Monday, August 15, 2011

The Basics of Reliability Series: Work Execution

This post is the first in a five part series that will include single point lessons that can be used to further communicate each of the topics to your organization. 

Work execution management is the full process that has to occur from the time a problem is first discovered until it is planned, scheduled, and repaired, failure history is collected, and the work order is closed or completed. This process is the backbone of reliability improvement; without it, it is very hard to see results in most of the other areas. For example, if you implement predictive tools without a good work process, all you get is a lot of identified work with no way of having it completed efficiently and effectively.

 Work Execution Management Single Point Lesson Figure 1

We will use the WE single point lesson (see figure 1), which includes the funnel model for planning and scheduling and the as is and to be reengineered model, to help individuals understand the following key points.
Forecasting work is not easy, but it is a required part of a successful work process.
Work approval processes are important for control of maintenance spending and to ensure best resource utilization.
Ready and Total Backlog concepts help maintenance managers to control staffing decisions with science instead of emotion. Planners and managers must be communicating constantly in order to properly provide for the Ready Backlog.
The funnel model also shows us where in the process we will develop effective work procedures and how we ensure that particular process has the correct inputs.
The WE single point lesson illustrates what the schedule output looks like and what inputs must be provided, including details from both operations and maintenance inputs of resources, downtime, and priority.
Last but not least, it drives the need for the process to ensure nothing is left out or missed. This process reengineering is shown as a big wasteful “as is” block that is refined into the more concise and direct “to be” block. Metrics are used to drive this change and ensure the return on investment.
We get all of this from two simple graphics that you can draw and share in a matter of minutes. 

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