction to ISO5500 by N. A. J. Hasting 7.Machinery failure analysis and troubleshooting Book by Heinz P. Bloch 8. Accelerated reliability engineering Book by Gregg K. Hobbs 9. SMRP Metrics 10. ASQ - CRE Handbook #reliabilityengineering #bookstores

📌𝐖𝐡𝐚𝐭’𝐬 𝐭𝐡𝐞 𝐞𝐚𝐬𝐢𝐞𝐬𝐭 𝐰𝐚𝐲 𝐭𝐨 𝐝𝐨 𝐚𝐧 𝐑𝐂𝐀? That’s probably the 5 WHYS approach! The 5 WHYs approach is quick and easy— You simply ask ‘WHY’ five times. You don’t need much training to learn it. And you don’t use complicated processes or software. “It’s just what we need!” 𝐁𝐮𝐭 𝐢𝐬 𝐢𝐭 𝐫𝐞𝐚𝐥𝐥𝐲? The biggest issue with 5 WHYs is that people focus on the tool rather than the process and outcome. The 5 WHYs process all to often gets people to think in single, linear causes. And in doing so they often forget contributing causes. They can easily miss systemic causes. You must understand that getting to the bottom of a major failure could be relatively simple. And at the same time, analysing a minor failure could actually turn out to be technically complex. See, complex problems can have multiple root causes. And the 5 WHYs might make it seem like there's only one. At the same time, people also assume that if a failure had a low impact, the root cause can be easily identified. So, there’s a real danger of stopping at symptom-level causes without getting to the true root. And that’s where we go wrong. 𝐓𝐨 𝐚𝐯𝐨𝐢𝐝 𝐭𝐡𝐢𝐬 𝐩𝐢𝐭𝐟𝐚𝐥𝐥, 𝐲𝐨𝐮 𝐧𝐞𝐞𝐝 𝐭𝐨 𝐚𝐩𝐩𝐫𝐨𝐚𝐜𝐡 𝐭𝐡𝐞 𝟓 𝐖𝐇𝐘𝐒 𝐰𝐢𝐭𝐡 𝐟𝐥𝐞𝐱𝐢𝐛𝐢𝐥𝐢𝐭𝐲 𝐚𝐧𝐝 𝐨𝐩𝐞𝐧𝐧𝐞𝐬𝐬 𝐭𝐨 𝐨𝐭𝐡𝐞𝐫 𝐭𝐞𝐜𝐡𝐧𝐢𝐪𝐮𝐞𝐬 𝐢𝐟 𝐭𝐡𝐞 𝐢𝐧𝐢𝐭𝐢𝐚𝐥 𝐚𝐧𝐚𝐥𝐲𝐬𝐢𝐬 𝐢𝐧𝐝𝐢𝐜𝐚𝐭𝐞𝐬 𝐚 𝐦𝐨𝐫𝐞 𝐜𝐨𝐦𝐩𝐥𝐞𝐱 𝐢𝐬𝐬𝐮𝐞. Instead, use the 5 WHY technique for what appear to be ‘simple’ failures on the surface. But adopt a more rigorous technique if your initial WHY shows that there is a lot more to the story than you initially thought. #maintenance #reliability #ReliabilityAcademy

