Comments on: The use of equipment checklists - an emotion-packed discussion http://blogs.reliableplant.com/490/equipment-checklists/ Blogs from ReliablePlant.com Thu, 18 Mar 2010 01:29:57 +0000 http://wordpress.org/?v=2.6.3 By: Carl http://blogs.reliableplant.com/490/equipment-checklists/#comment-5379 Carl Thu, 20 Aug 2009 06:39:19 +0000 http://blogs.reliableplant.com/?p=490#comment-5379 Very interesting discussion here, tackling exactly one of the issues im dealing with right now. Im freshly graduated from university and have taken the role of maintenance engineer in a rapidly growing company. We comlpeted our third factory last year and by the end of the year we should have our 4th up and running. I am all for the checklist mentality because even in my little experience (3 years) I have seen several hours wasted a week from incorrect settings, incomplete assemblies etc. However my dilemma is how to implement these checklists and what to do with them. I will have to resort to the more experienced operators to be able to get a complete list for each machine and obviously add my own input with regards to good practice. I've won the management over with this idea just by showing them the figures of down time but now im at the critical stage of kick starting this new procedure. I like the laminated checklist and grease pencil idea, ive used it in other places and it works. However are the operators simply expected to tick off what they have done? Will this then hold them responsible? The feeling I have gotten from the operators is that these checklists will be simply a measure for management to "cover their asses" and be able to pin the blame on the "poor operator" in the event of an oversight. Another dilemma is whether i should believe the system i develop is good and implement it throughout the facilities or should i test run it on a couple of production lines? Both have their pros and cons... I'd like to draw on your years of experience to help me out here! We do learn from our mistakes but im a firm believer of learning from others' mistakes too! Thanks Very interesting discussion here, tackling exactly one of the issues im dealing with right now. Im freshly graduated from university and have taken the role of maintenance engineer in a rapidly growing company. We comlpeted our third factory last year and by the end of the year we should have our 4th up and running.
I am all for the checklist mentality because even in my little experience (3 years) I have seen several hours wasted a week from incorrect settings, incomplete assemblies etc. However my dilemma is how to implement these checklists and what to do with them. I will have to resort to the more experienced operators to be able to get a complete list for each machine and obviously add my own input with regards to good practice. I’ve won the management over with this idea just by showing them the figures of down time but now im at the critical stage of kick starting this new procedure. I like the laminated checklist and grease pencil idea, ive used it in other places and it works. However are the operators simply expected to tick off what they have done? Will this then hold them responsible? The feeling I have gotten from the operators is that these checklists will be simply a measure for management to “cover their asses” and be able to pin the blame on the “poor operator” in the event of an oversight.
Another dilemma is whether i should believe the system i develop is good and implement it throughout the facilities or should i test run it on a couple of production lines? Both have their pros and cons…
I’d like to draw on your years of experience to help me out here! We do learn from our mistakes but im a firm believer of learning from others’ mistakes too!
Thanks

]]> By: TimT http://blogs.reliableplant.com/490/equipment-checklists/#comment-4569 TimT Fri, 24 Jul 2009 15:50:22 +0000 http://blogs.reliableplant.com/?p=490#comment-4569 Very good discussion. Coming from a military background working on fighter jet engines, we always used checklist then had a inspector go over our work. I'm trying to push checklist now and it is hard for most because they never had it. Biggest response is "I've been doing this for over 30 years" Managment and Supervisors need not just a buy in, but actually be trained thereselves to understand the importance so that it's not just a "temporary fix" but something that has to stay, has to be continuously monitored and improved, just like reliability and training.(which is another story) I've been doing this kind of work for over 35+ years and it's really sad to see how our "craftmenship" is steadilty declining. So many people just come to work, do their time and go home.(kinda like prisoners) Our craft Pride is dying so it up to people like you to keep these blogs going. Maybe through this we can keep our jobs at home. Very good discussion. Coming from a military background working on fighter jet engines, we always used checklist then had a inspector go over our work. I’m trying to push checklist now and it is hard for most because they never had it. Biggest response is “I’ve been doing this for over 30 years” Managment and Supervisors need not just a buy in, but actually be trained thereselves to understand the importance so that it’s not just a “temporary fix” but something that has to stay, has to be continuously monitored and improved, just like reliability and training.(which is another story) I’ve been doing this kind of work for over 35+ years and it’s really sad to see how our “craftmenship” is steadilty declining. So many people just come to work, do their time and go home.(kinda like prisoners) Our craft Pride is dying so it up to people like you to keep these blogs going. Maybe through this we can keep our jobs at home.

