Helping People Deal With Change
Whether it be in the form of yet another revised policy or procedure to adopt, a new product to make and sell, the latest technology upgrade to learn, a corporate restructuring to figure out (and survive), a new set of job duties to make “happen” – or one of a myriad of other possibilities – continual change is a reality of business life. And can be a painful reality for many people – including the folks who report to us.
Certainly, as leaders, we also are subject to change. And we’re not exempt from the discomfort that comes with it. But we have to get passed that … we need to “suck it up.” We have to focus on our people (rather than ourselves) and be sensitive to their fears, concerns, and needs about stepping out of the comfort zones. Ultimately, we must be facilitators of change – not dictators, nor mere messengers, nor “victims” of it, ourselves. That is what leadership is all about … that’s part of the heat that comes with our leadership kitchens.
HOW TO HELP PEOPLE DEAL WITH CHANGE
• Explain WHY the change is required / necessary
• Describe the expected benefits to be gained ("What’s in it for us")
• Provide training and resources necessary to implement the change
• Solicit / address any employee questions and concerns
• Be patient – expect mistakes as new habits are formed
• And most importantly …
• Demonstrate support and commitment to the change, yourself.

Tip excerpted from LEAD RIGHT: Every Leader’s Straight-Talk Guide to Job Success
By Steve Ventura

Register for the next no travel-no cost Reliability Roadmap Change Management Web Workshop

Thermographers continually face the issues presented by reflection and emissivity. Electrical cabinets are full of different materials of varying emissivity ranging from .95 to 0.15 and these values can change with both age and temperature.
The use of infrared target markers helps to standardize the emissivity and gives a non-reflective target therefore reducing issues caused by reflection. Emissivity targets also give a very useful point of reference for the thermographer and as they can be marked with a unique number are excellent references for the technicians who may have to repair the issues found during the infrared survey.

Find out more information about IRID labels

Cold Weather Battery Maintenance Tip
With winter setting in the cold weather can kill a battery and cause a vehicle not to start. A battery loses 1/3 of its cranking power at 32 degrees Fahrenheit, and at 0 degrees, it has less than half its cranking power. It is a good idea to check the cranking power of the battery prior to installing it and starting the vehicle.

Tip provided by Fred Hiers
Dimension Technology Solutions, Inc.
Englewood, CO

Wrenches, Wrenches, everywhere but not a one that fits:
Here is a simple rule of thumb to determine wrench sizes for heavy hex nuts (ASTM-A194/ANSI-B18.2.2 as an example) or bolts/studs (Example –class 2A UNRC or UNR2A/ ASME B1.1-1989) when you forgot the measuring tape back at the shop or office, but you know the bolt /stud size.
The simple rule of thumb of is to take the bolt / stud size (+) plus half of the stud/bolt size (+) plus 1/8” equals (=) wrench size.
To make this more tangible here are two examples of this rule in practice:
Example for a 1” (inch) heavy hex nut : 1” + ½” (half of stud size) + 1/8” = 1-5/8” wrench
For the lower grades or classes of hex nuts/bolts/studs and some SAE fasteners the same rule of thumb applies except omit the 1/8”.
Example for a 1” (inch) standard/lower grade nut : 1” + ½” (half of stud size) = 1-1/2” wrench

Tip provided by
Don Olszewski
The Timken Company

Can these RCM-2009 Case Studies Help Your Company?
• Reliability Centered Design
• The Psychology of RCM (Reliability-Centered Mindset)
• Measuring plant performance - The need for metrics standardization
• Master Records are Not Optional! Get the Detail Work Behind You
• Keith Mobley on Developing an Effective Workforce
• Reliability in Design and Procurement
• Developing and Implementing RCM for a Limited Staffed Facility
• Reposition plant culture to achieve EAM results
• Reliability in the Regulatory and Compliance Environment
• Developing a Skilled Workforce: Shaw Industries’ START Program
• Allison Transmission Machine and Equipment Purchase Process
• The Statistical Outliers Are In Control Of Asset Management
• Roadmap for Effective EAM Implementation or Re-implementation
• The Dead Zone In Work Management
• Condition-Based Maintenance - How Do You Solve The Scheduling Challenges
• Completing the P-F Curve
• Help Wanted
• Creating an Asset Management Framework For Successful EAM Configuration
• Blended Training: Combining Live training and e-learning for optimum results
• 99% Reliable 100% of the Time: How an airline meets amazing reliability metrics under the worst of conditions
• Measure Behavior – Measure Success!
• EAM Supporting Lean Maintenance
• Engineering Content Management
• There’s More to Training than Skills Development
• The Concorde Disaster Explained; an interface of Nuclear Work Model & Root Cause Analysis
• Enhancing electrical safety through RCM
• The Optimization Trap
• The Analytics Advantage
• Advanced Degree Programs For Maintenance and Reliability
• A facilitated-group approach to RCM
• Reliability Beyond Maintenance
• Optimized Planning and Scheduling
• Calibration Management and your ERP: have the best of both worlds
• Craft Training Solutions for a Retiring Workforce
• RCM - From Analysis to Action: How to Successfully Implement RCM
• The RCM Project Management Guide
• Maintenance Planning and Scheduling: Back to Basics
• Business applications for iPod generations
• Workforce Development
• When Does It Pay To Use Reliability Centered Maintenance?
• Infrared Thermography As An Asset Management Tool
• Management Considerations for CBM Success
• Air Liquide Breaks Down Condition Monitoring Information Silos

