Essential First Aid Skills for Maintenance Workers
Essential First Aid Skills for Maintenance Workers
Steven Cumper, B.App.Sc. (Osteo.), M.Ost.
Posted 5/2/2024
Introduction – First Aid for Maintenance Workers
When it comes to maintenance, you’ve got your hands full keeping everything in working order. Not to mention the meticulous records you have to keep, or the late hours you spend working emergency calls.
On top of all of that, there is an element of safety and injury prevention that has to be at the forefront of your mind at all times, and it can be hard to keep track of everything you need to know. You can’t afford to be off your game, or there could be serious consequences.
That’s why having a thorough understanding of what first aid skills for maintenance workers look like and why they matter is so critical. While the hope is that you never have to use the knowledge, it can be the difference between life and death in an urgent situation.
Understanding the Importance of First Aid in Maintenance Settings
OSHA sets specific requirements for maintenance workers because they recognize that there are inherent risks in the job. Because of the kinds of equipment and tools that maintenance workers use and the types of hazardous conditions you often have to work in, it’s important that you have a good understanding of first aid concepts.
Failing to stay up to date on first aid recommendations and procedures is dangerous and could cost you or your team members in an emergency.
Common Injuries and Emergencies Faced by Maintenance Workers
Depending on your sector, some injuries are more common than others for maintenance workers. For example, a janitor might be prone to slips and falls, while an electrician might be more likely to deal with electrocution. Take a look at some of the types of injuries that are common in maintenance professions.
Burns
When dealing with equipment that can get hot, burns are a serious risk. Having the right supplies to treat burns, including burn cream and bandages, can help with the immediate pain of a burn.
Chemical Exposure
Maintenance workers like janitors, plant workers, and building managers may be exposed to harsh and dangerous chemicals on the job. These can be harmful if ingested or if they get in the eyes or on the skin. Make sure your first aid kit includes an eyewash solution that can help protect your eyes from further injury in the event of a splash.
Slips and Falls
No matter what kind of maintenance you do, slips and falls are a hazard. Janitors and building maintenance workers who have to walk over slick floors are at a particularly high risk. Falls can cause bruising, sprains, and even fractures or head injuries.
Electric Shock
For electricians and building managers, or any maintenance worker who comes into contact with electricity at work, electric shock is a real hazard. This can be extremely serious and even lead to death if not dealt with appropriately. Sometimes, CPR is necessary to be administered after someone has been shocked.
Broken Bones
There’s not much you can do for a broken bone until you can get to a hospital, but there are some things you can do to help mitigate the pain caused by these fractures. Ice (check your first aid kit for instant ice packs), stopping bleeding, and getting the injured person into a still position can help prevent further damage.
Lacerations
Lacerations sometimes require sutures, which you won’t have in your first aid kit. But for smaller cuts or while you wait on an ambulance, you can apply pressure to stop bleeding and use bandages to prevent anything from getting into the wound.
Basic First Aid Techniques Every Maintenance Professional Should Know
While there are many important techniques to learn in order to be able to administer first aid effectively, these are some of the most critical:
CPR
If you haven’t gotten CPR certified, make that a priority and take care of it as soon as possible. Every maintenance worker should be able to confidently perform CPR in case of an emergency that causes someone’s heart to stop. This can happen from electric shock, heart attacks, and even severe injury.
Using a Tourniquet
If severe bleeding is happening as a result of a workplace injury, you need to know how to stop it. Your first aid kit should include a tourniquet, which can be used to stop serious bleeding. Machine-related injuries that may include severed digits or limbs can cause excessive blood loss that can be prevented with a proper tourniquet.
Treating Burns
Burns are tricky because it is not always easy to tell which ones need emergency treatment and which ones are surface-level. When in doubt, it’s always best to call for help. In the meantime, you’ll need to know how to treat the burn to help with any pain and prevent scarring as much as possible.
Essential First Aid Supplies for Maintenance Teams
Do you know what is in your workplace’s first aid kit? If you haven’t looked it over recently, it’s a good idea to familiarize yourself with the essential first aid kit supplies you have available if an injury were to occur at work.
A great first-aid kit includes an assortment of clean, unexpired supplies that can treat minor injuries, or help buy time until help arrives for more serious ones. Your first aid kit should include these basic items:
Bandages
Gauze
Gloves
Alcohol wipes
Eyewash solution
Antibiotic ointment
Acetaminophen or ibuprofen
Aspirin
Depending on where you work, more items may be recommended for your kit. That’s because different types of injuries are more common in different environments.