]]> By: Dibyendu Mukherjee http://blogs.reliableplant.com/490/equipment-checklists/#comment-3404 Dibyendu Mukherjee Wed, 03 Jun 2009 15:21:30 +0000 http://blogs.reliableplant.com/?p=490#comment-3404 Most important thing about check list is that it enables condition based maitenance( and avoid time based maitenance), also reduce cost of maitenance. It also enable one to know his/her equipment very well. Most important thing about check list is that it enables condition based maitenance( and avoid time based maitenance), also reduce cost of maitenance. It also enable one to know his/her equipment very well.

]]> By: B D PAWAR http://blogs.reliableplant.com/490/equipment-checklists/#comment-3085 B D PAWAR Mon, 25 May 2009 08:49:04 +0000 http://blogs.reliableplant.com/?p=490#comment-3085 Error in operation or maint. ultimetly results in to loss or waste. It is necessary to have a system that could result in to min. efforts to get maximum output with maximum accurecy. The "Check List" with practicaly important parameters will result in to good outcomes. Most of us fail in preparing correct check list and unable to traind subordinate about importance and use of check list. Needs to prepare interesting check list which shall be usable to improve reliability of equipment in long run. Error in operation or maint. ultimetly results in to loss or waste. It is necessary to have a system that could result in to min. efforts to get maximum output with maximum accurecy. The “Check List” with practicaly important parameters will result in to good outcomes.
Most of us fail in preparing correct check list and unable to traind subordinate about importance and use of check list.

Needs to prepare interesting check list which shall be usable to improve reliability of equipment in long run.

]]> By: john crossan http://blogs.reliableplant.com/490/equipment-checklists/#comment-1068 john crossan Fri, 10 Apr 2009 03:17:19 +0000 http://blogs.reliableplant.com/?p=490#comment-1068 Absolutely. Not an option, and managers and supervisors need to make that clear and actually have to be out there making sure checklists are being used. That's really the only way to do mandatory. It's really just another aspect of safety. But there's always selling. Have to change the attitude that "Real men (and women) don't use checklists". Absolutely. Not an option, and managers and supervisors need to make that clear and actually have to be out there making sure checklists are being used. That’s really the only way to do mandatory. It’s really just another aspect of safety. But there’s always selling. Have to change the attitude that “Real men (and women) don’t use checklists”.

]]> By: Greg Buscarello http://blogs.reliableplant.com/490/equipment-checklists/#comment-1051 Greg Buscarello Thu, 09 Apr 2009 15:58:28 +0000 http://blogs.reliableplant.com/?p=490#comment-1051 I have been teaching alignment (among other subjects) for over 20 years and one of the most important concepts is the pre-alignment checklist. While every student would agree (at least by the end of the class) that such a procedure is a good idea, the percentage of those who will be using it on a regular basis a year later is very small. The difference comes from the expectations of management and supervision. Once they agree that the procedure makes sense and ideally have an input on the details of the list, they need to be told that to skip it is not an option. The buy in from the mechanic must happen first through training and involvement in the process, but after that a clear message must be given that "we're serious about this!" I have been teaching alignment (among other subjects) for over 20 years and one of the most important concepts is the pre-alignment checklist. While every student would agree (at least by the end of the class) that such a procedure is a good idea, the percentage of those who will be using it on a regular basis a year later is very small. The difference comes from the expectations of management and supervision. Once they agree that the procedure makes sense and ideally have an input on the details of the list, they need to be told that to skip it is not an option. The buy in from the mechanic must happen first through training and involvement in the process, but after that a clear message must be given that “we’re serious about this!”

