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
Maintenance Technology September 2016 - 49
Maintenance Technology September 2016 - 50
Maintenance Technology September 2016 - 51
Maintenance Technology September 2016 - 52
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
Maintenance Technology September 2016 - 62
Maintenance Technology September 2016 - 63
Maintenance Technology September 2016 - 64
Maintenance Technology September 2016 - 65
Maintenance Technology September 2016 - 66
Maintenance Technology September 2016 - 67
Maintenance Technology September 2016 - 68
Maintenance Technology September 2016 - 69
Maintenance Technology September 2016 - 70
Maintenance Technology September 2016 - 71
Maintenance Technology September 2016 - 72
Maintenance Technology September 2016 - 73
Maintenance Technology September 2016 - 74
Maintenance Technology September 2016 - 75
Maintenance Technology September 2016 - 76
Maintenance Technology September 2016 - 77
Maintenance Technology September 2016 - 78
Maintenance Technology September 2016 - 79
Maintenance Technology September 2016 - 80
Maintenance Technology September 2016 - 81
Maintenance Technology September 2016 - 82
Maintenance Technology September 2016 - 83
Maintenance Technology September 2016 - 84
Maintenance Technology September 2016 - 85
Maintenance Technology September 2016 - 86
Maintenance Technology September 2016 - 87
Maintenance Technology September 2016 - 88
Maintenance Technology September 2016 - 89
Maintenance Technology September 2016 - 90
Maintenance Technology September 2016 - 91
Maintenance Technology September 2016 - 92
Maintenance Technology September 2016 - 93
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-jan-feb-2024
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-april-2022
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-october-2021
https://www.nxtbook.com/atp/MaintenanceTechnology/efficient-plant-june-2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanfeb2021
https://www.nxtbook.com/atp/MaintenanceTechnology/epjulyaug2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epfeb2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjan2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovdec2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptoct2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptember2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epaugust2018
https://www.nxtbook.com/atp/MaintenanceTechnology/0818schneider
https://www.nxtbook.com/atp/MaintenanceTechnology/epjuly2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtsept2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJune2015
https://www.nxtbook.com/atp/MaintenanceTechnology/M
https://www.nxtbook.com/atp/MaintenanceTechnology/0415endress
https://www.nxtbook.com/atp/MaintenanceTechnology/MTApril2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTMarch2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTFebruary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJanuary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTDecember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTNovember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTOctober2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTSeptember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2014
https://www.nxtbookmedia.com