Hello, Design Out Maintenance is a strategy derived from Reliability-Centered Maintenance (RCM) designed to reduce or eliminate the need for maintenance. Can anyone provide some real-life examples of how this approach is implemented in practice? Thank you and cheers!
Hello Rennie, I have a few suggestions for you to consider. One way to prevent hidden failures is by making modifications that reveal any potential issues, eliminating the need for constant maintenance. For example, a standby generator that was altered to run continuously now serves as a cautionary tale after failing to operate when needed. While this modification required an initial investment, it ultimately prevented embarrassment. Another strategy is to strengthen structures beyond the asset's expected lifespan, eliminating the need for corrosion or fatigue inspections. This approach can be applied to any item with a defined safe lifespan, ensuring longevity beyond your tenure with the company. For random and unpredictable failures, consider implementing design modifications to address the issue. For instance, switching to rubber tires can eliminate the risk of punctures, though other maintenance may still be necessary. I hope you find these suggestions helpful. - Steve
Is design out the final option after exhausting all efforts to engage project management and team members effectively? How valid is this statement?
Josh, the response to this question may vary among different individuals. In our opinion, project management changes can usually be implemented quickly with minimal costs, compared to design modifications which can be time-consuming and expensive. Additionally, modifications often get placed on a long list of other changes, making it difficult for them to get approved unless they promise exceptional returns on investment. Companies tend to prioritize modifications with significant returns rather than basing decisions solely on positive net present value. These are just my insights. Best regards, Steve.
Steve, when you mention "startling returns," are you referring to achieving the highest returns, quick returns, or easily attainable gains that capture attention? I have some knowledge about project prioritization from my education, but I am curious if industrial plants actually utilize this method when determining which modifications to implement. It seems like they may simply assess the need for modification projects through basic cost/benefit analysis for each project, rather than conducting comprehensive project ranking exercises for all proposed modifications. If project ranking is carried out, who takes charge and coordinates the process - the maintenance department or the project department that oversees modification change requests, or the finance department?
Hello Josh, To me, achieving impressive results means seeing a quick return on investment within weeks. These modifications are often easy wins, which is why I consider them essentially the same thing. The varying approaches to managing modifications in industries make it challenging to evaluate the extent of their impact on rankings. Some companies allow technicians to make changes without any oversight, while others have strict controls in place where all modifications must be approved by headquarters. Many companies lack clear guidelines on modifications, leading to a haphazard process where decisions are left to individuals to approve or deny. In cases where there is a formal process, significant issues and complex approval procedures may lead supervisors to overlook the rules and allow modifications to proceed. This presents a concerning picture for a profession that should value professionalism. There is still much progress to be made in this area. Steve
One real-life example I've seen of Design Out Maintenance being put into practice is within the wind turbine industry. In an effort to lessen the high maintenance costs and work associated with these giant structures, engineers have started producing turbines with fewer moving parts and implementing enhanced communication technology. This essentially 'designs out' many maintenance tasks, as there are fewer parts that could fail, and the technology allows for remote monitoring and troubleshooting. Also, components are now made more robust and failure-resistant, meaning they require less regular upkeep.
Absolutely! One practical example of the Design Out Maintenance (DOM) strategy can be seen in the wind energy industry. To mitigate regular maintenance needs, companies are designing and manufacturing larger, more efficient wind turbines with fewer moving parts. Fewer moving parts mean less friction and wear-and-tear, hence reducing the need for regular maintenance. So, this approach essentially involves an upfront investment in advanced design and manufacturing to save on long-term maintenance costs.
Hey there! One great example of Design Out Maintenance in practice is in the aerospace industry, where manufacturers like Boeing and Airbus focus on designing aircraft components that require minimal maintenance. For instance, advanced materials that resist corrosion or wear reduce the frequency of inspections and repairs. Additionally, companies in the automotive sector are increasingly using modular designs, allowing for easier and more reliable part replacements, which ultimately cuts down on maintenance needs. Cheers!
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Answer: - Design Out Maintenance is a strategy derived from RCM that aims to reduce or eliminate the need for maintenance by improving the design of equipment or systems. It focuses on addressing maintenance issues during the design phase to enhance reliability and reduce maintenance requirements.
Answer: - One example of implementing Design Out Maintenance strategy is designing equipment with self-lubricating components to eliminate the need for manual lubrication and reduce maintenance frequency. Another example is using corrosion-resistant materials in the design to extend the equipment's lifespan and minimize maintenance needs.
Answer: - Organizations can benefit from implementing Design Out Maintenance strategy by reducing maintenance costs, minimizing downtime, improving equipment reliability, and enhancing overall operational efficiency. By addressing maintenance issues during the design phase, organizations can achieve long-term cost savings and improved performance.
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