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Abnormalitiesarerepresentedbythedefectsthatenter ourassets(pointPonthePFcurve)andwilleventually leadtoalossoffunctionfromanassetifleft unresolvedandwillresultinafunctionalfailure(pointF onthePFcurve). PointP PointF
FormalReportingvs.InformalReporting Thequestionhereisthenatureofthereportingofthe abnormalitywithsomemethodsbeingmoreeffective thanothers.Moreoftenthanwecaretoadmit,small problemsgrowintocatastrophicproblemsduetothe organizationsfailuretorespondproperly.Emails, telephonecalls,andverbaldiscussionsontheshopfloor orinthelunchroomareallexamplesofinformal methodsofreportingabnormalities. Inordertoensurethattheorganizationcanrespondina timelymanner,itiscriticalthatabnormalitiesare reportedinaformalmanneronethatisuniversally recognizedandreactedtobytheorganization. WorkRequestsTheprimarymethodofreporting abnormalitiesinmanyorganizationsistheworkrequest generallymaintainedinadatabaseknownastheEAM orCMMS.Thisdatabaseallowsallmemberof organizationtoviewandfocusonthesamelistof reportedabnormalities.Theworkrequestmustbethe firstchoiceleveragedwhenreportingabnormalities. AbnormalityTagsInmanyorganizations,asegmentof thepersonnellackthetrainingordatabaseaccess necessarytoformallyreportproblems.Whenthis situationoccurs,thosepersonnelmustreverttooneof theinformalmethodsofreportingabnormalities leadingtolostopportunitiesandunnecessaryfailures. Asthepersonnelinthiscategoryaregenerallyoperators, theabnormalitytagsusedaspartoftheOperatorCare programprovideaformalmethodtoformallyreportan abnormality.Inaddition,thebrightcoloredtagsusedin theprocessprovideavisualcluetotheexistenceand locationoftheabnormalityintheworkplace.
ThePFCurve
Copyright2011
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OperatorCareAbnormalityReporting
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TheTaggingProcessThetagswegenerallyrecommend foruseconsistsofatwoparttag;afrontsectionprinted onbrightcoloredpaper,abacksectionprintedonanoil andwaterresistantmaterialsuchasTyvek,withcarbon paperinbetween. Whentheoperatornoticesanabnormality,theywillfill outthetopsectionofthetag,withtheinformationbeing transferredtothebackofthetagviathecarbonpaper. Theelementresistantsectionofthetag(backhalf)is attachedtotheequipmentnearthelocationofthe abnormality,andthetophalfplacedinacentrally locatedlocationthatisaccessibletoalloperations, maintenance,andsupervisorypersonnel. Inthosesituationswheretheoperatorsdonothave accesstothedatabase,werecommendthatthe supervisordirectlyresponsibleforsupportingthe OperatorCareprocessineachareabetaskedwithtaking thenewabnormalitytagsandcreatingacorresponding workrequestinthecomputerdatabase.Thistaskmust beperformedonashiftbyshiftbasis. Withthebrightcolorofthetagsbeingused,thevisual managementaspectoftheabnormalityreporting processisaccentuated.Maintenancepersonnelare deployedtorespondtoproblemsviatheestablished workmanagementprocess,whileoperatorscanoversee andmonitortheresponsetotheabnormalitiesreported bymonitoringthetagstheyhavecreatedontheir operatorcareboard.
AbnormalityTags Conclusion: Mostoftheequipmentfailuresthatwesufferthrough everydaycouldbeavoidediftheorganizationwasable toreactappropriately. Moreoftenthannot,ourinadequateresponseisnotdue totechnicalissues,butratherrelatestocommunication issuesandourinabilitytoformallyreportandrespondto thewarnings(abnormalities)thattheequipmentis sendingtous.
Copyright2011
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