The Maintainers

The 5S methodology is a systematic approach to workplace organization and visual management, originating from Japanese manufacturing practices. Comprising five core principles, each beginning with the letter &#8216;S,&#8217; 5S stands for Seiri (整理), Seiton (整頓), Seiso (清掃), Seiketsu (清潔), Shitsuke (躾). In English, these translate to Sort, Set in Order, Shine, Standardize, and Sustain.



The 5S methodology is often attributed to the Japanese manufacturing sector, particularly to the Toyota Production System (TPS). While the specific inventor or originator is not clearly defined, 5S principles emerged as a part of the broader Lean manufacturing philosophy and continuous improvement practices pioneered by Toyota.



<h2 class="wp-block-heading has-large-font-size">The 5S methodology consists of five fundamental principles, each beginning with the letter &#8216;S&#8217;:</h2>



<ol>
<li>Sort (Seiri):</li>
</ol>



In this initial step, the focus is on eliminating unnecessary items from the workplace. This involves a critical evaluation of tools, materials, and equipment, retaining only what is essential for daily operations.



<ol start="2">
<li>Set in Order (Seiton):</li>
</ol>



Once the unnecessary items are removed, the next step involves organizing the remaining items in a systematic and efficient manner. This includes defining specific locations for tools, labeling, and ensuring easy accessibility.



<ol start="3">
<li>Shine (Seiso):</li>
</ol>



Maintaining a clean and organized workspace is integral to the 5S philosophy. Regular cleaning activities not only enhance visual management but also contribute to a safer and more pleasant work environment.



<ol start="4">
<li>Standardize (Seiketsu):</li>
</ol>



Standardization involves creating uniform processes and procedures for maintaining the first three S&#8217;s. It ensures that the improvements made are sustained over time, promoting consistency and stability in operations.



<ol start="5">
<li>Sustain (Shitsuke):</li>
</ol>



The final S focuses on creating a culture of continuous improvement. Sustaining the gains achieved through the previous steps involves ongoing training, regular audits, and fostering a mindset of continuous refinement.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1015" height="1094" src="https://blog.themaintainers.com/wp-content/uploads/image-17.png" alt="the 5s cycle" class="wp-image-487" srcset="https://blog.themaintainers.com/wp-content/uploads/image-17.png 1015w, https://blog.themaintainers.com/wp-content/uploads/image-17-768x828.png 768w" sizes="(max-width: 1015px) 100vw, 1015px" /></figure>



<h2 class="wp-block-heading has-large-font-size">Why Implement the 5s?</h2>



Implementing the 5S methodology in your production process can yield substantial benefits, significantly enhancing efficiency and overall operational performance. Firstly, the &#8220;Sort&#8221; step ensures that your workspace is decluttered and only essential items are retained, eliminating unnecessary distractions and reducing the risk of errors. This leads to a more organized and focused work environment. The &#8220;Set in Order&#8221; principle facilitates a systematic arrangement of tools and materials, optimizing accessibility and minimizing time wasted on searching for items. This, in turn, streamlines workflows, leading to increased productivity.



The &#8220;Shine&#8221; aspect emphasizes cleanliness and regular maintenance, creating a work environment that is not only aesthetically pleasing but also promotes employee health and safety. A clean and well-maintained workspace can contribute to higher morale and a sense of pride among workers. The &#8220;Standardize&#8221; step establishes consistent processes and procedures, reducing variability and improving overall quality control. Standardization also facilitates easier training of new employees, ensuring that everyone follows the same best practices.



Lastly, the &#8220;Sustain&#8221; phase focuses on embedding the 5S principles into the organizational culture, fostering a continuous commitment to improvement. This long-term commitment results in a workplace that is not only more efficient but also adaptable to changes and challenges.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="787" height="983" src="https://blog.themaintainers.com/wp-content/uploads/image-16.png" alt="benefits of 5s" class="wp-image-486" srcset="https://blog.themaintainers.com/wp-content/uploads/image-16.png 787w, https://blog.themaintainers.com/wp-content/uploads/image-16-768x959.png 768w" sizes="(max-width: 787px) 100vw, 787px" /></figure>



How Does 5s Relate to Lean?



The 5S methodology and <a href="https://tractian.com/en/blog/lean-manufacturing-in-maintenance-how-to-reduce-waste">Lean principles</a> share common ground as both are rooted in Japanese manufacturing philosophies, aiming for efficiency, waste reduction, and continuous improvement. However, they are distinct in their focus and scope.



5S is primarily concerned with organizing the workplace, minimizing waste, and creating a structured and efficient environment. The focus is on visual management, cleanliness, and establishing standardized processes.



On the other hand, Lean manufacturing, often referred to as simply &#8220;Lean,&#8221; is a broader philosophy that encompasses various principles and practices aimed at reducing waste, improving efficiency, and delivering value to customers. Lean thinking goes beyond the physical organization of the workplace and includes concepts such as just-in-time production, continuous improvement (Kaizen), and respect for people. Lean aims to create a culture of continuous improvement throughout the entire organization, involving employees at all levels.



