TABLE OF CONTENTS In Chapter 8, we looked at a number of case histories relating to major disasters. The sequence of events leading to these disasters appears to follow a common pattern. Production losses are also due to similar failures. When people ignore warning signs, process deviations or equipment failures may lead to loss of process control. If we do not resolve these in time, they can escalate into serious failures. We can reduce the risks of safety or environ- mental incidents and minimize production losses by improving the effectiveness of the relevant systems.
In order to reduce risk to tolerable levels, we need data and tools to analyze performance. With these elements in place, we can put together a plan to improve system effectiveness. In this concluding chapter, we will examine implementation issues, and see what practical steps we can take. In Appendix 12-1, we will look at applications outside the equipment maintenance area, using the more holistic definition of maintenance.
When there are no constraints at the input and output ends of a plant, it can produce to its design capacity. The only constraint is its own operational reliability. The ratio of the actual production to its rated capacity is its system effectiveness. It takes into account losses due to trips, planned and unplanned shutdowns, and slowdowns attributable to the process or equipment failures. A simple way to picture this concept is to think of the plant or system being connected to an infinite supply source and an...
