Articles | The True Cost of Poor Lubrication | ReliabilityWeb.com: A Culture of Reliability
This is a good article about why a lubrication excellence program is needed to alter the culture of an organization.
Cultural change within an existing maintenance or engineering team is a challenge, often difficult and never something that can occur overnight.
No silver bullets - just simple fundamental best practices put in motion.
Blog on Reliability Centric Thoughts
Sunday, October 28, 2012
Why do Work Instructions Fail?
Work instructions are written documents intended to convey how to do a job.
Recently I had the chance to interact with a talented team and discovered why work instructions often fail to produce the desired result - which I will call a well executed job.
The challenge was to build a software model of a system using a leading software, after 12 hours of intense instruction on how to utilize the software, made easier by requiring each student to follow a written work instruction that was contained on 5 pages - including exact screen shots of the finished product, and intermediate step results. The written work instruction also included screen shots of database view of the data required to be populated into the software model so the users of the document could self check their data input.
The purpose of the exercise limited to 1.5 hours was to type the data into the software - reinforcing the previous training provided on how to utilize the software, and then build upon the base model to enhance some fundamental concepts about reliability.
The work instruction document on further examination had been through the following developmental processes.
The work instruction document required the input of a simple 5 location reliability centered maintenance analysis that included weibull failure parameters (provided in work instruction) cost of spare parts, cost of each labor hour (weighted cost), down time effects in cost and operational criticality and safety criticality.
Student Questions that surfaced during the data entry phase indicated their prior training was reasonably successful and thus revealed 4 typo's in the work instructions existed. These were countered by verbal work instructions during the work performance to alter the written work instructions during work performance.
After data was entered the basic task was to prove their software model was equal to others thus - 12 students performed a 10 year life simulation to estimate the effects and costs associated with the base strategy.
If all data had been entered the same - 12 identical results would be obtained.
Question Two - How many correct results were there?
If you say less than 12 - why?
Recently I had the chance to interact with a talented team and discovered why work instructions often fail to produce the desired result - which I will call a well executed job.
The challenge was to build a software model of a system using a leading software, after 12 hours of intense instruction on how to utilize the software, made easier by requiring each student to follow a written work instruction that was contained on 5 pages - including exact screen shots of the finished product, and intermediate step results. The written work instruction also included screen shots of database view of the data required to be populated into the software model so the users of the document could self check their data input.
The purpose of the exercise limited to 1.5 hours was to type the data into the software - reinforcing the previous training provided on how to utilize the software, and then build upon the base model to enhance some fundamental concepts about reliability.
The work instruction document on further examination had been through the following developmental processes.
- It had been developed by a knowledgeable Engineer - from a working version of the model to be built.
- The exercise had been run 2 other times - and the results of those exercises used to refine the document's accuracy.
- Prior to use, 2 more engineers reviewed the documents proof reading it for errors and found none.
The work instruction document required the input of a simple 5 location reliability centered maintenance analysis that included weibull failure parameters (provided in work instruction) cost of spare parts, cost of each labor hour (weighted cost), down time effects in cost and operational criticality and safety criticality.
Student Questions that surfaced during the data entry phase indicated their prior training was reasonably successful and thus revealed 4 typo's in the work instructions existed. These were countered by verbal work instructions during the work performance to alter the written work instructions during work performance.
After data was entered the basic task was to prove their software model was equal to others thus - 12 students performed a 10 year life simulation to estimate the effects and costs associated with the base strategy.
If all data had been entered the same - 12 identical results would be obtained.
Question Two - How many correct results were there?
If you say less than 12 - why?
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