Maintenance Technology September 2016 - 75

14 If poor quality maintenance causes so many incidents in highly regulated and hazardous industries such as Nuclear Power Generation and Civil Aviation, what proportion of failures may be being caused by maintenance within your organisation? What could maintenanceinduced failures be costing your organisation? We should do something to reduce the number of equipment failures that are being caused, not prevented, by maintenance. This article suggests that the most appropriate approach is: * Admit that human error is inevitable (even in maintenance!) and design our systems and processes around this inevitability * Use appropriate tools to ensure that we are not unnecessarily over-maintaining plant and equipment (and therefore increasing the risk associated with the fact that this work may not be performed correctly), and * Work to improve the quality with which maintenance activities are performed - including error-proofing where possible. Human Error is Inevitable Reason and Hobbs identified a number of physiological and psychological factors which contribute to the inevitability of human error. As a result of these contributing factors, the types of errors that occur most often in maintenance include: * Recognition failures - these include nondetection of problem states * Memory failures * Skill-based slips * Rule-based errors including: ° Misapplying a good rule - using a rule in a situation where it is not appropriate ° Applying a bad rule - this is most common when people pick up others' "bad habits" * Knowledge-based errors * Violations - deliberate acts which violate procedures Think of your own situation - have you ever committed an error? For most of us, the consequences of our past errors are relatively minor - but that was largely due to luck and the situation that we were in at the time. Numerous research studies have shown that over 50% of all equipment fails prematurely after maintenance work has been performed on it. In the most embarrassing cases, the maintenance work performed was intended to prevent the very failures that occurred. This article outlines the key things that maintenance managers can do to reduce or eliminate the impact of human error in maintenance. Avoid Unnecessary "Preventive" Maintenance Given the statistics mentioned earlier from Nowlan and Heap's work, it is clear that overmaintaining equipment is not only a waste of time and money, but also increases the risk of safety and environmental incidents, as well as potentially causing expensive and unnecessary failures. Techniques based on the application of RCM principles are an extremely effective way of weeding out this unnecessary maintenance, and streamlining and optimising equipment preventative maintenance (PM) programs. Our analysis of PM programs in place at our clients has indicated that in almost all organisations there is a huge amount of unnecessary routine maintenance being performed. In some situations, fewer than 10% of the existing PM tasks were optimal, and it is not unusual for us to identify that as much as half of the routine maintenance activities were, at best, a complete waste of time. In many cases, the performance of some of these "preventive" maintenance activities were potentially causing equipment failures, rather than preventing them - particularly where these activities involved intrusive, fixed interval inspections and overhauls. At one major offshore oil and gas platform in Western Australia, a comprehensive review of the PM program led to a 25% reduction in the amount of routine PM being performed. It also led to a 25% reduction in the amount of corrective maintenance being performed. Clearly, in this case, a fair proportion of the PM that had previously been performed was actually causing, rather than preventing, failures. SOLUTIONS AUGUST 2016 10127-4056 SMRP Solutions SE.indd 14 8/22/16 9:43 AM

Table of Contents for the Digital Edition of Maintenance Technology September 2016

Editorial
Uptime
On The Floor
Old-School Approach To New-World Technology
Art Meets Reliability Science
Commit To Safety
Robot-Human Interaction Getting Safer
Sanitary, Stainless Conveyors Not The Same
Reduce Hidden Process-Safety Costs
Pace Your Reliability Program
Win The War With 'Lubrication By Design'
SAP Tips And Tricks
Understand Pump Vibration
Select The Right Relay
Bearing Care
Clear Up HOA Confusion
Potato Waste Becomes Clean Water, Energy
Products
Showcase
Ad Index
Final Thought
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - Cover1
Maintenance Technology September 2016 - Cover2
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - 2
Maintenance Technology September 2016 - 3
Maintenance Technology September 2016 - Editorial
Maintenance Technology September 2016 - 5
Maintenance Technology September 2016 - Uptime
Maintenance Technology September 2016 - 7
Maintenance Technology September 2016 - On The Floor
Maintenance Technology September 2016 - 9
Maintenance Technology September 2016 - Old-School Approach To New-World Technology
Maintenance Technology September 2016 - 11
Maintenance Technology September 2016 - 12
Maintenance Technology September 2016 - 13
Maintenance Technology September 2016 - 14
Maintenance Technology September 2016 - 15
Maintenance Technology September 2016 - Art Meets Reliability Science
Maintenance Technology September 2016 - 17
Maintenance Technology September 2016 - 18
Maintenance Technology September 2016 - 19
Maintenance Technology September 2016 - Commit To Safety
Maintenance Technology September 2016 - 21
Maintenance Technology September 2016 - 22
Maintenance Technology September 2016 - 23
Maintenance Technology September 2016 - Robot-Human Interaction Getting Safer
Maintenance Technology September 2016 - 25
Maintenance Technology September 2016 - Sanitary, Stainless Conveyors Not The Same
Maintenance Technology September 2016 - 27
Maintenance Technology September 2016 - 28
Maintenance Technology September 2016 - Reduce Hidden Process-Safety Costs
Maintenance Technology September 2016 - 30
Maintenance Technology September 2016 - Pace Your Reliability Program
Maintenance Technology September 2016 - 32
Maintenance Technology September 2016 - 33
Maintenance Technology September 2016 - 34
Maintenance Technology September 2016 - 35
Maintenance Technology September 2016 - Win The War With 'Lubrication By Design'
Maintenance Technology September 2016 - 37
Maintenance Technology September 2016 - 38
Maintenance Technology September 2016 - SAP Tips And Tricks
Maintenance Technology September 2016 - Understand Pump Vibration
Maintenance Technology September 2016 - Select The Right Relay
Maintenance Technology September 2016 - Bearing Care
Maintenance Technology September 2016 - 43
Maintenance Technology September 2016 - Clear Up HOA Confusion
Maintenance Technology September 2016 - Potato Waste Becomes Clean Water, Energy
Maintenance Technology September 2016 - 46
Maintenance Technology September 2016 - 47
Maintenance Technology September 2016 - 48
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Maintenance Technology September 2016 - 50
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Maintenance Technology September 2016 - Showcase
Maintenance Technology September 2016 - Ad Index
Maintenance Technology September 2016 - 55
Maintenance Technology September 2016 - Final Thought
Maintenance Technology September 2016 - Cover3
Maintenance Technology September 2016 - Cover4
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