Maintenance: How not to hate it
-
Upload
brian-gongol -
Category
Engineering
-
view
5.111 -
download
0
description
Transcript of Maintenance: How not to hate it
![Page 1: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/1.jpg)
MAINTENANCE:HOW NOT TO HATE IT
Brian GongolDJ Gongol & Associates, Inc.
November 6, 2014
Nebraska Section AWWAFall Conference
![Page 2: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/2.jpg)
Terrorism is scary.
![Page 3: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/3.jpg)
We spend massive sums on detection
NSA CIA TSA FBI Homeland Security Local law enforcement
![Page 4: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/4.jpg)
Cameras
![Page 5: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/5.jpg)
Sensors
Radiation X-ray Biological weapons Full-body scanners
![Page 6: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/6.jpg)
The detection doesn't always work
Resulting in failuresthat grip the
world's attention
![Page 7: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/7.jpg)
Detection failures
1993 WTC bombing Khobar Towers bombing 9/11 Shoe bomber Underwear bomber Boston Marathon bombing Malaysia Airlines Flight 370 (?)
![Page 8: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/8.jpg)
More attention leads to more surveillance
Even though the events are incredibly rare
![Page 9: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/9.jpg)
Story-tellers magnify the story
Reporters, pundits, politicians, and others
![Page 10: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/10.jpg)
...until we spend billions without thinking twice
$16.6 billion a year
![Page 11: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/11.jpg)
What's a lot scarier?
Deferred maintenance.
![Page 12: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/12.jpg)
Scarier, really?
Not to diminish the tragedies that have occurred,but they are extremely low-probability events.Your individual chances of being affected are
indistinguishable from zero.
But our choices as a society mean thatinfrastructure failures are certain to occur,
with extremely widespread impact,and can range from inconveniences to calamities.
![Page 13: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/13.jpg)
Truth time
It should terrify us to think that wechoose to put ourselves at risk
solely due to a lack of willpowerto take responsibility for
an entirely preventable condition
![Page 14: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/14.jpg)
$3.6 trillion in deferred maintenance
Anti-terrorism: $16.6 billion spent yearly
$50 per person
Deferred maintenance: $3,600.0 billion needed
$11,000 per person
![Page 15: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/15.jpg)
That's $3,600 billion
Or about 217 years of anti-terrorism funding
![Page 16: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/16.jpg)
Nobody talks about it, though.
![Page 17: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/17.jpg)
A simple question and a troubling answer
Who has been asked to defer maintenancebecause of a budget shortfall?
![Page 18: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/18.jpg)
A simple question and a troubling answer
Who has been asked to accelerate maintenanceto make up for what has been deferred?
![Page 19: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/19.jpg)
That gap you're seeing
We treat "maintenance" like a bank accountfrom which we only ever borrow
![Page 20: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/20.jpg)
Maintenance means just holding the line
What we should really advocate iscontinuous improvement
![Page 21: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/21.jpg)
You're in an unenviable position
Having to address an expensive problemwith under-funded resources
![Page 22: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/22.jpg)
A three-fold strategy for easier maintenance
![Page 23: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/23.jpg)
1. Fix our concept of maintenance
It can't always be an emergency
![Page 24: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/24.jpg)
2. Make practical maintenance easier
![Page 25: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/25.jpg)
3. Communicate the problem effectively
![Page 26: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/26.jpg)
CONCEPT
![Page 27: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/27.jpg)
Even nature has maintenance cycles
![Page 28: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/28.jpg)
Small forest fires are natural
![Page 29: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/29.jpg)
Big fires result from human intervention
![Page 30: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/30.jpg)
Not all maintenance is worth doing!
![Page 31: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/31.jpg)
Maintenance is about one thing
Getting the full life-cycle value from a product
![Page 32: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/32.jpg)
Extending life means actively saving money
![Page 33: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/33.jpg)
Think of operational savings in pretax dollars
$1.25 to $1.33 in pretax incometo the ordinary taxpayer
![Page 34: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/34.jpg)
So let's save some money!
![Page 35: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/35.jpg)
Types of maintenance
Fix on failure Scheduled Preventive Predictive
![Page 36: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/36.jpg)
Each approach has its place
![Page 37: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/37.jpg)
Fix on failure
When it's cheap, simple, and in-stock, like a pen
![Page 38: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/38.jpg)
Scheduled maintenance
When there is lots of data from prior experience
![Page 39: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/39.jpg)
Preventive maintenance
When a failure puts you at serious riskof long-term downtime
![Page 40: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/40.jpg)
Predictive maintenance
When the signals of trouble are well-knownand surveillance is cheap
![Page 41: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/41.jpg)
In the context of your health...