Conclusion: Empowering Maintenance Workers with Life-Saving Skills
First aid for maintenance workers is more than a set of skills; it is life-saving information that can make a difference in your life, or that of a coworker. Proper training and preparedness are essential to worker safety. Since maintenance workers are at particular risk for workplace injuries, it’s critical that you know what to do when someone gets hurt.
Steven Cumper
Steven John Cumper, B.App.Sc. (Osteo.), M.Ost., is a businessman with a strong background in biomedical science and osteopathic medicine. He founded Medshop while studying at RMIT University in Australia, expanding its reach to markets in Papua New Guinea, Singapore, and Malaysia. In September 2021, the Bunzl Group acquired a majority stake in Medshop, but Cumper remains involved as the Managing Director (Medshop Group). His journey from Zimbabwe to the UK and Australia reflects his dedication to academia and entrepreneurship, combining diverse knowledge and experience.
On the job accidents and injuries are most often a result of negligence and unsafe working conditions. In an effort to protect workers, the Occupational Safety and Health Administration (OSHA), created standards 1910.132 and 1910.133, to address requirements for providing Personal Protective Equipment (PPE) and eye protection in the workplace. However, most employers find it hard to sort through the standards to get to the heart of what they really mean in everyday life.
On the job accidents and injuries are most often a result of negligence and unsafe working conditions. In an effort to protect workers, the Occupational Safety and Health Administration (OSHA), created standards 1910.132 and 1910.133, to address requirements for providing Personal Protective Equipment (PPE) and eye protection in the workplace. However, most employers find it hard to sort through the standards to get to the heart of what they really mean in everyday life.
Significant engineering and test efforts
have been undertaken in the last few years into the area of arc flash/blast hazards in electrical equipment. The result has been a better understanding of arcing faults and how to prevent and/or minimize the hazards to personnel and equipment. This paper highlights some of the findings that may help in safety management and equipment selection. This paper concludes with some design considerations that will help reduce the hazards of arcing faults.
Significant engineering and test efforts
have been undertaken in the last few years into the area of arc flash/blast hazards in electrical equipment. The result has been a better understanding of arcing faults and how to prevent and/or minimize the hazards to personnel and equipment. This paper highlights some of the findings that may help in safety management and equipment selection. This paper concludes with some design considerations that will help reduce the hazards of arcing faults.
There are three basic electrical hazards that cause injury and death: shock, arc-flash, and arc-blast. Following these safety principles can result in a safer work environment and prevent injuries or even death.
There are three basic electrical hazards that cause injury and death: shock, arc-flash, and arc-blast. Following these safety principles can result in a safer work environment and prevent injuries or even death.
It's hard to imagine belt conveyors anywhere playing a more important role than at South Africa's Kendal Power Station. Here, the world's largest black-coal-fired electrical generating complex converts up to 1.4 million tons a month into more than 4100 megawatts, enough to supply three cities the size of nearby greater Johannesburg.
It's hard to imagine belt conveyors anywhere playing a more important role than at South Africa's Kendal Power Station. Here, the world's largest black-coal-fired electrical generating complex converts up to 1.4 million tons a month into more than 4100 megawatts, enough to supply three cities the size of nearby greater Johannesburg.
In 2001, close to 100,000 people were treated in U.S. Hospital emergency rooms for eye injuries related to the workplace, yet this figure actually only represents a small portion of the total number of injuries. According to the U.S. Bureau of Labor Statistics, each day, as many as 2,000 workers incur eye injuries related to their jobs. According to Prevent Blindness America (PBA), 90% of these injuries are preventable.
In 2001, close to 100,000 people were treated in U.S. Hospital emergency rooms for eye injuries related to the workplace, yet this figure actually only represents a small portion of the total number of injuries. According to the U.S. Bureau of Labor Statistics, each day, as many as 2,000 workers incur eye injuries related to their jobs. According to Prevent Blindness America (PBA), 90% of these injuries are preventable.
In this advisory, we are going to demonstrate how hazardous, documented, service, repair, and troubleshooting recommendations have proliferated the fluid power industry, leaving unsuspecting persons vulnerable to possible injury or death. Unsafe service, repair, and troubleshooting recommendations are running rampant throughout the fluid power industry - and there is no end in sight!
