100 Years in Maintenance: Practical Lessons from Three Lifetimes at Process Plants

The chain of habit coils itself around the heart like a serpent, to gnaw and stifle it.
William Hazlitt, Writer and Critic.
Author: Jim Wardhaugh
Location: 2.3.3 Corporate Technical Headquarters
I left my Far Eastern idyll for cold dark Europe. Those who move the pawns in the corporate headquarters noticed my success in my assignment in the Far East. So they head-hunted me and I joined this elite group. The job was to help locations that were less well performing to make significant improvements. I met Vee Narayan, who was already in this group; later, Mahen Das also joined us.
As an electrical engineer, I had been extensively involved in previous lives for the implementation of computerized maintenance management systems (CMMS). So I became responsible for electrical maintenance and CMMS implementation.
An Electrical Engineers' Conference gave me the opportunity to prompt the collection of some data. In the Far East, I found that motor repairs were a significant ongoing manpower consumer and, hence, cost. I decided to put some effort into collecting data on this subject so that we could make informed decisions.
A few of our bigger locations and the Institute of Electrical and Electronic Engineers (IEEE) had been collecting data for many years. We captured this data and collated them (see Tables 39.1 and 39.2). We found large differences between our numbers and those from IEEE. We can account for these in part by the difference in the ways of collecting...