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Raul Martins

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Everything posted by Raul Martins

  1. Hi everyone, Peter Drucker, an Austrian management consultant, educator and author, who is also known as the founder of modern management, has a quote that says: “If you can’t measure it, you can’t improve it.” In short, this is because if you cannot measure something, and know the results, you can’t possibly get better at it. For this reason, this week we will be discussing about something that plays a pivotal role by showing you and your team if you are on the right track on the road to reliability: Key Performance Indicators Also known as KPI’s, key performance indicators, as its own name says, are metrics that a team measures the performance of a specific area or process by helping us to make the right decisions to correct or to make improvements. However, it is important to mention that not choosing the right KPI’s or tracking them incorrectly, might be worse than not tracking any metrics at all. For instance, imagine yourself heading to North with your family and your GPS pointing you at the wrong direction. I can tell that your trip would take a bit longer in the best-case scenario. Having said that, which KPI’s should you track? To be honest, this answer varies from industry to industry, as well as how advanced your processes are. See below some metrics that should be a good option if you want to start measuring the performance of your maintenance department: Now it is your turn! Have you used this KPI’s before? Which KPI’s do you track? Would you add any other KPI's to this list? Finally, I would like to say thanks to @Jim Vantyghem. He is a great enthusiast of this topic, as well as really knowledgeable and has been discussing it with us lately. Thank you very much for sharing your thoughts with our community! Regards, Raul Martins
  2. Hi @NikosPant, I also see the use of detailed work instructions and internal training are an excellent way to reduce rework levels at low cost, as well as an opportunity to recognize experienced technicians. Companies usually have several technicians are a cut above on specific tasks that could be training other technicians to improve their skills. In regards to the Smart glasses, the experts are staff members of the equipment supplier or engineers that provide such support? Regards, Raul Martins
  3. Hi @Jim Vantyghem, That is great news! Here in Australia the number of new cases has been really low over the last month (10 new cases a day on average). The restrictions are being eased in three stages. Here in Queensland, the first one was on May 15, when restaurants were allow to offer dine-in for up to ten customers at a time, beaches were re-opened and people were allowed to drive up to 150km from their houses. Then on June 12 more restrictions will be eased (up to 20 customers on restaurants, campings re-opened, etc.). Finally, on July 10, the third stage will allow gatherings of up to 100 people, interstate traveling and more. In short, slowly things are getting back to normal here. On the other hand, in Brazil the situation is out of control. Nearly 400k cases, more than 1,000 people died only yesterday and no signals of flattening the curve at all.
  4. Hi @IrWCSoh, I haven't seen this colour coded drawing before. I like it, It seems to be really interesting and handy. Congratulations! Regards, Raul Martins
  5. Hi @Engrjoe and @Andronica Kwapeng, Great replies! As you mentioned, in addition to training, it is extremely important to have specific information about the pieces of equipment easily accessible for the maintenance technicians. No one is required to have everything in their minds when they are assemblying an asset, so having solid work instructions, up-to-date drawings and bill of materials, detailing the steps of each task is a vital part on solving such issue. Regards, Raul Martins
  6. Hi @Phil Kluetz, It is good to have you back aboard! Looking forward to seeing you here. Good luck on the new journey! Regards, Raul Martins
  7. Hello everyone, As mentioned in the title of the topic, congratulations! You, as an experienced Maintenance and Reliability professional, were assigned to a new task: Reduce the assembly issues of a maintenance team. Unfortunately, as the world is going through tough times, which includes your company, your budget to invest in training and improvements is really low and you have to look for cheap alternatives that will bring a positive outcome. That being said, how would you tackle this issue? Improve the process? Work instructions? Internal training? Well, it is up to you. Just bear in mind that you need to be creative and really low-cost. Also, Don’t forget about explaining your strategy and how this would solve such issue. Regards, Raul Martins
  8. Hi @UptimeJim, I meant they would struggle considering small changes, such as changing a lubricant of a single piece of equipment. For this situation, you might have some success even without a senior sponsorship, although it might not be easy to convince the fitters and maintenance technicians. However, when it comes to bigger changes, especially cross departamental and process-related (how people do their jobs), I totally agree. Without that top sponsorship, there is no chance of success. Regards, Raul Martins