In this advisory, we are going to demonstrate how hazardous, documented, service, repair, and troubleshooting recommendations have proliferated the fluid power industry, leaving unsuspecting persons vulnerable to possible injury or death. Unsafe service, repair, and troubleshooting recommendations are running rampant throughout the fluid power industry - and there is no end in sight!
About 80 percent of maintenance mistakes involve human factors (HF), according to the Federal Aviation Administration. The maintenance world has unique HF issues that are more severe and longer lasting than elsewhere in aviation. Operators are looking at various techniques to combat HF challenges.
About 80 percent of maintenance mistakes involve human factors (HF), according to the Federal Aviation Administration. The maintenance world has unique HF issues that are more severe and longer lasting than elsewhere in aviation. Operators are looking at various techniques to combat HF challenges.
Hydraulic systems must store fluid under high pressure. Three kinds of hazards exist: burns from the hot, high pressure spray of fluid; bruises, cuts or abrasions from flailing hydraulic lines; and injection of fluid into the skin. Safe hydraulic system performance requires general maintenance. Proper coupling of high and low pressure hydraulic components and pressure relief valves are important safety measures.
Hydraulic systems must store fluid under high pressure. Three kinds of hazards exist: burns from the hot, high pressure spray of fluid; bruises, cuts or abrasions from flailing hydraulic lines; and injection of fluid into the skin. Safe hydraulic system performance requires general maintenance. Proper coupling of high and low pressure hydraulic components and pressure relief valves are important safety measures.
When a piece of production machinery broke down at the Whirlpool plant in Findlay, Ohio, several years back, it was accepted practice for the machine operator to call maintenance and then sit back and wait for the problem to be fixed. Critical information and knowledge was not shared between the operator and maintenance technician. Like many companies, these workers were stuck in traditional roles - operators run the machines, maintenance fixes the machines, and the two do not cross. As a result, productivity opportunities were missed.
When a piece of production machinery broke down at the Whirlpool plant in Findlay, Ohio, several years back, it was accepted practice for the machine operator to call maintenance and then sit back and wait for the problem to be fixed. Critical information and knowledge was not shared between the operator and maintenance technician. Like many companies, these workers were stuck in traditional roles - operators run the machines, maintenance fixes the machines, and the two do not cross. As a result, productivity opportunities were missed.
I use the term RCPE because it is a waste of good initiatives and time to only find the root cause of a problem, but not fixing it. I like to use the word problem; a more common terminology is Root Cause Failure Analysis (RCFA), instead of failure because the word failure often leads to a focus on equipment and maintenance. The word problem includes all operational, quality, speed, high costs and other losses. To eliminate problems is a joint responsibility between operations, maintenance and engineering.
I use the term RCPE because it is a waste of good initiatives and time to only find the root cause of a problem, but not fixing it. I like to use the word problem; a more common terminology is Root Cause Failure Analysis (RCFA), instead of failure because the word failure often leads to a focus on equipment and maintenance. The word problem includes all operational, quality, speed, high costs and other losses. To eliminate problems is a joint responsibility between operations, maintenance and engineering.
Hour after hour, in businesses of all sizes, these workhorses respond to the men and women who operate them – by pounding, cutting, crushing, welding, stitching or whatever other task they were designed for, to fashion the products that will be marketed to hungry consumers. But there is a fearful downside to this scenario: the machine cannot distinguish between a piece of wood, steel or fabric and the operator’s body.
Hour after hour, in businesses of all sizes, these workhorses respond to the men and women who operate them – by pounding, cutting, crushing, welding, stitching or whatever other task they were designed for, to fashion the products that will be marketed to hungry consumers. But there is a fearful downside to this scenario: the machine cannot distinguish between a piece of wood, steel or fabric and the operator’s body.
Because maintenance departments are often recognized as caretakers of company safety initiatives, they're inundated with all things safety: messages, procedures, meetings, checks, equipment, training and permits, etc. Despite their good intentions, however, some maintenance professionals still get hurt on the job. To understand why, we need only to draw a parallel with automobile accidents.
Because maintenance departments are often recognized as caretakers of company safety initiatives, they're inundated with all things safety: messages, procedures, meetings, checks, equipment, training and permits, etc. Despite their good intentions, however, some maintenance professionals still get hurt on the job. To understand why, we need only to draw a parallel with automobile accidents.
