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The true cost of poor quality | Hydrocarbon Processing | April 2015. Good article on using RCA to drive production/operations improvement.
At many installations a significant level of effort is provided by the external resources of maintenance and reliability consultants.
‘Bucket’ work orders for recording hours are a sure indicator/sign of business process failure around the CMMS. These buckets of time fulfil a misplaced management need to account for the billing of maintenance hours, even though there is no evidence
The upside of condition-based monitoring and digital control systems is that they are proactive in preventing failure but the downside is they frequently mask the cause of failures. These near misses should be treated as failures and analysed as such.
The Big Picture – to get the big picture of events over time you need to obtain and analyse a lot of data from a number of different sources, CMMS, condition monitoring, SCADA, DCS, Production reporting. It is always difficult
There is a lot of interesting discussion and theory around staff resistance to maintenance program initiatives regarding buy-in, training and supporting the maintenance program, however I think the simple insight is that the Supervisors and Technicians have seen it all