While 5S is a specific methodology focused on workplace organization and standardization, Lean is a broader philosophy that incorporates a range of principles, tools, and practices with the overarching goal of creating a more efficient and value-driven organization. 5S can be considered a subset or foundational element within the broader framework of Lean manufacturing.

The 5S methodology is a systematic approach to workplace organization and visual management, originating from Japanese manufacturing practices. Comprising five core principles, each beginning with the letter &#8216;S,&#8217; 5S stands for Seiri (整理), Seiton (整頓), Seiso (清掃), Seiketsu (清潔), Shitsuke (躾). In English, these translate to Sort, Set in Order, Shine, Standardize, and Sustain. The [&hellip;]

Implementing 5s Methods To Improve Your Production

Takt time, sometimes referred to as Takt, is a key principle of <a href="https://themaintainers.com/blog/using-lean-manufacturing-to-optimize-your-maintenance">lean manufacturing</a>. It refers to the rate at which you need to complete a product or service to satisfy customer demand.



The Takt time formula in Lean can be represented as below:



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1343" height="647" src="https://blog.themaintainers.com/wp-content/uploads/image-14.png" alt="takt time equation" class="wp-image-459" srcset="https://blog.themaintainers.com/wp-content/uploads/image-14.png 1343w, https://blog.themaintainers.com/wp-content/uploads/image-14-768x370.png 768w" sizes="(max-width: 1343px) 100vw, 1343px" /></figure>



 Available Production Time refers to the total amount of time available for production during a specific period, and Customer Demand means the amount of products or services that customers require during the same period. This is expressed as a rate or quantity, such as units per day, hours per week, or calls per hour.



For instance, if a customer needs an order fulfilled every two hours, you, as the producer, must ensure you can finish making that product in two hours or less. if a toothbrush factory operates 480 minutes per day and customers demand 240 toothbrushes per day, Takt time is two minutes. Similarly, if customers want two toothbrushes per month, Takt time is two weeks. This sense of consistent timing is why Takt time is often referred to as the heartbeat of a lean production system.



<figure class="wp-block-image size-full"><img decoding="async" loading="lazy" width="1040" height="474" src="https://blog.themaintainers.com/wp-content/uploads/takt-breakdown.png" alt="an explanation of cycle time" class="wp-image-456" srcset="https://blog.themaintainers.com/wp-content/uploads/takt-breakdown.png 1040w, https://blog.themaintainers.com/wp-content/uploads/takt-breakdown-768x350.png 768w" sizes="(max-width: 1040px) 100vw, 1040px" /></figure>



Why are the Benefits of Takt Time?



Takt optimizes your team’s efficiency and productivity, as well as reduces instances of waste. It helps you maintain a continuous work flow and ensures otimized storage space as you avoid over or under production. Production Alignment: Takt time synchronizes production rates with customer demand, preventing overproduction or underproduction and ensuring a smooth workflow.



Waste Reduction: By adhering to Takt time, companies can minimize waste, optimize resource utilization, and identify and eliminate inefficiencies in the production process.



Customer Satisfaction: Takt time helps meet customer demand consistently, reducing lead times and enhancing customer satisfaction through timely product delivery.



Continuous Improvement: As a metric, Takt time serves as a baseline for continuous improvement efforts, enabling teams to set performance targets, measure results, and identify opportunities for ongoing enhancements.



Efficient Resource Planning: Takt time facilitates efficient workforce planning by indicating the necessary staffing levels to meet customer demand, helping companies optimize their workforce and avoid unnecessary costs.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="782" height="348" src="https://blog.themaintainers.com/wp-content/uploads/image-15.png" alt="the benefits of takt" class="wp-image-460" srcset="https://blog.themaintainers.com/wp-content/uploads/image-15.png 782w, https://blog.themaintainers.com/wp-content/uploads/image-15-768x342.png 768w" sizes="(max-width: 782px) 100vw, 782px" /></figure>



Other benefits of Takt are: Reducing works in progress (WIP),



Builds a foundation for value stream mapping,



Identification of bottlenecks,



Standardized work routines,



Providing a data-centric basis for scheduling, and;



Providing a real-time target for operators to “win the shift.”



Takt ensures customer satisfaction is met, while reducing efficiencies on the production line.



While takt time is a valuable concept in lean manufacturing, it does have some limitations and considerations:



Demand Variability/Assumption of Stable Demand: Takt time may be less effective in industries with unpredictable or highly variable customer demand.



Complex or Inconsistent Products/Processes: It may not suit industries with complex products or processes requiring flexibility beyond a fixed production pace.



Neglects Quality Considerations: Takt time focuses on production rates and may not explicitly address quality concerns if not balanced with appropriate measures.



Limited Flexibility: The fixed nature of takt time may pose challenges in dynamic environments, where sudden changes or disruptions require a more flexible production approach.



While takt time is a powerful tool for many manufacturing contexts, its effectiveness depends on the specific characteristics of the industry, the nature of the products, and the reliability of demand forecasting. It&#8217;s important to recognize its limitations and consider alternative approaches in situations where these limitations may impact its applicability.