Work-related deaths at U.S. manufacturing plants declined 14.0 percent in 2007, marking a rebound from the 16.0 percent increase that occurred in 2006. This was among the findings of the new Census of Fatal Occupational Injuries report released recently by the U.S. Department of Labor's Bureau of Labor Statistics.
Work-related deaths at U.S. manufacturing plants declined 14.0 percent in 2007, marking a rebound from the 16.0 percent increase that occurred in 2006. This was among the findings of the new Census of Fatal Occupational Injuries report released recently by the U.S. Department of Labor's Bureau of Labor Statistics.
For management, new and untrained employees present a different set of costly challenges. For example, productivity will drop due to lost time, there may be overtime expenses, insurance costs will rise and there can be potential lost customer sales. Worker's compensation claims will also increase and lead to higher premiums. How can these problems be avoided? What are some steps that can be put in place to help alleviate these concerns for new and untrained workers already in the workforce? Ideally, health and safety programs that offer basic training will fit the bill quite nicely. New and untrained workers need to learn about personal protective equipment (PPE), back-injury prevention, health and safety regulations and hazard recognition.
For management, new and untrained employees present a different set of costly challenges. For example, productivity will drop due to lost time, there may be overtime expenses, insurance costs will rise and there can be potential lost customer sales. Worker's compensation claims will also increase and lead to higher premiums. How can these problems be avoided? What are some steps that can be put in place to help alleviate these concerns for new and untrained workers already in the workforce? Ideally, health and safety programs that offer basic training will fit the bill quite nicely. New and untrained workers need to learn about personal protective equipment (PPE), back-injury prevention, health and safety regulations and hazard recognition.
The challenge of managing the aspects of occupational health and safety (OH&S) in the workplace can often times feel overwhelming. There are many legal, moral and financial reasons for you to pay attention to OH&S obligations. With all of these challenges, it's important not to waste time, money or place efforts on things that simply don't work. In terms of successfully managing OH&S issues, the following Top 10 list includes some of the common errors that organizations make.
The challenge of managing the aspects of occupational health and safety (OH&S) in the workplace can often times feel overwhelming. There are many legal, moral and financial reasons for you to pay attention to OH&S obligations. With all of these challenges, it's important not to waste time, money or place efforts on things that simply don't work. In terms of successfully managing OH&S issues, the following Top 10 list includes some of the common errors that organizations make.
The issuance of safety eyewear to employees requires more than a handout. An important thing to remember when issuing safety eyewear is that in order to put your safety program into action, you need to communicate and educate your employees. Merely handing out free safety goggles and glasses and saying "wear these when you are working or else..." will only get you so far. Employees need to know why it is important to wear protective eyewear, and they need you to make it easy for them to do so effectively. It often helps to recite employee eye injury statistics to show workers the reality of the hazards around them, and give them a starting point for improvement.
The issuance of safety eyewear to employees requires more than a handout. An important thing to remember when issuing safety eyewear is that in order to put your safety program into action, you need to communicate and educate your employees. Merely handing out free safety goggles and glasses and saying "wear these when you are working or else..." will only get you so far. Employees need to know why it is important to wear protective eyewear, and they need you to make it easy for them to do so effectively. It often helps to recite employee eye injury statistics to show workers the reality of the hazards around them, and give them a starting point for improvement.
With literally thousands of dangerous materials being used/transported/discarded every day, the process of choosing protective clothing has become increasingly complex for today's safety and hygiene professional. It is important to understand the distinction between three broad types of protective garments used today. Generally classified as disposable, reusable, and limited-use garments, these three general categories provide a basic framework for clothing decisions.
With literally thousands of dangerous materials being used/transported/discarded every day, the process of choosing protective clothing has become increasingly complex for today's safety and hygiene professional. It is important to understand the distinction between three broad types of protective garments used today. Generally classified as disposable, reusable, and limited-use garments, these three general categories provide a basic framework for clothing decisions.
When we have catastrophic events such as the club fire in RI, the inspection process that allowed code violations to go uncorrected for two years needs to be revisited. Many inspectors view their daily work in a way that results in the low hanging fruit getting picked, but the more difficult to reach fruit on high branches going untouched. When an agency is responsible for inspections for compliance with safety, health, fire and/or environmental standards there needs to be a meaningful quality control or improvement program in place. Citizens or your community deserve no less.
