Dr. Horst Grothus
take Deterioration and Defects for granted
chances control your quality - right?]
Dr. Horst Grothus,
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What are Defects?
Components of your plant equipment might deteriorate (e.g. wear, corrode, contaminate, break etc.).
When this deterioration has reached an amount, you cannot further tolerate, you call this a "Defect".
Classifying "Defect Symptoms"
A "Defect Symptom" is what you see when looking at a defective component.
You can define certain capacities of these Defect Symptoms and specify their "Admissability" and "Controllability".
My "Defect Standard" is based on the analyses of several hundred thousands of defects occurring in many different kinds of industrial plants.
Most defects do not "develop" but are provoked by faults!
About 30% of all defects occur in a plant more or less regularly ("Chronically"), namely
However about 70% of all defects never occur repetitively at the same component at the same location, but only one single time. These "Sporadic Defects"
Which defects can be detected in time and repaired, before causing break downs?
Some Defect Symptoms develop rather steadily and could be detected before causing the piece of equipment to break down.
The "Defect Standard" indicates, which defects symptoms technically could thus be properly controlled.
Out of all defects actually triggering an equipment break down you could control
When considering a "normal" production plant, where break downs triggered by defects occur roughly evenly at mechanical and electrical components (50% each), your inspections just can control only (50% of mechanical plus 10% of electrical, i.e. 0,5*50% + 0,1*50%=) 30% of your break downs. This is very unfortunate, but true!
Preventive and Condition Based Maintenance work - unfortunately - rather poor!
Ideally you would presume to inspect literally all components developing defects and thereby triggering break downs. You would need to inspect
Even applying devices automatically monitoring these components would (except at extremely dangerous pieces of equipment, like Nuclear Power Plants) hardly be economical, because
Inspections and other means of Condition Based Maintenance can therefore only be economical and efficient caring for those elements
Your only alternative: Avoiding defects, not inspecting them.
If you can - as demonstrated - control Loss Events triggered by defects only to a very limited amount, you must avoid the defects. This you will do
Look at defects quite differently from now on: They do not develop automatically, but are being produced by faults in you organization!
If you have any questions: Just tell me. I shall be glad to assist you.