Human error rate is high and thus without repeatable, effective maintenance procedures create errors which are called failures. Maintenance professionals actually think procedures are not required because they "know how to do it". However, this couldn't be further from the truth. Over our careers we have seen thousands of examples of human variation creating equipment failure.
We as humans are built to produce variation in almost everything we do. Most people deny this human variation exists. However, when managers are asked if they ever could not find their car keys they look at me sheepishly and say, "Yes, great point". Many companies honestly believe there maintenance staff members are paid to "know how to do it" without a procedure with specifications, step by step instructions, etc. What if a maintenance employee does "know how to do it" every time?
One must take into consideration skill level, current state mind, and current working condition, in order to mitigate human error. In addition, what would happen if new information presents itself based on failure data? The only way to ensure this new information is used effectively would be to write or change a procedure.
"Well-designed maintenance procedures and a solid procedures feedback and follow-up process will mitigate human induced failures and allow for continuous improvement to occur naturally".
If a company wants to optimize asset reliability, then repeatable, effective procedures cannot be optional. Did you know that the most complex equipment ever built was a nuclear submarine and that the first nuclear submarines experienced failures due to lack of effective procedures, thus ending in catastrophic failure?
You can download this article at: https://worldclassmaintenance.org/articles-of-the-week
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Ricky Smith CMRP CMRT
Vice President
World Class Maintenance
Central, SC
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