When we have catastrophic events such as the club fire in RI, the inspection process that allowed code violations to go uncorrected for two years needs to be revisited. Many inspectors view their daily work in a way that results in the low hanging fruit getting picked, but the more difficult to reach fruit on high branches going untouched. When an agency is responsible for inspections for compliance with safety, health, fire and/or environmental standards there needs to be a meaningful quality control or improvement program in place. Citizens or your community deserve no less.
Republic Windows & Doors transformed their plant safety for the sake of their workers. By implementing 3 "outs" they were able to make significant safety gains in just a few short years, even with high turnover rates and unskilled labor. If they can improve safety and job quality at the same time, so can you!
Republic Windows & Doors transformed their plant safety for the sake of their workers. By implementing 3 "outs" they were able to make significant safety gains in just a few short years, even with high turnover rates and unskilled labor. If they can improve safety and job quality at the same time, so can you!
The notions "one tool does all" or "any tool will do" result in wasted effort, poor quality work, damage to the misused tool, and exposing the user to possible injury, according to the Hand Tools Institute, an association of American manufacturers of quality hand tools. As with hammers, pliers, wrenches and all other hand tools, design is a key element to the type of work a tool is intended to do properly and safely, says HTI. Clamps are no exception and should be selected to conform to the work they are to perform.
The notions "one tool does all" or "any tool will do" result in wasted effort, poor quality work, damage to the misused tool, and exposing the user to possible injury, according to the Hand Tools Institute, an association of American manufacturers of quality hand tools. As with hammers, pliers, wrenches and all other hand tools, design is a key element to the type of work a tool is intended to do properly and safely, says HTI. Clamps are no exception and should be selected to conform to the work they are to perform.
The potential-to-functional failure interval (P-F interval) is one of the most important concepts when it comes to performing Reliability-Centered Maintenance (RCM). Remarkably, the P-F interval is also one of the most misunderstood RCM concepts. The failure mode analysis becomes even more complicated when you are dealing with several P-F intervals for one failure mode. This paper will help clarify the P-F interval and the decision-making process when dealing with multiple P-F intervals.
The potential-to-functional failure interval (P-F interval) is one of the most important concepts when it comes to performing Reliability-Centered Maintenance (RCM). Remarkably, the P-F interval is also one of the most misunderstood RCM concepts. The failure mode analysis becomes even more complicated when you are dealing with several P-F intervals for one failure mode. This paper will help clarify the P-F interval and the decision-making process when dealing with multiple P-F intervals.
Reactive maintenance is here defined as all maintenance work that was scheduled less than 20 hours before it was executed. It makes sense that there is a strong correlation between safety incidents, injuries and reactive maintenance. In a reactive situation you might not take the time you should to plan and think before you take action. The urgency also call out the so common hero in maintenance crafts people and they take risks they should not take.
Reactive maintenance is here defined as all maintenance work that was scheduled less than 20 hours before it was executed. It makes sense that there is a strong correlation between safety incidents, injuries and reactive maintenance. In a reactive situation you might not take the time you should to plan and think before you take action. The urgency also call out the so common hero in maintenance crafts people and they take risks they should not take.
Life without standards would result in near chaos for both manufactures and consumers. Just think if you could not rely on the strength of a critical fastener in an aircraft fuselage, the quality of the glass in a high rise building, the voltage fluctuation of the electrical grid at a faraway vacation destination, a crucial replacement for an electrical motor, the purity of a critical medication or the mere annoyance of not finding a correct battery for that digital camera. In short, as consumers, we would soon notice the lack of standards when the safety, quality, fit, reliability and compatibility of the products we consume, purchase and rely on are compromised.
Life without standards would result in near chaos for both manufactures and consumers. Just think if you could not rely on the strength of a critical fastener in an aircraft fuselage, the quality of the glass in a high rise building, the voltage fluctuation of the electrical grid at a faraway vacation destination, a crucial replacement for an electrical motor, the purity of a critical medication or the mere annoyance of not finding a correct battery for that digital camera. In short, as consumers, we would soon notice the lack of standards when the safety, quality, fit, reliability and compatibility of the products we consume, purchase and rely on are compromised.
“Prevention is better than cure”, this proverb sounds rightly in case of maintenance also. If the maintenance is prevented, then the availability of the plant increases and the overall cost reduces. Every effort should be made to avoid maintenance, which can be achieved through continuous monitoring of equipment and upgrading the sophistication of the equipment through better design and process improvement.
