Case Studies in Maintenance and Reliability: A Wealth of Best Practices. V. Narayan
Impetus for this Book
Books dealing with maintenance subjects seem to focus on answering these questions: What should be done? How should it be done? And sometimes, when or why should it be done? Books on reliability seem to focus on mathematical aspects; the average maintenance manager or supervisor finds it hard to relate their content to the reality they face in their work.
We decided we would write about learning experiences from our working lives. We describe the hand we were dealt and how our team handled the situation in those circumstances. In hindsight, we found some underlying truths or principles in these experiences which we believe may be applicable in other situations. Based on these descriptions, readers can decide whether they should consider a different approach from the ones they currently follow.
1.3 The Shewhart Cycle
Edward Demingi describes Shewhart’s continuous improvement cycle with the Plan-Do-Check-Act sequence. We use an adaptation of this, with the Plan, Schedule, Execute, and Analyze phases, shown in Figure 1.1. We have grouped our chapters under these four headings. Although some of the chapters could be placed under two or more headings, we chose the heading that seemed appropriate from our perspective. To these four, we added two more headings: Leadership and People. The subjects covered in the various chapters fall under one of these six headings. We hope that the grouping helps readers to find what they are looking for easily.
1.4 Chapter Contents
In each chapter, we describe an event or situation that one of us experienced personally. We have tried to relate the events factually, at least as far as we could remember them. In order to protect the identities of those involved, we have not revealed the names of the locations or of the individuals. The key issues are 1) how the people involved handled the event and 2) the results or outcome of their effort. We have summarized our own learning from each situation. We also included underlying principles we feel are relevant: these are stated at the end of each chapter.
Figure 1.1 Continuous Improvement Cycle
At the time of the events described in the book, we did not know many of the relevant underlying theories or philosophies. We picked up most of the concepts subsequently, sometimes many years later. Had we known them at the time, we may have found the solutions with less effort. For the benefit of readers who may need them, we have described the relevant theory or methodology in appendices.
1.5 Locations
We have, between the three of us, worked in about 20 locations. In a consulting role, we have advised at least 30 locations around the world. Each site had its own way of doing things. So that readers can appreciate the different pressures the locations faced, we have provided an overview in Chapter 2. Because there may be more than one chapter about a given location, some of the common information is described in this chapter. Hopefully, this will avoid needless repetition, but it does mean that before reading a chapter, readers may have to go back to Chapter 2 to get the overview.
Where relevant, we have given some information about the cultural and social climate that prevailed in that location. So that the events described are placed in context, we have provided additional background material at the beginning of each chapter.
1.6 Glossary, Acronyms and Abbreviations
Please refer to these if certain words or acronyms are not clear.
1.7 Acknowledgements
I had the pleasure of meeting Charles Latino in Chicago at the Maintenance and Reliability Technology Summit in 2005. Charles is a well-known reliability and maintenance guru, and I was thrilled to listen to his brilliant lecture. I knew his son Bob Latino through a web site forum in which we both participate, and from his excellent book Root Cause Analysisii. Hearing Charles’ talk spawned the idea for this book. I consider it a great honor that he has written the foreword.
A former fellow student and friend from my University days, Satish Shirke, agreed to do the illustrations for the book. Satish lives in California, but we managed the trans-Atlantic communications quite well. He did a great job, but because of his workload, he could not continue. I was in a spot, desperately seeking a good illustrator to replace Satish. When Steven van Els, based in Suriname in South America, offered to help, I was delighted. I ‘met’ Steven on the reliability.com web site and have a great deal of respect for his knowledge and experience. Steven has done an absolutely superb job, converting our crude sketches and charts into excellent figures or tables. He also added value by creating drawings to illustrate the text at his own initiative. As a real world practicing maintenance manager, his comments on the chapters were invaluable. My friend Narmada Guruswamy helped design the cover pages separating the six main parts of the book.
The International Labour Office in Geneva gave us permission to use two tables and three charts from an excellent reference book entitled Introduction to Work Studyiii published by them. Mr. Peter Morgon of Lithgow & Associates and MPI Publications, publishers of Fitz’s Atlasiv, very kindly agreed to our reproducing graphical coating breakdown standards from their book.
Earlier I have had the pleasure of working with the team from Industrial Press Inc., the publishers of this book. Janet Romano designed the cover and provided much needed support with the publication and printing, and Suzanne Remore kept us on our toes in meeting schedules. Patrick Hansard is a pleasure to work with and a great person to handle sales and marketing. I have known John Carleo, the Director of Publications, for over three years. He has been a friend, philosopher and guide, and an enthusiastic supporter. In practical terms, this meant fast responses to my queries and requests, and guidance in all aspects of publication.
Christine Wardhaugh, Madhu Das, and my wife Lata have been ever so patient and tolerant with the three of us. Both Christine and Madhu accused me of being a slave driver. Lata came to my support, saying I was both a slave and a slave driver!
Mahen, Jim, and I are grateful to all of these wonderful people.
References
| i | Deming, W. Edwards. 2000. Out of Crisis. Cambridge: MIT Press. ISBN:026 254 1157. |
| ii | Latino, R.J. and K.Latino. 2002. Root Cause Analysis: Improving Performance for Bottom-Line Results. Boca Raton: CRC Press. ISBN: 084 931 318X. |
| iii | Kanawaty, G., ed. 1992. Introduction to Work Study. 4th (revised) ed. Geneva: ILO Publications. ISBN: 92-2-107108-1. |
| iv | Weatherhead, Roger and Peter Morgan, Lithgow & Associates, ed. Fitz’s Atlas™ of Coating Defects. Surrey: MPI Publications. ISBN: 0 9513940 2 9. URL: http://www.mpigroup.co.uk/fitzs-atlas.asp |
Author: V. Narayan
We, the three authors—Jim Wardhaugh, Mahen Das, and Vee Narayan—have worked in a number of locations around the world. In this chapter, we will describe each location briefly so that you have an overview of the sites and get an idea of the facilities and prevailing culture. In the chapters that follow, we will refer to these locations by their reference number. Please see the relevant section here before proceeding to the chapter you wish to read.
2.1 Locations in the Middle East and South Asia
2.1.1 Facility: Pharmaceutical Plant
This small company made a range of over-the-counter drugs. The main products were throat lozenges, pain-relief balms, and tablets for relief from colds and headaches. They also produced