  9. Hi @SEIDEL MURIEL, Innovation plays a key role on the sustainability of a company, especially in times like this that many businesses are struggling financially. If we want to create an innovative environment, we need to give people the chance of thinking, creating, as well as failing. Many managers do not accept failures, regardless their consequences are bad or not. However, there will always be risks involved in a change, in an innovation and this will certainly happen sooner or later. We have to try our best to avoid it, but when it happens, we have to learn from it, fix the mistakes done in the past and look at the future and do not give up. There is a quote by Thomas Edson that says: I have not failed. I've just found 10,000 that won't work. How about you? What are your thoughts about innovation? Regards, Raul Martins
  10. Hi @Andrej, Great comment! I agree when you say that people need to know WHY the change is happening. This reminded me of a leadership video by Simon Sinek, called "How great leaders inspire action", in which he talks about "WHY". The link is below for those who are interested in having a look: https://www.ted.com/talks/simon_sinek_how_great_leaders_inspire_action About the senior sponsorship, that is true. I have seen many projects failing due to lack of an executive support, especially those projects that are changing/improving a process. If people do not see a clear sponsorship from senior management, the change agent will struggle at every single step. I did not know Prosci. I just checked their website and it looks like a really good company and source of information. They have a section with articles and webnars that look quite helpful as well. Thanks for sharing it with us. Regards, Raul Martins
  11. Hi all, Changing is not something easy. Although we might say that we like it, our subconscious is not a big fan at all. This is because there is something that always come along with changes: risk. However, imagine if human kind did not take risks throughout the years where we would be right now. Probably, we still would be living in caves. When it comes to a company, especially, an asset intensive industry, we have to use a staged approach as the risks for the business and for the health and safety of those who work at it can be significant. This staged approach is also called change management process. Basically, such process is a sequence of activities/tasks that move a proposed change from an idea, to a fact. Here, we have to: 1- Identify the changes; 2- Determine your objectives; 3- Plan for the change; 4- Identify your stakeholders; 5- Gather data and facts for evaluation; 6- Assess all the risks involved and create a plan to mitigate them; 7- Create a solid change case; 8- Communicate what is going on, especially the future vision; 9- Monitor and manage the progress, risks and stakeholders engagement; 10- Celebrate key achievements; 11- Review and improve it continuously. Following those steps will help you to achieve a successful change. However, do not forget to be the change agent for your change. The change agent (you) is responsible to implement the change successfully by providing all the required resources for the change and keeping others engaged throughout all the changes proposed. Ensure you understand the processes, the steps needed and impacts of your change from different perspectives (technical, financial, feasibility, etc.). Have your stakeholders by your side all the time, show them the benefits for the organization and for themselves. Show people you know and you really believe on what you are doing. At the end of the day, your change will only be successful, if you are able to make it stick. Regards, Raul Martins
  12. Hi @Fred Ward, I have been through something similar in the best during small preventive shutdowns. Basically, we took two actions to try to improve this situation: 1- A Shutdown Planning meeting, where we discussed with the production supervisor every single task that would be done on that particular day and by what time we would need it ready for us, including a priorization of tasks, displaying which one should be ready first. After agreeing during the meeting, an email was sent with main topics discussed during the meeting, including the plant release time to everyone, including maintenance and production managers; 2- Making notes of every releasing plant time, especially for those tasks that were delayed due to not having the plant ready for maintenance. Then, another email used to be sent to everyone, including the maintenance and production managers, highlighting everything that went wrong during the shutdown, which includes tasks not completed on time due to plant release delays + by what time it was agreed to be released + actual time released. Just be careful when sending email with this sort of information to make sure the operators will not feel atacked by the info, but as an impartial way of recording what went wrong. Trying to understand the reason of not releasing the plant on time and trying to help them out solving these sort of problems when we could might be aa good option. Hope this helps. Regards, Raul Martins