How Does Takt Relate to OEE? Overall equipment effectiveness is a valuable metric that has an end goal of “perfect” production, i.e. an ideal cycle time (100% performance) with no defects (100% quality) and no planned or <a href="https://themaintainers.com/blog/the-cost-of-downtime-whats-the-impact-on-your-bottom-line">unplanned downtime</a> (100% <a href="https://themaintainers.com/blog/availability-and-its-impact-on-your-maintenance">availability</a>).



Takt time is more relevant to production efficiency than effectiveness/OEE, where 100% efficiency is characterized by takt; good pieces equals target count/production.



In simple terms, the target for OEE is ideal cycle time, whereas the target for efficiency is takt. Ideal cycle time is the theor​​etical fastest time for a production process, and includes no budgeted losses. And takt, again, is the cycle time that aligns demand with production.



While OEE is a valuable metric for manufacturers, operators find efficiency to be often more meaningful, as it has a very obvious interpretation. A good efficiency score means your plant is efficient. OEE metrics on the other hand are more vague, as they are relative.



<figure class="wp-block-image size-full"><img decoding="async" loading="lazy" width="653" height="314" src="https://blog.themaintainers.com/wp-content/uploads/takt-table.png" alt="a table highlighting the difference between oee and efficiency" class="wp-image-457"/></figure>



Takt time serves as a powerful tool in enhancing both maintenance and production processes. By establishing a synchronized rhythm that aligns with customer demand, Takt time minimizes waste, optimizes resource utilization, and fosters a more efficient workflow. This strategic approach not only supports production efficiency but also enables proactive and preventive maintenance, ensuring that equipment and processes remain reliable and operational, contributing to overall organizational success.

Takt time, sometimes referred to as Takt, is a key principle of lean manufacturing. It refers to the rate at which you need to complete a product or service to satisfy customer demand. The Takt time formula in Lean can be represented as below: Available Production Time refers to the total amount of time available [&hellip;]

Implementing Takt Time to Improve Your Process

Earlier this week, the International Maintenance Conference (IMC) unfolded its magic on the picturesque Marco Island in Florida. Attending this remarkable event was a journey into the future of maintenance practices, where industry experts, thought leaders, and innovative technologies converged to shape the landscape of maintenance and reliability.



It is always an honor to attend the conference, and we have to say one of the standout features of IMC 2023 was the lineup of extraordinary speakers who graced the stage. From seasoned industry veterans to rising stars in the field, the conference boasted an array of thought-provoking sessions that delved into the latest trends, challenges, and solutions within the maintenance realm.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1600" height="1200" src="https://blog.themaintainers.com/wp-content/uploads/image-4.jpeg" alt="a talk open to all attendees" class="wp-image-444" srcset="https://blog.themaintainers.com/wp-content/uploads/image-4.jpeg 1600w, https://blog.themaintainers.com/wp-content/uploads/image-4-768x576.jpeg 768w, https://blog.themaintainers.com/wp-content/uploads/image-4-1536x1152.jpeg 1536w" sizes="(max-width: 1600px) 100vw, 1600px" /></figure>



We want to extend our gratitude and heartfelt congratulations to the event organizers, hosts, sponsors, and everyone else that made such a thoughtful and enriching event a successful reality. <a href="https://www.linkedin.com/in/reliabilityweb" target="_blank" rel="noreferrer noopener">Terrence O’Hanlon</a> &amp; <a href="https://www.linkedin.com/in/maura-abad-b1aab96b" target="_blank" rel="noreferrer noopener">Maura Abad</a> from <a href="https://reliabilityweb.com/" target="_blank" rel="noreferrer noopener">Reliabilityweb.com</a> showed the true power of the Maintenance industry coming together! Reliabilityweb.com curated a fantastic schedule full of interesting forums, reputable speakers, and fun social events to make IMC 2023 not only a great learning experience, but an unforgettable community gathering.



Renowned experts shared their insights on predictive maintenance, asset management strategies, and the integration of cutting-edge technologies. Keynote speeches by industry luminaries not only illuminated the present state of maintenance but also provided a visionary outlook on where the industry is headed.



Among the memorable speakers was <a href="https://www.linkedin.com/in/alanfriedmanvibe" target="_blank" rel="noreferrer noopener">Alan Friedman</a>, whose captivating talk on Vibration Sensors (“Will Wireless Sensors Replace Vibration Technicians?”) left a lasting impression. The audience was treated to a wealth of knowledge, gaining valuable insights that promised to reshape their approach to maintenance in the years to come. More on that in a future article!



Another enlightening experience were the numerous RAP (Reliability And Asset Performance) Talks hosted for all 1100+ attendees to be a part of. The RAP Talks happened throughout the conference, and were led by renown speakers such as Ron Moore, Simon Murray, and Ramesh Gulati. These presentations were focused around bringing reliability to the forefront, and how today’s maintenance teams can achieve it through a blend of new and old strategies.&nbsp;



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1600" height="1200" src="https://blog.themaintainers.com/wp-content/uploads/image-3.jpeg" alt="an IMC &quot;RAP&quot; talk" class="wp-image-443" srcset="https://blog.themaintainers.com/wp-content/uploads/image-3.jpeg 1600w, https://blog.themaintainers.com/wp-content/uploads/image-3-768x576.jpeg 768w, https://blog.themaintainers.com/wp-content/uploads/image-3-1536x1152.jpeg 1536w" sizes="(max-width: 1600px) 100vw, 1600px" /></figure>



The conference was a bustling hub of innovation, with the exhibition floor dotted by the latest technological marvels. The latest advancements in maintenance technology were on full display, captivating attendees with the promise of increased efficiency, reduced downtime, and enhanced asset performance.