Prevent, Don't Just Repair: Master Equipment Reliability with RCA When critical equipment fails, it's a setback. You manage it. You repair it. It's part of the business. But when the same equipment fails again, it's no longer just an inconvenience—it's a pattern that's costing you more than just repairs. It's time to break the cycle with Root Cause Analysis (RCA). Introducing the RCA Essentials Workshop, https://lnkd.in/d8ZDB4vM where you will learn how to: ·     Predict and prevent equipment failures before they happen again. ·     Go beyond quick fixes to implement sustainable solutions. ·     Understand the underlying causes of failures to avoid future costs. ·     Empower your team to take proactive measures, ensuring reliability and efficiency.   In the RCA Essentials Workshop, you'll gain the tools and insights to not just respond to failures, but to anticipate and prevent them. Your responsibility doesn't end at getting equipment back up—it's to eliminate the chance of another failure, at all costs.   With our expert-led sessions, you'll discover how to: ·     Save on costs by reducing downtime and repeat repairs. ·     Improve operational efficiency with a proactive maintenance culture. ·     Enhance equipment lifespan through informed analysis and action. ·     Deliver on the promise of reliability that your clients and stakeholders expect.   🔍 Workshop Focus: Proactive Prevention Strategies 🛠️ Techniques: Advanced RCA Methodologies 📈 Outcome: Reduce Failures, Increase ROI   Don't let history repeat itself with costly equipment failures. Secure your place in the RCA Essentials Workshop and turn reliability into your competitive edge.   📅 Date: May 8-9, 2024 | October 1-2, 2024 📍 Location: Atlanta, GA 👥 For: Maintenance Teams, Managers, and Decision-Makers Register today and commit to a future where equipment failure is a thing of the past. Join expert guides Ken Latino and Robert (Bob) Latino #rca #reliability #rootcauseanalysis #atlanta Prelical Solutions, LLC.

❗New Case Study Alert❗ Erik Hupjé from Reliability Academy brings us the latest case study, now on RELIABILITY CONNECT! Erik takes you through the history of RCM and reveals 9 essential principles that every maintenance & reliability practitioner should know and live by. Click the link and elevate your PM strategy today! 🔗 Read now: https://hubs.la/Q02D9G_q0

Root Cause Analysis 5 Whys

Now that the 7 questions of RCM have been covered (see previous videos if you missed them) we need to go back to the start - the operating context. Just like the project charter provides the background of a project, the operating context sets the scene and background for Reliability Centered Maintenance. This video is all part of our ongoing step by step guide into Reliability Centered Maintenance. Want to know more about how maintenance and reliability training can help you and your team? Take a look at our other videos in the series or check out our website: 🌐https://lnkd.in/eFs_NZZs #reliability #maintenance #rcm #reliabilitycenteredmaintenance #assetmanagement https://lnkd.in/eUHQHaXn

Twenty years ago, on the Maintenance forum at the AMP website, a post titled "What Comes First in Reliability Improvement?" featured a response from V. Narayan that remains the best answer I’ve encountered. I’d like to share it here on LinkedIn after two decades: "For any Company that thinks (or knows) its current performance is poor, e.g., that its reliability is low, downtime is high, costs are high, it is at Point A. World beaters are at Point B. The trouble is that many Companies who are at Point A fool themselves into believing they are at Point B, or least part way there. Now to the next issue. To get from Point A to Point B, you can walk or run. If the Company is the equivalent of a toddler, with few strengths,it should learn to walk before starting to run. It needs a level of maturity, get its house in order before reaching out. I think your quote applies well to such Plants, and I think there are many more of these than mature ones. The world has moved but they are still there, 50 years behind. If such a Compsny gets the basics right, viz., cleanliness, a good lub program and keeps things aligned, balanced and bolts tight, they can get rid of 50-60% of their reliability problems. You dont need RCM, TPM, Six Sigma to do this. When they have 'learned to walk', they are ready to 'run' with RCM or other tools. Let us not kid ourselves; RCM is only the front end, all it produces is a plan. You still have to execute the work according to this plan and to the right quality standards before it shows on the bottom line. Companies that have not learned to walk will falter and fall if they are just given a high quality RCM based plan. In my view, RCM is a means to an end, it is not the end. It is a great process, in the right hands. In my view, you have to earn your spurs to be allowed into the RCM world. - V.Narayan." Note: V. Narayan, was one of my mentors 20 years ago, that inspired me to enter the field of Reliability Engineering. He has also written several remarkable books on the subject. #Reliability #Maintenance #RCM #ContinuousImprovement #LessonsFromThePast