![Page 42: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/42.jpg)
Fix on failure
Bandage on a papercut
![Page 43: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/43.jpg)
Scheduled maintenance
Getting your annual physical(prostate exams, colonoscopies, cholesterol tests...)
![Page 44: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/44.jpg)
Preventive maintenance
Regular exercise
![Page 45: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/45.jpg)
Predictive maintenance
Blood pressure checks Body-composition bathroom scales Blood-sugar tests
![Page 46: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/46.jpg)
We rely too heavily on fix-on-failure
(Not a recommended maintenance strategy.)
![Page 47: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/47.jpg)
You would never fly Fix-On-Failure Airlines
![Page 48: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/48.jpg)
Now that we get the concept...
![Page 49: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/49.jpg)
PRACTICE
![Page 50: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/50.jpg)
Avoid the curse of Shary Bobbins
![Page 51: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/51.jpg)
Always put safety first
![Page 52: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/52.jpg)
You are the most valuable piece of equipment
![Page 53: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/53.jpg)
Lock out, tag out
![Page 54: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/54.jpg)
Check for gases
![Page 55: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/55.jpg)
Seriously. Check for gases.
![Page 56: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/56.jpg)
Prevent slips, trips, and falls
Carpet pattern designed as if to maximize disorientationCenturyLink Center, Omaha
![Page 57: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/57.jpg)
Prevent muscle strain
![Page 58: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/58.jpg)
Keep safety equipment in good repair
Guards Belts Sensors Handrails
![Page 59: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/59.jpg)
Measurement means control
![Page 60: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/60.jpg)
Everyone knows quantitative measurements
![Page 61: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/61.jpg)
Pump run times
![Page 62: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/62.jpg)
Energy consumption
![Page 63: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/63.jpg)
Flows
![Page 64: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/64.jpg)
Pressure readings
![Page 65: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/65.jpg)
Oil temperatures
![Page 66: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/66.jpg)
Motor casing temperatures
![Page 67: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/67.jpg)
But qualitative measurements matter, too
![Page 68: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/68.jpg)
Vibration
![Page 69: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/69.jpg)
Smells/scents/odors
![Page 70: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/70.jpg)
Smells/scents/odors
bitter burnt citrusy fermented fishy fresh fruity grassy hot moldy musty
oily oppressive organic pungent rotten sharp smoky sour sulfuric sweet
![Page 71: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/71.jpg)
Sounds
![Page 72: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/72.jpg)
Sounds
bassy buzz chirp clack clap click crescendo dissonant echo grind growl harmonic hum knock loud muffled
piercing ping quiet rattle rhythmic ringing rumble screech sharp squeak squeal staccato tap whinny whoosh
![Page 73: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/73.jpg)
Why take measurements?
And keep qualitative records?
![Page 74: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/74.jpg)
From fix-on-failure to anticipation
Making the change meanscollecting and using data
![Page 75: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/75.jpg)
Not appropriate to everything
![Page 76: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/76.jpg)
Litmus test
If downtime would wake you in the middle of the nightand a replacement isn't on your own shelf,
use some kind of predictive/preventive measurement
![Page 77: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/77.jpg)
Make it easy to measure and record
![Page 78: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/78.jpg)
Make it easy to review performance
![Page 79: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/79.jpg)
Take the time to review
![Page 80: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/80.jpg)
I-35W: Calculations were "too much work"
![Page 81: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/81.jpg)
Take records straight to a tablet or netbook Eliminates handwriting errors Eliminates copying errors Promotes rapid visualization
![Page 82: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/82.jpg)
Prices are so low, it's highly justifiable
![Page 83: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/83.jpg)
Use free resources
![Page 84: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/84.jpg)
![Page 85: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/85.jpg)
Calendars
![Page 86: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/86.jpg)
Charts and task lists
![Page 87: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/87.jpg)
7x7
![Page 88: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/88.jpg)
Make them easy to digest at a glance
![Page 89: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/89.jpg)
People like to keep up unbroken chains
![Page 90: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/90.jpg)
"X" days without a safety incident
![Page 91: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/91.jpg)
Know your indicators
Problem indicators Smoke from under the hood
Planned indicators Squeaking brakes
![Page 92: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/92.jpg)
Conduct a post-mortem on failures and incidents
What did it cost you? What signals were missed?