Augmented reality (AR) and virtual reality (VR) applications garnered attention, offering immersive experiences in training, troubleshooting, and equipment maintenance. Attendees had the opportunity to witness firsthand how these technologies could revolutionize the way maintenance tasks are performed, providing a glimpse into a future where real-world and digital environments seamlessly intertwine.



Predictive and Prescriptive maintenance solutions were another highlight, with companies showcasing state-of-the-art sensors and monitoring systems. <a href="http://tractian.com/en/" target="_blank" rel="noreferrer noopener">TRACTIAN Technologies</a> demonstrated their prowess, with their US Patented AI-Assisted Maintenance on full display through their hardware and software solutions. The integration of AI and machine learning algorithms demonstrated how data could be harnessed to predict equipment failures, enabling proactive maintenance strategies that save both time and resources.



<figure class="wp-block-image aligncenter size-full is-resized"><img decoding="async" loading="lazy" src="https://blog.themaintainers.com/wp-content/uploads/tractian-booth-scaled.jpg" alt="an image of the tractian booth" class="wp-image-437" style="width:471px;height:628px" width="471" height="628" srcset="https://blog.themaintainers.com/wp-content/uploads/tractian-booth-scaled.jpg 1920w, https://blog.themaintainers.com/wp-content/uploads/tractian-booth-768x1024.jpg 768w, https://blog.themaintainers.com/wp-content/uploads/tractian-booth-1152x1536.jpg 1152w, https://blog.themaintainers.com/wp-content/uploads/tractian-booth-1536x2048.jpg 1536w" sizes="(max-width: 471px) 100vw, 471px" /></figure>



The convergence of the Internet of Things (IoT) was evident, with smart sensors and connected devices providing real-time data streams. This interconnected ecosystem laid the foundation for a more intelligent and responsive maintenance infrastructure, where data-driven decisions could be made instantaneously.



<blockquote class="wp-block-quote">
&#8220;This event was immensely valuable for all the attendees! It provided a unique opportunity for networking and benchmarking with some of the top maintenance leaders from around the globe,&#8221; said Daniel DeAbreu of TRACTIAN. &#8220;Being here provided us invaluable insights and perspectives, it without a doubt broadened everyone’s horizons in the maintenance industry.&#8221;
</blockquote>



Beyond the technological showcase, the IMC served as a vibrant meeting ground for professionals from diverse sectors of the maintenance and reliability community. The networking opportunities were unparalleled, allowing attendees to forge new connections, exchange ideas, and gain valuable insights from their peers.



Community-building events, such as roundtable discussions, workshops, and collaborative problem-solving sessions, facilitated the exchange of best practices, real-world experiences, and happy-hour socials highlighted the friendly and collaborative maintenance culture. The diversity of attendees, ranging from CEOs to frontline maintenance technicians, created a dynamic environment where perspectives converged to shape a holistic understanding of the challenges faced by the industry.



The sense of camaraderie among attendees was palpable, fostering an atmosphere of collaboration rather than competition. Shared experiences and success stories resonated throughout the conference halls, creating a supportive community that went beyond organizational boundaries.



The power of community was exemplified in the interactive forums where attendees could pose questions, seek advice, and engage in lively discussions. Whether it was troubleshooting a specific maintenance issue or brainstorming innovative solutions, the collaborative spirit of the IMC demonstrated the strength that comes from a united community of maintainers.



Being a part of IMC was a transformative experience that left an unforgettable mark on the landscape of maintenance and reliability. From enlightening keynote speeches to the dazzling array of cutting-edge technologies, the event showcased the evolution of an industry poised for innovation.



Our team is extremely pleased to have participated in this year&#8217;s IMC and we are already excited for the 38th edition. The next event is already scheduled, and details can be found at <a href="https://web.cvent.com/event/70ca4b9b-907a-4eb4-b192-dc27db409ef3/summary" target="_blank" rel="noreferrer noopener">this link.</a>



—-



Sponsor companies: ABB, ABS Group, Accenture, Allied Reliability, Amazon Web Services, Aquitas Solutions, Aspen Technology Inc., Asset Analytix, Asset Watch, Association of Asset Management Professionals, Augury, AVEVA, Banetti, Blueprint Intelligence, Boston Dynamics, Cohesive, Emerson Automation Solutions, Exiscan, FOTRIC, Grace Technologies, Hansford Sensors, Hendrix Precision Maintenance Services, Hexagon, I-care Reliability, IBM, IFS, IMI Sensors a PCB Division, Interloc, InterPro Solutions, John Crane, KCF Technologies, Life Cycle Engineering, LUDECA Inc., MaintainX, Maven Asset Management, MaxGrip, Nanoprecise Sci Corp, Projetech, Prometheus Group, RDI Technologies, Reliabilityweb.com, ReliabilityX, SDI, SDT Ultrasound Solutions Inc, SEAM Group, SiggaTechnologies, SKF USA Inc., Strategic Maintenance Solutions, Teledyne FLIR, TRACTIAN, UE Systems Inc, Visual Planner Digital Platform, Wilcoxon Sensing Technologies, ZPro Solutions Inc.