“Prevention is better than cure”, this proverb sounds rightly in case of maintenance also. If the maintenance is prevented, then the availability of the plant increases and the overall cost reduces. Every effort should be made to avoid maintenance, which can be achieved through continuous monitoring of equipment and upgrading the sophistication of the equipment through better design and process improvement.
ISO 12100 is a fundamental safety standard being developed that will apply to a very broad array of machinery. There are many machines that have specific industry consensus standards that pertain to the particular equipment (e.g., power presses, robots, packaging machinery). There are many more machines for which no industry specific standard exists. In this case, the ISO “A level” standard ISO 12100 Safety of Machinery applies. Complying with the requirements of ISO 12100 is a critical first step in achieving mobility of equipment and consistent operations.
ISO 12100 is a fundamental safety standard being developed that will apply to a very broad array of machinery. There are many machines that have specific industry consensus standards that pertain to the particular equipment (e.g., power presses, robots, packaging machinery). There are many more machines for which no industry specific standard exists. In this case, the ISO “A level” standard ISO 12100 Safety of Machinery applies. Complying with the requirements of ISO 12100 is a critical first step in achieving mobility of equipment and consistent operations.
We as safety professionals aren't exempt. Have you seen this: Workers don't change their actions? Tell them again (with a why-didn't-you-listen undertone). Policies and procedures not followed? Write additional (and more detailed) rules. Training didn't change their behavior? Put them through the same training again and again (until they "get it"). Try, try, try again to solve safety problems, but don't confuse persistence with obstinancy.
We as safety professionals aren't exempt. Have you seen this: Workers don't change their actions? Tell them again (with a why-didn't-you-listen undertone). Policies and procedures not followed? Write additional (and more detailed) rules. Training didn't change their behavior? Put them through the same training again and again (until they "get it"). Try, try, try again to solve safety problems, but don't confuse persistence with obstinancy.
Certified mail has arrived. The letter carrier isn't Ed McMahon. Uh Oh! It's a citation package from the USDOL/OSHA. What do you do? You glance at the paperwork to be sure it really relates to an OSHA inspection at one of your sites. You notice some rather heavy penalties. You are shocked, irate and feel as if you've been branded "corporate slime." You try to convince yourself that you've been in lots of workplaces that are more dangerous than yours. You need this like a centipede needs sore feet. Options pop through you mind.
Certified mail has arrived. The letter carrier isn't Ed McMahon. Uh Oh! It's a citation package from the USDOL/OSHA. What do you do? You glance at the paperwork to be sure it really relates to an OSHA inspection at one of your sites. You notice some rather heavy penalties. You are shocked, irate and feel as if you've been branded "corporate slime." You try to convince yourself that you've been in lots of workplaces that are more dangerous than yours. You need this like a centipede needs sore feet. Options pop through you mind.
As many of us strive to improve the reliability of our plants, several comments bemoan how challenging that is to do in an era of continuous deep cost cutting. They say that in their operation, maintenance is seen as a cost, and is one of the first things to arbitrarily cut. Some think their operations have cut too far! What they seek is a way to justify a strong maintenance capability. I submit that one approach is to speak of maintenance as an “investment in capacity.” Use the language that plant managers, controllers and senior management understands: capital investment and return on investment (ROI).
As many of us strive to improve the reliability of our plants, several comments bemoan how challenging that is to do in an era of continuous deep cost cutting. They say that in their operation, maintenance is seen as a cost, and is one of the first things to arbitrarily cut. Some think their operations have cut too far! What they seek is a way to justify a strong maintenance capability. I submit that one approach is to speak of maintenance as an “investment in capacity.” Use the language that plant managers, controllers and senior management understands: capital investment and return on investment (ROI).
"Listen: I’m a mechanic, not a clerk. Do you want me to do the work OR fill out these work orders? If I wasted all that time filling in those silly blanks on your paperwork I’d never get caught up! Besides, I don’t know why we need ‘em anyway. Let’s just do the work like we’ve always done.” Sound familiar? Maintenance work orders are often seen as an extra burden to the maintainers as well as those who are requesting the work to start with. “Paperwork. Needless paperwork. That’s all it really is anyway. I just want to call the mechanic and get this work done fast!” But without work order history, the maintenance organization is at risk and equipment problems will likely worsen.
