Efficient Plant April 2019 - 31

Answers to questions
facing today's reliability
& maintenance
professionals

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Evolution of R&M
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APRIL 2019

Dr. Klaus M. Blache
Univ. of Tennessee Reliability
& Maintainability Center
(RMC)

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Maintenance and reliability concepts have been evolving for a long
time with increasing complexity and
capabilities. This is further complicated
by global competition, the high number
of trades/technicians leaving the workforce, changing business dynamics, and
the ongoing need to improve culture.
The "fix it when it's broken mentality"
was the norm prior to 1950. Unfortunately,
there are still too many facilities operating
with that philosophy. In the mid-60s, we
saw some early computer usage, mainly for
task reminders and basic work orders. In
the mid-70s there were still Fortran punch
cards being used on large IBM computers.
As computers got smaller and capabilities
increased, computerized maintenance management systems (CMMS) got better and
usage accelerated.
In the mid-to-late-90s, PCs quickly
took over. Then came wireless/mobility,
cloud-based computing, and the rise of predictive technologies and condition-based
maintenance. Data from these new tools
and techniques provided analytics that led
to predictive maintenance. Beginning in
the late-70s, there was increasing focus on
reliability-centered maintenance, failure
modes and effects analysis, and root-cause
analysis. Later came design for reliability
and maintainability (R&M) and PM (preventive maintenance) optimization.
For several decades, there were good
apprentice programs for trades. Very few
companies still have them and not enough
young people are moving in that direction.
Also, not enough plant-floor people have

Asset
Management:
Evolution to
Revolution

the discipline, precision maintenance, and
reliability skills needed to optimize operational performance. This has emerged as a
strong need in the past 10 years.
It took more than 60 years to get from
the Maytag Man (a bored repairman depicting product dependability of the Maytag
brand) and the maintenance attitude of the
period to current practices. Then came the
IoT (Internet of Things), big data, wireless,
mobility, and better access to real-time data.
John Moubray had a much earlier version of a chart similar to the version shown
below (Reliability-Centered Maintenance,
2nd edition, John Moubray, Industrial Press,
NY, 1992). When John and I first met in
Aberdeen, Scotland, in the 80s, many of the
items on the chart (beginning about 2010)

Increasing acceptance, usability, and ROI

Q

Asset management is changing rapidly. Where is it all
headed?

department | on the floor

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>2025

Increasing capability with new tools and techniques

EFFICIENTPLANTMAG.COM |

31


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Efficient Plant April 2019

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