Earlier this week, the International Maintenance Conference (IMC) unfolded its magic on the picturesque Marco Island in Florida. Attending this remarkable event was a journey into the future of maintenance practices, where industry experts, thought leaders, and innovative technologies converged to shape the landscape of maintenance and reliability.

Embracing Innovation and Building Connections at IMC 2023

In the ever-evolving landscape of success and achievement, Forbes has consistently spotlighted the trailblazers, visionaries, and game-changers who are redefining industries and shaping the future. The annual release of the <a href="https://www.forbes.com/30-under-30/2024/manufacturing-industry" data-type="link" data-id="https://www.forbes.com/30-under-30/2024/manufacturing-industry" target="_blank" rel="noreferrer noopener">Forbes Under 30</a> list is a momentous occasion to reflect on the extraordinary talents and accomplishments of the young minds who have captured our collective imagination.



Forbes’ Under 30 has become synonymous with excellence, showcasing individuals under the age of 30 across various categories, from technology and finance to healthcare and the arts. These rising stars embody the spirit of innovation, resilience, and leadership, making significant contributions to their respective fields and inspiring a new generation of aspirants. The world of manufacturing innovation is no different. As technology progresses, the world continues to be inspired by the novel ideas that elevate our capabilities as human beings, and excites us for what the geniuses among us come up with next.



<h2 class="wp-block-heading has-large-font-size">2024’s list had several standouts with a focus on sustainability, automation, and artificial intelligence. Forbes editors (with the expertise of independent judges) evaluated more than 11,000 candidates, judging them on financials, impact, creativity and potential. </h2>



<h2 class="wp-block-heading has-large-font-size">Here’s what we’re excited about:</h2>



<figure class="wp-block-image size-full"><img decoding="async" loading="lazy" width="1280" height="785" src="https://blog.themaintainers.com/wp-content/uploads/tractian.jpg" alt="" class="wp-image-405" srcset="https://blog.themaintainers.com/wp-content/uploads/tractian.jpg 1280w, https://blog.themaintainers.com/wp-content/uploads/tractian-768x471.jpg 768w" sizes="(max-width: 1280px) 100vw, 1280px" /></figure>



Source: TRACTIAN



Artificial intelligence driven startup <a href="https://www.forbes.com/profile/tractian/?list=30under30-manufacturing-industry/&amp;sh=2d9e5bc24a37">TRACTIAN</a>. Cofounded by Igor Marinelli, Leonardo Vieira, and Gabriel Lima, the company develops hardware and software to monitor the condition of machinery and industrial assets. Their end-to-end solution includes a cutting-edge vibration and temperature sensor for condition monitoring, an advanced energy meter coupled with an Energy Management System (EMS), and a CMMS/EAM software built to streamline operational management with real-time, mobile data. With their patented AI-enabled fault diagnosis platform, TRACTIAN is empowering maintenance workers and their teams to be better than ever.



<hr class="wp-block-separator has-alpha-channel-opacity is-style-default"/>



<figure class="wp-block-image size-full"><img decoding="async" loading="lazy" width="710" height="474" src="https://blog.themaintainers.com/wp-content/uploads/ammobia.jpg" alt="" class="wp-image-406"/></figure>



Source: Forbes



Karen Baert and Tristan Gilbert’s startup <a href="https://www.forbes.com/profile/ammobia/?sh=4f1769db7c66">Ammobia</a>. Their company approaches sustainability with a unique goal: producing low-cost green ammonia. Approximately 175 million tons of ammonia are produced annually around the globe, usually in the form of fertilizer. Due to its energy-intensive production, there is a significant amount of greenhouse gasses released as a byproduct. Baert and Gilbert are working to enable ammonia as a clean chemical, fertilizer, and energy carrier to support a decarbonized future.



<hr class="wp-block-separator has-alpha-channel-opacity"/>



<figure class="wp-block-image size-full"><img decoding="async" loading="lazy" width="800" height="530" src="https://blog.themaintainers.com/wp-content/uploads/heliponix-anu.jpg" alt="" class="wp-image-404" srcset="https://blog.themaintainers.com/wp-content/uploads/heliponix-anu.jpg 800w, https://blog.themaintainers.com/wp-content/uploads/heliponix-anu-768x509.jpg 768w" sizes="(max-width: 800px) 100vw, 800px" /></figure>



Source: Anu



Scott Massey’s <a href="https://www.forbes.com/profile/scott-massey/?list=30under30-manufacturing-industry/&amp;sh=7a684c95202b">Anu</a>. A smart garden appliance that allows users to grow fresh produce at home, negating the need for garden plots or expansive backyards, as well as reducing water waste by 98%. Massey is no stranger to small space plant setups, having designed a hydroponic plant growth chamber for NASA while doing engineering research at Purdue.