"Listen: I’m a mechanic, not a clerk. Do you want me to do the work OR fill out these work orders? If I wasted all that time filling in those silly blanks on your paperwork I’d never get caught up! Besides, I don’t know why we need ‘em anyway. Let’s just do the work like we’ve always done.” Sound familiar? Maintenance work orders are often seen as an extra burden to the maintainers as well as those who are requesting the work to start with. “Paperwork. Needless paperwork. That’s all it really is anyway. I just want to call the mechanic and get this work done fast!” But without work order history, the maintenance organization is at risk and equipment problems will likely worsen.
The true translation — might it be proper to say a new and improved translation? — is being used today by Cervecería Cuauhtemoc Moctezuma, one of the largest brewers of beer in Latin America. Known throughout this company as Mantenimiento Alto Desempeño (MAD), or translated as High-Performance Maintenance, the concept of TPM is alive and well at the company's six plants in Mexico. Perhaps the best example is at CCM's brewery in Tecate, located a short drive from the U.S.-Mexico border on the Baja California peninsula.
The true translation — might it be proper to say a new and improved translation? — is being used today by Cervecería Cuauhtemoc Moctezuma, one of the largest brewers of beer in Latin America. Known throughout this company as Mantenimiento Alto Desempeño (MAD), or translated as High-Performance Maintenance, the concept of TPM is alive and well at the company's six plants in Mexico. Perhaps the best example is at CCM's brewery in Tecate, located a short drive from the U.S.-Mexico border on the Baja California peninsula.
A chaotic or traumatic event can happen to anyone at any time or place. Would you be ready if it happened to you? Anything that threatens your sense of safety and security either physically or mentally can be considered a traumatic event. How well you respond to and recover from such events primarily depends on your overall state of well-being. Let's look at ways to develop the Internal Resources and External Resources you need to put yourself in the best possible position to deal with chaotic events.
A chaotic or traumatic event can happen to anyone at any time or place. Would you be ready if it happened to you? Anything that threatens your sense of safety and security either physically or mentally can be considered a traumatic event. How well you respond to and recover from such events primarily depends on your overall state of well-being. Let's look at ways to develop the Internal Resources and External Resources you need to put yourself in the best possible position to deal with chaotic events.
For the most part, we can describe in fairly exacting detail the functional components of a strong reliability program. Moreover, we are confident that implementing these reliability practices will yield results that benefit virtually every aspect of our business and provide distinct competitive advantage. However, we seldom see these reliability practices and results in an operating plant. This is what I call the Reliability Paradox.
For the most part, we can describe in fairly exacting detail the functional components of a strong reliability program. Moreover, we are confident that implementing these reliability practices will yield results that benefit virtually every aspect of our business and provide distinct competitive advantage. However, we seldom see these reliability practices and results in an operating plant. This is what I call the Reliability Paradox.
When a firm makes the decision to divest of a plant, management immediately begins to take actions to increase the perceived value of the asset. Just as an individual thoroughly cleans and details an automobile before putting it up for sale, plant owners want to make the plant look as good as possible to drive up the prospective buyer's perceived value of the plant or to cover "warts" that suitors might view as liabilities - a practice commonly referred to as "window dressing." Some of these window dressings can have an adverse impact on the reliability of the plant, thus reducing the plant's true value, which, unfortunately, won't be felt for months or years after you've bought the plant.
When a firm makes the decision to divest of a plant, management immediately begins to take actions to increase the perceived value of the asset. Just as an individual thoroughly cleans and details an automobile before putting it up for sale, plant owners want to make the plant look as good as possible to drive up the prospective buyer's perceived value of the plant or to cover "warts" that suitors might view as liabilities - a practice commonly referred to as "window dressing." Some of these window dressings can have an adverse impact on the reliability of the plant, thus reducing the plant's true value, which, unfortunately, won't be felt for months or years after you've bought the plant.
This column is likely to create a lot of reactions from the academia of reliability and maintenance management, and all comments are welcome. Reliability Centered Maintenance (RCM) has its place, but many times plants jump into training programs and attempt to implement RCM long before they are ready for it. This application makes RCM more of a trap, than a helpful tool to implement.
This column is likely to create a lot of reactions from the academia of reliability and maintenance management, and all comments are welcome. Reliability Centered Maintenance (RCM) has its place, but many times plants jump into training programs and attempt to implement RCM long before they are ready for it. This application makes RCM more of a trap, than a helpful tool to implement.