![Page 93: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/93.jpg)
Primary predictive-maintenance indicators
Temperatures Oil/lubricant conditions Ultrasonic analysis Vibration Performance trends
![Page 94: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/94.jpg)
Nobody wants to do the dirtiest job
![Page 95: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/95.jpg)
Create a culture that encourages maintenance
Starting with ownership of the process
![Page 96: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/96.jpg)
Wax/paint/clean the equipment
![Page 97: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/97.jpg)
Broken window effect
![Page 98: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/98.jpg)
A baseline for what's right...
...makes it easier to see when something's wrong
![Page 99: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/99.jpg)
A hidden payback
When you practice regular maintenance,you get to know the equipment
on an expert level
Expert-level understanding makestrouble resolution much faster
![Page 100: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/100.jpg)
What you have in common with machines
Some of the things thatmake your life more pleasant
help equipment, too
![Page 101: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/101.jpg)
Winter heating
Proper heating in winter prevents freezing
![Page 102: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/102.jpg)
Summer cooling
Well-ventilated motorsare more reliable and more efficient
![Page 103: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/103.jpg)
Turn better maintenance into a game
![Page 104: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/104.jpg)
Rival departments (or shifts)
![Page 105: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/105.jpg)
Rival communities
![Page 106: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/106.jpg)
Leverage your efforts & improve motivation
Friendly rivalries withsomething on the line
(pride or a small wager)raise the level of performance
all around
![Page 107: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/107.jpg)
Make it a measurable goal with a small wager
Doughnuts?Lunch?
A round of beers?
![Page 108: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/108.jpg)
Buddy system aids information-sharing
![Page 109: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/109.jpg)
Create your own "peer group"
Valuable for comparisons in reports
![Page 110: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/110.jpg)
If you're doing well
The peer group helps you take credit
![Page 111: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/111.jpg)
If you're doing badly
Peer pressure can motivate improvement
![Page 112: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/112.jpg)
If you need more resources
The peer group helps you make the case
![Page 113: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/113.jpg)
Reward good maintenance ideas
Multi-thousand-dollar ideas go un-sharedbecause people don't think they'll be rewarded
![Page 114: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/114.jpg)
Rewards beget buy-in
"You can achieve amazing progressif you set a clear goal and find a measurethat will drive progress toward that goal
in a feedback loop."- Bill Gates
![Page 115: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/115.jpg)
Use mental tricks to help yourself
Make maintenance automatic
![Page 116: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/116.jpg)
Conserve mental energy
Don't make more choices than necessary
![Page 117: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/117.jpg)
Color-coded tools
![Page 118: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/118.jpg)
Opt-in versus opt-out
When the default option is participation, one-third of people stick with retirement plans who wouldn't have signed up on their own
![Page 119: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/119.jpg)
Add a third choice to make
![Page 120: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/120.jpg)
Add a third choice to make
![Page 121: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/121.jpg)
Batches of three
Just clustering tasks and choicesin groups of three
reduces the mental taxof decision-making
![Page 122: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/122.jpg)
Conserve mental energy for what matters
"What do you want for dinner?"
"I don't know. What do you want?"
"I don't know."
![Page 123: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/123.jpg)
Tools under $25 to improve maintenance
![Page 124: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/124.jpg)
Kneepad
![Page 125: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/125.jpg)
Graph pads
![Page 126: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/126.jpg)
Fold-out two-wheeler
![Page 127: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/127.jpg)
Lock-out, tag-out devices
![Page 128: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/128.jpg)
Pilot's kneeboard
![Page 129: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/129.jpg)
Custom toolkits for frequent tasks
![Page 130: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/130.jpg)
Foam roller
![Page 131: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/131.jpg)
Reach extender
![Page 132: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/132.jpg)
Zip ties (cable ties)
![Page 133: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/133.jpg)
Carabiners
![Page 134: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/134.jpg)
It is not wasteful to duplicate tools
If it's the difference between doing the maintenance and not If it saves time on a quick payback period
![Page 135: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/135.jpg)
Play hurt sometimes
Figure out what is adding extra strain,then eliminate it
![Page 136: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/136.jpg)
Concept and practice: Done.
Now...
![Page 137: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/137.jpg)
COMMUNICATION
![Page 138: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/138.jpg)
Get the resources you need
![Page 139: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/139.jpg)
Explaining to people who don't do maintenance
Maybe not even at home
![Page 140: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/140.jpg)
Give them three forecasts
Best case, worst case, and most likely(Remember: People default to the middle)
![Page 141: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/141.jpg)
We have to engage people who think:
Infrastructure happens by magic The work gets done by people who are beneath them
![Page 142: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/142.jpg)
Professionals speak up for themselves
CPAs funding "Feed the Pig" commercials Medical journals in the news Trial lawyers making campaign contributions
![Page 143: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/143.jpg)
We can't be timid about real needs!