<hr class="wp-block-separator has-alpha-channel-opacity"/>



The Forbes 30 Under 30 in Manufacturing &amp; Industry not only recognizes exceptional talent but serves as a testament to the transformative power of youth in an industry traditionally associated with experience. As we reflect on the past year of groundbreaking achievements, it is evident that these young innovators are reshaping the landscape of manufacturing through ingenious solutions, sustainable practices, and technological prowess. Their stories inspire not only the current generation but also future leaders to push the boundaries of what is possible in this dynamic field.



See the full list <a href="https://www.forbes.com/30-under-30/2024/manufacturing-industry" target="_blank" rel="noreferrer noopener">here</a>.

In the ever-evolving landscape of success and achievement, Forbes has consistently spotlighted the trailblazers, visionaries, and game-changers who are redefining industries and shaping the future. The annual release of the Forbes Under 30 list is a momentous occasion to reflect on the extraordinary talents and accomplishments of the young minds who have captured our collective [&hellip;]

Revolutionizing Industry: Meet the Forbes 30 Under 30 Entrepreneurs Transforming Manufacturing

Availability is a valuable metric in manufacturing and maintenance. But what does it mean for your production and plant, and how does it differ from Reliability?



Availability speaks to the “degree to which a system, subsystem or asset is in a specified operable and committable state at the start of a mission, when the mission is called for at an unknown or random time (​​Blanchard, 1998).” 



In simple terms, availability means the duration of time a system is available and able to perform its tasks.



This definition sets it apart from reliability, as reliability refers to the probability that a system or asset will work without failure, i.e. is reliable. Availability is driven by time loss whereas Reliability is driven by the occurrence frequency and total impact of failures.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1600" height="570" src="https://blog.themaintainers.com/wp-content/uploads/image-12.png" alt="a simple chart showing the difference between availability and reliability" class="wp-image-395" srcset="https://blog.themaintainers.com/wp-content/uploads/image-12.png 1600w, https://blog.themaintainers.com/wp-content/uploads/image-12-768x274.png 768w, https://blog.themaintainers.com/wp-content/uploads/image-12-1536x547.png 1536w" sizes="(max-width: 1600px) 100vw, 1600px" /></figure>



It is important to note that an available asset is not always reliable, and a reliable asset is not always available.



<h2 class="wp-block-heading">How to Calculate Availability?</h2>



The equation to calculate availability is straightforward: uptime over total elapsed time (uptime plus downtime), multiplied by 100.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1600" height="570" src="https://blog.themaintainers.com/wp-content/uploads/image-12.png" alt="availability equation" class="wp-image-396" srcset="https://blog.themaintainers.com/wp-content/uploads/image-12.png 1600w, https://blog.themaintainers.com/wp-content/uploads/image-12-768x274.png 768w, https://blog.themaintainers.com/wp-content/uploads/image-12-1536x547.png 1536w" sizes="(max-width: 1600px) 100vw, 1600px" /></figure>



An alternate equation for availability is a ratio of the Mean Time To Failure (MTTF) and Mean Time Between Failure (MTBF), as seen below:



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1548" height="498" src="https://blog.themaintainers.com/wp-content/uploads/image-11.png" alt="another availability equation" class="wp-image-394" srcset="https://blog.themaintainers.com/wp-content/uploads/image-11.png 1548w, https://blog.themaintainers.com/wp-content/uploads/image-11-768x247.png 768w, https://blog.themaintainers.com/wp-content/uploads/image-11-1536x494.png 1536w" sizes="(max-width: 1548px) 100vw, 1548px" /></figure>



Both equations should provide you with the same percentage, and as thus is simply a matter of preference.



<h2 class="wp-block-heading">Why is Tracking Availability Important?</h2>



Monitoring your production’s availability is important for several reasons. As a maintenance manager, you want to be keenly aware of how your current maintenance strategies and practices are maintaining uptime.&nbsp;



An asset’s availability is directly proportional to overall output and performance. <a href="https://themaintainers.com/blog/the-cost-of-downtime-whats-the-impact-on-your-bottom-line">Downtime has been increasingly costly</a>, valued at almost $500,000 per hour of downtime in the oil and gas sector and over $2 million per hour in the automotive sector. Knowing your availability, and thus being able to implement improvements, allows you to reduce unplanned downtime and its associated impacts, financially or otherwise. Maximizing availability and reducing downtime safeguards your company’s production and profitability.



<h2 class="wp-block-heading">How to Improve Your Availability</h2>



As mentioned above, a low availability has significant repercussions on your bottom line, and it’s in your best interest to ensure that uptime is at its peak. But how do you actually improve this particular metric? We’ve outlined three proven strategies that can benefit your availability and uptime. 