March 23-26, 2009 - Daytona Beach Hilton, Florida
Early bird registration applies through February 23 so sign up today
Special Team Discount:  Buy 2 passes and get a 1 bonus pass at no cost

Request an RCM-2009 Brochure and Program Guide now or reserve you seat today

Striking a Balance on Detailed Procedures versus Craft Skills
So what is better, having skilled craftspeople who know how to perform the work or having effective procedures to ensure that less experienced craftspeople can execute the work?
While this past fall’s stock market downturn may have delayed the plans for many approaching retirement, the Baby Boomers will be exiting the workforce at some point. Hopefully, you are preparing for their exit by capturing the knowledge they have gained over the last 20-25 years in detailed maintenance procedures that can be reused to ensure precision maintenance practices.
To demonstrate the point, consider this example. A craftsman who ‘owned’ a particular blower housed under a silo could execute a parts replacement in roughly 4 hours on a regular basis. One day, he happened to be on vacation when the repair was needed. That never happens, does it? Four craftspeople and twenty hours later, the same repair was done that normally took 4 hours. Obviously, the individual craftsman had figured out shortcuts that eliminated the additional work. Needless to say, those shortcuts were captured in the job plan for reuse on the next repair.
That said, I hope you recognize that detailed procedures alone aren’t a substitute for skilled experience. To ensure equipment reliability, we need precision maintenance using both the procedures and experience. They complement each other. Have your craftspeople document their steps on a print out of the PM or job plan while they are doing the work. Ensure that the Planner/ Scheduler uses the returned documents to update the PM Procedures or job plan in a continuous loop fashion. You should be constantly updating the knowledge and skills of your people through apprenticeship, formal training, and short toolbox training sessions so that you strike a balance between detailed procedures and developing skills.

Tip provided by Jeff Shiver, CMRP, CPMM
People and Processes
Learn about public and on-site training by People and Processes

Infrared inspections are a routine inspection in all areas of our plants.
Most believe it is all about what the infrared camera sees, forgetting that there is a human who is one of the most significant and important components of any good Predictive maintenance program, the brains behind the camera. The camera is only as good as the operator, his knowledge and skill manipulating the camera to get the best possible image each and every time is key to excellent report with pertinent information for the department requesting the infrared scans..
The camera operator also brings other assets into the mix each time he completes an infrared route, he brings his other senses along as well. Nothing can replace this invaluable set of tools, which with the knowledge on how the system works, can assist the local departments immeasurably by giving them a heads up on equipment that may require immediate attention. This is very relevant today with the cutbacks in manpower across industry, a knowledgeable thermographer is another skilled tradesman to be utilized in your maintenance program.
What we have here are some images captured on regular rounds, this is a motor that was running extremely hot, over 100 deg C, it was discovered that all of the motors were running this hot, it was unusual. The thermographer found the source of the problem by just looking around, the end bells for the fans were plugged with grease and dirt. Once cleaned all of the motor’s operating temperatures dropped to normal levels of around 40 deg C. See attached PDF.

Other things found on routine rounds were a emergency stop Pushbutton station that was at over 100 deg C, water had entered the box and shorted the leads and melted the pushbutton down. This effectively eliminated the redundant spare pump motor from starting, not to mention the hot steam from burning someone who opened the box to see what the problem was. With the infrared images at hand the electrician opened the box cautiously, when he did steam billowed out of the box, this possibly eliminated a possible burn to the electricians hand.
The other set of eyes will also notice damage like this water damage inside a local disconnect that had several hot connections.
Something always to keep in mind when scanning, stay aware of what is around you could get hints on what is happening and insight into unseen problems.

Reader Tip provided by Geoff Generalovic
Project Technical coordinator
ERS- PTS PTSG Electrical Monitoring ( Infrared and Motor Testing)
ArcelorMittal Dofasco
Read this tip as a PDF with images

Thanks Geoff - Your Stainless Steel, Diamond Plate, Reliabilityweb.com Coffee/Travel Mug is on the way!

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Register for the next no travel-no cost Reliability Roadmap Infrared Web Workshop