  13. Hi @SEIDEL MURIEL, Every week we post a different topic. Other maintenance strategies, such as detective and predcitive maintenance are on my list and will be posted soon. Stay tuned to our community and feel free to create independent topics so we and other users can share their thoughts. Regards, Raul Martins
  14. Hi @UptimeJim, That MTBF mistake is something very commonly made. Not only when it comes to task frequency, but also for spare part strategy. Great explation about using risk and economic as an approach to achieve positive outcomes from your PM. By the way, I went through a situation this weekend that a component wore through, causing significant damage to a piece of equipment. This looks like a good opportunity to use some LDA concepts to improve it. Regards, Raul Martins
  15. Hi all, Time based maintenance (TBM) is part of a preventive maintenance approach, which aims at replacing a piece of equipment or component based on how long it has been running. Such activities are scheduled, have a determined interval, and should contribute effectively to prevent the occurrence of a failure mode, and are based on the economic life cycle of the asset, or on the appropriate interval for a component to be replaced. In order to determine this interval, do not forget of going through your asset maintenance history, check with experienced colleagues their thoughts and use as much quantitative analysis as you can, such as Life Data Analysis (LDA) and Reliability Growth Analysis (RGA). Yet, one of the most important steps when creating your time based maintenance plan is understanding the characteristics of the failure. A TBM will help you with age-related issues, such as some wear out or corrosion problems. This is because age-related failures, allow you to estimate an optimal time to replace an item. On the other hand, when a TBM strategy is used for a random failure, like operational problems, or using the wrong lubricant, this will make your costs go through the roof, as you will be replacing parts unnecessarily on your PM, as well as the failures will keep happening. In short, time based maintenance can be one of your biggest allies when building a reliability program and improving your plant’s results. However, determining the failures modes and their characteristics are vital to make it happen in an efficient way. Regards, Raul Martins
  16. Hi @Mazlan Md Suki, Welcome to Road to Reliability online community! Hope you enjoy your time here. Looking forward to reading about your experiences. Regards, Raul Martins
  17. Hi @Hadwll, That is great! Everyone has to be involved in the defect elimination process, especially frontline operators and maintenance technicians, as they quite often know what are the causes and solutions for the failures. Yet, sometimes they do not have the right tools to solve such failures. Having someone from outside that will bring a different perspective and resources to solve them working along with them is key. Regards, Raul Martins
  18. Hi @NikosPant, 100% agree. Recently I have been through a situation that I struggled to receive the spare parts list from the OEM, as they said their policy does not allow doing so. It is simply nonsensical in my view and this sort of OEM should not be considered during a quotation at all. Establishing a process as you mentioned is key to avoid this sort of issue. Regards, Raul Martins
  19. Hi @Mushanguri Innocent, That sounds really good. In my view, this daily approach will strengthen the culture of keeping the BoM up to date and create an ownership feeling about them. Regards, Raul Martins
  20. Hi @IrWCSoh, Welcome aboard and congratulations for your initiative! Feel free to go through some of our topics and share your thoughts with our community members. Regards, Raul Martins
  21. Hi all, Even though many tools are available nowadays to improve companies results, many businesses still struggle with poor reliability and productivity. The reasons vary from lack of knowledge about maintenance processes, to poor leadership, and many more. However, we won’t be discussing this today. We will be talking about something that, although everyone knows how important it is, just a few really look after: BoM. But, what the heck is BoM? BoM stands for Bill of Materials, which is a list of materials needed to accomplish a particular assembly or task. The BoM can also be a listing of parts required to support the operations and maintenance of piece of equipment. It contains primarily consumable items and replacement components that may be inventoried as a spare. Impellers, bearings, shafts, conveyor belts, or lubricants can be part of your BoM. Having a bill of material properly managed on you CMMS not only can save you a lot of time, but also it can save many dollars (or your local currency). This is because if you don’t have a proper BoM will mean that during an emergency, you will be rushing to find the components you need, which not necessarily mean that you will find them quickly, as you will probably be looking for the equipment manual, or reaching out its OEM asking for