<ol>
<li>Implement Predictive Maintenance Strategies:</li>
</ol>



Implementing predictive maintenance strategies involves using advanced technologies such as vibration analysis sensors and data analytics to monitor the condition of equipment in real-time. By analyzing data on equipment performance, businesses can predict when maintenance is needed, enabling them to schedule downtime at the most opportune times, reducing unplanned outages. This method helps prevent equipment failure and extends the lifespan of machinery. 



<ol start="2">
<li>Technology Integration and Automation</li>
</ol>



Embrace advanced technologies, such as automation, robotics, and Internet of Things (IoT) devices, to streamline processes and reduce the likelihood of errors and breakdowns. Automated systems can operate more consistently and provide real-time data on equipment health, enabling faster response to potential issues. This leads to improved overall system availability and performance. 



<ol start="3">
<li>Invest in a CMMS or an EAM.</li>
</ol>



A CMMS (computerized maintenance management system) or an EAM (enterprise asset management) system is software that streamlines team communications and workflow. These types of software often have the capacity to automate scheduling for maintenance and planned downtime, generate collaborative <a href="https://themaintainers.com/blog/work-orders-in-maintenance-a-complete-guide">work orders</a>, and to analyze KPIs such as team performance and costs. Having all your documentation — from work orders to inventory — in one place ensures that the entire team is on the same page, and there is no redundancy from miscommunication.



TRACTIAN’s <a href="https://tractian.com/en/software-management-maintenance">TracOS™</a> makes maintenance management easier than ever. Optimize your work order process with a fully digitized and collaborative platform, fully integrated with QR codes that let you see the complete history of an assets maintenance. As tasks are assigned and completed, you can access performance metrics like cost per work order, inventory used, task completion time, team efficiency, and so much more, so you can learn where your areas of improvement are with real-time, accurate data. 



The TracOS™ platform learns your maintenance needs through work order history, and can plan and schedule the ideal preventive maintenance strategy for optimal asset performance.



<figure class="wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio"><div class="wp-block-embed__wrapper">
<iframe loading="lazy" title="TracOS™ - Asset Management has never been easier" width="500" height="281" src="https://www.youtube.com/embed/Hcn1W2MTKEo?feature=oembed" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" allowfullscreen></iframe>
</div></figure>



<a href="https://youtu.be/Hcn1W2MTKEo">https://youtu.be/Hcn1W2MTKEo</a>



Implementing these methods requires a holistic approach and often involves a cultural shift within the organization towards proactive maintenance and continuous improvement. Improving availability requires more than technical changes—it&#8217;s about fostering a culture that values proactive maintenance, ongoing improvement, and the adoption of advanced technologies. In today&#8217;s fast-paced manufacturing landscape, where time is of the essence, availability becomes the key factor that can shift organizations from reacting to issues to proactively building reliable systems.



The journey toward better availability is ongoing. Regular evaluations, insights from data, and a commitment to a culture of constant improvement are crucial. As we navigate the digital age, where data and machinery go hand in hand, the role of availability as a maintenance metric remains pivotal in shaping the future of effective, dependable, and sustainable manufacturing practices.

Availability is often used interchangeable with Reliability, however these are two very different maintenance metrics. Read more to see how they differ, and why Availability is vital to know.

Availability And Its Impact On Your Maintenance

In industrial maintenance, pinpointing system failures is crucial. Fault Tree Analysis (FTA) is key in this process, offering deep insights into complex failure networks.



Take a manufacturing plant&#8217;s conveyor belt system halt, for example. FTA digs beyond surface issues like motor failure, uncovering underlying causes such as electrical faults or maintenance oversights.



<h2 class="wp-block-heading">What is a fault tree analysis (FTA)?</h2>



It&#8217;s a systematic method that unravels failure events, revealing interconnected faults. FTA provides maintenance teams with a visual map to trace failure origins, aiding in effective decision-making and robust maintenance strategies.



The failure of a component in a system is often caused by the failure of other elements. For example, a vehicle&#8217;s braking failure can be caused by water in the brake cylinders, which in turn may be caused by failure of the cylinder seals.



A fault tree analysis, or FTA, provides a method of breaking down these chains of failures, with a key addition for identifying combinations of faults that cause other faults. This type of analysis provides maintenance team members a visual representation of how a problem occurred and the potential pathways that led to the main failure event. This process provides the analyzer with a logical sequence that helps identify the root causes of the failed event in question. When a fault tree analysis is used concurrently with other analysis methods, it provides a better overall picture for future maintenance strategies and decisions.



<h2 class="wp-block-heading">Using A Fault Tree Analysis</h2>



Fault Tree Analysis (FTA) is an important tool in risk assessment and system safety engineering, used for analyzing the potential failure modes within a system. There are three main components to this analysis:







<ol>
<li>The Fault Tree Diagram</li>
</ol>



This is the visual representation of the events leading up to the equipment’s breakdown or failure. It begins with the failure, and leads back to the root cause through a series of logical deductions.