Worn-out infrastructure is no goodfor the people actually doing the work,
and it does no service to customers
![Page 144: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/144.jpg)
Reluctant? Why?
Too time-consuming?Too much effort?No motivation?
![Page 145: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/145.jpg)
Just because we don't do it now...
...doesn't mean it goes away. It usually just gets worse.
![Page 146: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/146.jpg)
If time is short...
Can a better strategy save time?
![Page 147: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/147.jpg)
If time is short...
Are you valuing the opportunity cost of your time?
![Page 148: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/148.jpg)
If it requires too much effort...
Are we just hoping to run out the clockand avoid the eventual catastrophic failure?
![Page 149: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/149.jpg)
If you're unmotivated...
Think about saving yourself a 2 a.m. weekend call
![Page 150: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/150.jpg)
If it's external, examine why
Not enough staff or hours in the day? Not enough funding? No support from "on high"?
![Page 151: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/151.jpg)
Just because it isn't done
...doesn't mean it doesn't have to be done
![Page 152: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/152.jpg)
Troubles happen
Potholes Bridge collapses (I-35W) Levee failures (Hamburg) Main breaks Sewer backups
![Page 153: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/153.jpg)
People see (and feel) potholes
![Page 154: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/154.jpg)
Water-related utilities are relatively invisible
We have to speak up about the invisible"potholes" in water and sewer systems
![Page 155: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/155.jpg)
Cost deferral isn't cost prevention
![Page 156: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/156.jpg)
Cost deferral is usually cost compounding
![Page 157: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/157.jpg)
If we don't communicate what we need
...we shouldn't be surprised if we don't get it.
![Page 158: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/158.jpg)
You have to tell them what you need
![Page 159: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/159.jpg)
Add a little bit of "Why?"
Make it a "Why" that matters to the decision-maker
![Page 160: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/160.jpg)
Words matter
"Honey Wagon"
![Page 161: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/161.jpg)
Euphemisms don't really help
But we must considerreal perceptions andtheir consequences
![Page 162: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/162.jpg)
Since 1989, people have watched
![Page 163: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/163.jpg)
...which is a more compelling title than
![Page 164: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/164.jpg)
Words really do matter
The same food wasteis perceived differently
when it movesfrom the garbage can
to the compost bin
![Page 165: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/165.jpg)
Words really do matter
Consider the magical transformationfrom sludge to biosolids
![Page 166: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/166.jpg)
Honest improvements to "Maintenance"
Asset manager Capital-preservation specialist Incident-prevention supervisor Public-health technician Service reliability agent
![Page 167: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/167.jpg)
Alternative titles to avoid
Museum curator Crisis-response team Equipment babysitter
![Page 168: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/168.jpg)
People rarely ask what maintenance will cost
Or how much good maintenancechanges the life expectancy
![Page 169: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/169.jpg)
Caring for assets makes you a:
Guardian Conservator Trustee
Custodian Steward Fiduciary
![Page 170: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/170.jpg)
"Cheap" isn't always cheap
"Cheap" up-frontmay cost you a fortune
![Page 171: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/171.jpg)
Doing maintenance right saves you grief
AVOID PAIN!
![Page 172: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/172.jpg)
Good maintenance saves customers money
PLEASE THE PEOPLE!
![Page 173: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/173.jpg)
Summary:
Do the right maintenance for the right equipment Fix-on-failure, scheduled, preventive, predictive
Use your brain as often as your hands Place a real value on maintenance and communicate it
![Page 175: Maintenance: How not to hate it](https://reader033.fdocuments.us/reader033/viewer/2022052600/55865880d8b42a5b488b4670/html5/thumbnails/175.jpg)
References:
Cost of anti-terrorism: http://www.pewresearch.org/fact-tank/2013/09/11/u-s-spends-over-16-billion-annually-on-counter-
terrorism/
Cost of deferred maintenance: http://www.infrastructurereportcard.org/news/
Retirement opt-in participation: http://www.nber.org/bah/summer06/w12009.html
Airport security photo (public domain): https://twitter.com/TSAMedia_RossF/status/375424954600157185/photo/1
I-35W "too much work": http://www.startribune.com/local/minneapolis/52124637.html
I-35W photo (public domain): http://en.wikipedia.org/wiki/File:I35W_Collapse_-_Day_4_-_Operations_%26_Scene_(95).jpg
Osama bin Laden screen capture: http://www.fbi.gov/wanted/topten/usama-bin-laden
Aircraft boneyard photo (public domain): http://research.archives.gov/description/6505216
All other photos and illustrations are original work by Brian Gongol. Copyright and all other rights are reserved.