The 15 Most Common Obstacles to World-Class Reliability, A Roadmap for Managers

The 15 Most Common Obstacles to World-Class Reliability
A Roadmap for Managers
Don Nyman
152 Pages, Hardcover
Published: August, 2009

Reliability is dependent upon shared understanding and beliefs. Managers at all levels must understand how their decisions and directions often impact adversely the ability of their organization to achieve and perpetuate Reliability…thereby undermining realization of broad business objectives.

This book identifies and explores fifteen cultural obstacles commonly encountered by most organizations in their pursuit of World-Class Reliability. The intent is to provide senior management with a wake-up call. They must address the identified obstacles the people they have charged with pursuit of reliability (middle managers, engineers and functional specialists) can be successful. Otherwise, senior management is its' own worst enemy. It is a must-read for Senior Managers at all levels (Corporate to Plant and within Plant at Departmental levels).

• Examines the larger issues (culture, leadership, commitment, consistency) that functionaries cannot overcome without strong senior management involvement.
• Focuses on the managerial leadership, cultural change, organization-wide commitment, and perseverance required to transform the operational environment from reactive to proactive.
• Uses illustrations to visually convey Principles and Concepts of Maintenance/Reliability Excellence.
• Includes appendices that provide generic tools and plans used to drive the essential change.


Origin of Identified Obstacles & Insights Presented
Creating a Culture for Reliability

• Obstacle 1: Lack of Understanding, Beliefs and Commitment
• Obstacle 2: Lack of Integrated Missions, Plans, Goals, etc
• Obstacle 3: Emphasis on Cost Reduction vs. Reliability Excellence
• Obstacle 4: Failure to Effect the Cultural Change to Pro-Action
• Obstacle 5: Insufficient Organizational Stability
• Obstacle 6: Lack of Master Plan, Budget and Commitment

Structuring the Maintenance Organization for Reliability

• Obstacle 7: Organized for Reaction to Detriment of Reliability
• Work Type Organizational Structure

Clarifying Required Asset Capacity and Maintenance Workload

• Obstacle 8: No Clear Quantification of Required Asset Capacity
• Obstacle 9: No Clear Quantification of Workload & Required Access

Balancing Maintenance Resources & Workload

• Obstacle 10: Imbalance of Workload and Authorized Resources

Maintenance Skill Requirements

• Obstacle 11: Incumbent Skills Fall Short of Technology Requirements
• Souces of Skilled Technicians
• Education/Trainng Options
• The Skills Training Process
• Pay for Skills

Materials Support

• Obstacle 12: Procurement Focused on Initial Cost; Not Reliability
• Vendor Partnerships

Insufficient Preparation

• Obstacle 13: Planning
• Work Measurement

Insufficient Statement of Expectations

• Obstacle 14: The Coordination Process
• Scheduling
• Schedule Compliance
• Obstacle 15: Insufficient Leadership of Job Execution



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