information ASAP. Meanwhile, your plant may be offline waiting for a seal, or a simple bolt. On the other hand, having a not up-to-date bill of materials might lead to the same situation, or even worse. Imagine you are purchasing a component catalogued on you Bill of Materials that will use during that 12 hour outage. It is all good, the planning is flawless, you have enough labor, tools and spare parts. Nothing can go wrong. However, when the outage has come, that component that was bought in advance simply doesn’t fit. Welcome again to that situation mentioned above: you will be rushing to find the right component you need, which not necessarily mean that you will find it quickly, as you will probably be looking for the equipment manual, or reaching out its OEM asking for information ASAP. Meanwhile, your plant may be offline waiting for a seal, or a simple bolt. That being said, managing your Bill of Materials properly is key to improve your results and avoid problems. For this reason, ensure your company has an establish management of change process, people are aware of the importance of a BoM, and review it every time some changes. How about sharing your experience with us? How do you manage your Bill of Materials? Have you had problems before due to not up-to-date BoM’s? Have you created/updated a BoM that was used later on a tough situation and avoided those problems said above? Regards, Raul Martins
  22. Hi all, This week we will be discussing about one more defect elimination technique: Fishbone Diagram. What is Fishbone Diagram? This powerful Japanese tool was created by Dr. Kaoru Ishkawa, who was a Chemistry from Tokyo and worked in several industries, such as the Japanese army, chemical companies and universities. The purpose of the Fishbone Diagram is to provide a systematic approach to determine potential causes and root causes, by determining the relationship between causes and effects. Those are put in a diagram that looks like the skeleton of a fish, which explains its Fishbone Diagram name. Figure 1 – Example of Fishbone Diagram How should I use it? First of all, define what is the problem that will be analysed. The brainstorming process plays a really important role here, so gather information and an experienced team. List all the possible causes for the failure event. Analyse and verify each one (use as much data as you can) in order to understand if this can be a cause or if this can be ruled out until you find the root cause. Once this is done, create an action plan to eliminate the problem. A Fishbone Diagram example: See below an example of a Fishbone Diagram for a leaking pump: Figure 2 – Example of a leaking pump Fishbone Diagram When can I use it? Similarly to 5Whys (see topic here), the Fishbone Diagram can be used for many different problems, from a piece of equipment failure to a process failure. Yet, it is usually used to solve simple events. How about you? Have you used the Fishbone Diagram? Was it helpful to solve your problem? Regards, Raul Martins
  23. Although I live in Australia, I am originally from Brazil. So I have closely watched the situation in both countries. Australian has put strict measures in place, closing non-essential businesses for nearly three weeks now. On top of that, Australia has one of the highest test rates in the world. As a result, the curve has started to flatten. On the other hand, Brazil has done something similar to some European countries and the USA, and the test rates are quite low (although it has started to change), hence the number of cases are still getting higher and higher. When it comes to work, I have worked from home since the 23rd of March. In order to keep busy during my spare time, I have watched many series and movies, especially from Netflix, read some books and given my family and friends calls more often than before. @UptimeJim, thank you for offering free online courses at this moment, as many people are going through financial crysis due to the economic side effects of the virus. Regards, Raul Martins
  24. Hi @Andrej, Interesting approach for the 5Whys technique. This allows a wider understanding of the failure and its cause(s), which tackles part of the issues we mentioned before. Thank you for the IAEA document! It is great to have all of those RCA techniques in a single place. Regards, Raul Martins
  25. Hi all, Today we will be creating a slightly different topic than what we are used to. The world is going through an unprecedented situation, called COVID-19. Road to Reliability online community has members from many different countries and, although each country is currently facing a different situation, infection rates and putting different preventive measures in place, nearly everyone has been affected somehow. The idea of this topic is to have an open discussion about this situation. Feel free to share how you are going through it, what is the situation of your country/city, ask for or give ideas about how to deal with this (exercising, think about the future, watching movies, reading books, etc). Absolutely anything that will help you or others to move on and have a better day. Regards, Raul Martins
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