<ol start="2">
<li>The Events</li>
</ol>



This includes the occurrences that caused the failure, contributors, and the failure directly, and include everything that may have or has happened leading to the failure. Events can be either input (i.e., lead to other occurrences) or output (i.e., result from other circumstances).&nbsp;







<ol start="3">
<li>Logic Gates</li>
</ol>



Logic gates use an “and/ or” sequence to connect related events. Two input events that lead to an output event are connected through an “and” gate, while single input events that lead to an output event connect through an “or” gate. For instance, a broken wiring system and a burnt-out light bulb connect with an “and” gate. However, if only the wiring was faulty, an “or” gate is more appropriate.



<h2 class="wp-block-heading">How Does FTA Work?</h2>



FTA helps in understanding the relationships between various events and conditions that can lead to a specific undesired outcome. Here&#8217;s an overview of how FTA works:



1. Define the Top Event:



The first step in FTA is to clearly define the undesired outcome, often referred to as the &#8220;Top Event.&#8221; This is the event that is being analyzed and is usually placed at the top of the fault tree.



2. Identify Basic Events: 



Basic Events are the most elementary failures or events that can contribute to the Top Event. These are events that are assumed to occur independently of each other. Identify and list these events that could lead to the Top Event.



3. Construct the Fault Tree: 



Using logic gates (AND, OR, and NOT), construct the fault tree by connecting the Basic Events to the Top Event.



AND Gate: Represents that all input events must occur for the output event to occur.



OR Gate: Represents that any one or more of the input events can cause the output event to occur.



NOT Gate: Represents the negation of an event.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="1498" height="932" src="https://blog.themaintainers.com/wp-content/uploads/image-10.png" alt="a sample FTA" class="wp-image-384" srcset="https://blog.themaintainers.com/wp-content/uploads/image-10.png 1498w, https://blog.themaintainers.com/wp-content/uploads/image-10-768x478.png 768w" sizes="(max-width: 1498px) 100vw, 1498px" /></figure>



4. Assign Probabilities:



Assign probabilities to the Basic Events. This step involves estimating the likelihood of each Basic Event occurring and contributing to the Top Event. Probability values can be based on historical data, expert judgment, or other sources.



5. Calculate Top Event Probability:



Using the logic gates and assigned probabilities, calculate the probability of the Top Event occurring. This is often done using probabilistic models such as Boolean algebra or probability calculations.



6. Sensitivity Analysis:



Conduct sensitivity analysis to identify which Basic Events have the most significant impact on the Top Event. This helps prioritize risk mitigation efforts.



7. Interpret Results:



Interpret the results of the analysis. If the calculated probability of the Top Event is within acceptable limits, the system may be considered reliable. If it exceeds acceptable limits, further analysis and risk mitigation strategies may be necessary.



8. Risk Mitigation:



Based on the findings of the analysis, develop and implement risk mitigation strategies to reduce the probability of the Top Event occurring. This could involve design changes, redundancies, or other safety measures.



9. Documentation:



Document the fault tree analysis, including the identified events, probabilities, logic gates, and conclusions. This documentation is valuable for communication, future reference, and regulatory compliance.



Below is an example of a blank fault tree analysis diagram, and it is effectively a fill in the blank practice. You write the initial problem in the top rectangle before working through the various events that could have led to it in the subsequent boxes.



<figure class="wp-block-image"><img decoding="async" loading="lazy" width="721" height="726" src="https://blog.themaintainers.com/wp-content/uploads/image-9.png" alt="a blank FTA" class="wp-image-383"/></figure>



<h2 class="wp-block-heading">What Are The Benefits of A Fault Tree Analysis</h2>



Implementing FTA practices have significant benefits to organizations, managers, and maintenance teams.&nbsp;



<h3 class="wp-block-heading">Systematic Identification of Failure Modes:</h3>



By identifying the root causes of system failures, teams understand the vulnerabilities of a system and are able to develop targeted risk mitigation strategies.



<h3 class="wp-block-heading">Risk Assessment and Prioritization:</h3>



By assigning probabilities to events and calculating the probability of the top event (undesired outcome), organizations can prioritize their efforts and resources to address the most critical and potentially catastrophic failure modes, essential for effective risk management and decision-making.



<h3 class="wp-block-heading">Proactive Risk Management:</h3>



This proactive approach minimizes the likelihood of unexpected failures, reduces downtime, and enhances overall system performance.



<h3 class="wp-block-heading">Communication and Decision Support:</h3>



This visual representation makes it an effective communication tool for conveying complex risk scenarios to various stakeholders, including engineers, managers, and regulators. FTA results offer decision support by providing insights into the critical factors affecting system reliability, aiding decision-makers in developing effective risk mitigation strategies and optimizing resource allocation.



While a handy tool for every professional to know, FTA is not the right answer for all situations and teams. Implementing other preventive failure and maintenance strategies such as condition based monitoring tools like IoT sensors, or implementation of a CMMS to ensure accurate data recording and analysis, allows failure tree analyses to complement a pre-existing maintenance strategy, or allows teams to develop a comprehensive preventive maintenance strategy.

A fault tree analysis, or FTA, provides a method of breaking down these chains of failures, with a key addition for identifying combinations of faults that cause other faults. This type of analysis provides maintenance team members a visual representation of how a problem occurred and the potential pathways that led to the main failure event. This process provides the analyzer with a logical sequence that helps identify the root causes of the failed event in question.

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