]]> By: Bernie Price http://blogs.reliableplant.com/490/equipment-checklists/#comment-566 Bernie Price Thu, 12 Mar 2009 13:58:08 +0000 http://blogs.reliableplant.com/?p=490#comment-566 I have my clients use hand held data collectors while they are doing field inspections. The DMSI company who makes them, have software which will point to "The Pencil Whippers". It produces reports which condense the results allowing a maintenance or operating manager to see exactly what is happening. The resulting transparancy is the only stick needed. I have my clients use hand held data collectors while they are doing field inspections. The DMSI company who makes them, have software which will point to “The Pencil Whippers”. It produces reports which condense the results allowing a maintenance or operating manager to see exactly what is happening. The resulting transparancy is the only stick needed.

]]> By: Ron B http://blogs.reliableplant.com/490/equipment-checklists/#comment-565 Ron B Thu, 12 Mar 2009 13:31:57 +0000 http://blogs.reliableplant.com/?p=490#comment-565 The routes should have equipment with "I -Buttons" to verify compliance. Data collectors to have ID for route only. Random checks are essential by team leaders. Any variance to normal trends must be checked by another. Publish findings that have "saved" production and cost savings announced. All w.o. follow up to be published and tracked. The routes should have equipment with “I -Buttons” to verify compliance.
Data collectors to have ID for route only.
Random checks are essential by team leaders.
Any variance to normal trends must be checked by another.
Publish findings that have “saved” production and cost savings announced.
All w.o. follow up to be published and tracked.

]]> By: john crossan http://blogs.reliableplant.com/490/equipment-checklists/#comment-536 john crossan Mon, 09 Mar 2009 16:12:06 +0000 http://blogs.reliableplant.com/?p=490#comment-536 Bernie Thanks for bringing up mistake proofing. It's a key part of the ongoing continuous improvement of changeovers and startups. Eliminating adjustments, centerlining to identify repeatable settings that are made simply to fixed stop positions. Visual indicators and color coding to easily determine if things are in the right place. People really get into this and own it. Also just found recently published investigation into the crash of a Marine F18 in San Diego some months back http://www.latimes.com/news/local/la-me-miramar-jet-crash4-2009mar04,0,1947853.story found among other failings (including maintenance) that the pilot and his advisors failed to follow steps in a safety checklist that would have prevented flying a crippled plane over densely populated areas. This has ended the military careers of a number of those responsible and their superiors. (and four people were killed). Bernie
Thanks for bringing up mistake proofing. It’s a key part of the ongoing continuous improvement of changeovers and startups. Eliminating adjustments, centerlining to identify repeatable settings that are made simply to fixed stop positions. Visual indicators and color coding to easily determine if things are in the right place. People really get into this and own it.

Also just found recently published investigation into the crash of a Marine F18 in San Diego some months back
http://www.latimes.com/news/local/la-me-miramar-jet-crash4-2009mar04,0,1947853.story
found among other failings (including maintenance) that the pilot and his advisors failed to follow steps in a safety checklist that would have prevented flying a crippled plane over densely populated areas. This has ended the military careers of a number of those responsible and their superiors. (and four people were killed).

]]> By: Bernie price http://blogs.reliableplant.com/490/equipment-checklists/#comment-494 Bernie price Fri, 06 Mar 2009 05:13:50 +0000 http://blogs.reliableplant.com/?p=490#comment-494 John There is a comprehensive science / methodology called "error proofing" and several companies who are proponents of it. The current if not accepted GURU is professor James Reason of Manchester university but there are many others in the field. You and I arrived at the same point from similar directions......We know that a lack of "Operational Accuracy" is the main road block to achieving "World Class" performance. It is not all the other maintenance related issues we have worked on for so long. regards Bernie Price - Polaris Veritas Inc John

There is a comprehensive science / methodology called “error proofing” and several companies who are proponents of it.

The current if not accepted GURU is professor James Reason of Manchester university but there are many others in the field. You and I arrived at the same point from similar directions……We know that a lack of “Operational Accuracy” is the main road block to achieving “World Class” performance. It is not all the other maintenance related issues we have worked on for so long.

regards

Bernie Price - Polaris Veritas Inc

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