Defect Elimination

Defect Elimination | Bad Actor Management

Defect elimination is a systematic proactive approach to eliminating machine downtime and improves equipment reliability performance.

DE is an important reliability and business improvement tool that seeks to proactively identify product and process defects, allocate them a priority, and then identify and eliminate root causes.

A defect can be defined as “anything that erodes value; reduces production; compromises health, safety, or the environment, or creates waste”.

A defect can be introduced during the design phase, installation phase, or operational phase. If defects aren’t eliminated during the design or installation phase, sometimes companies just live with them throughout the operational phase. Many defects are introduced during the operational phase. Typically, these are induced by operational or maintenance practices. To compound the problem, many of the defects are what we call chronic. In other words, they occur over and over, never getting repaired or resolved. Chronic defects could be holdovers from the design and installation phase or introduced during the operational phase.

The financial impact of defects is hard to quantify and difficult to measure, but their reduction or elimination represents a significant improvement in financial gain.

Defect Elimination: It’s a Culture

Defect elimination isn’t a job designed strictly for the O & M team. It is expected that every functional staff in the organization is observant enough to spot a defect and eliminate it instantly. Companies can achieve DE culture or zero defect culture by simply adopting 3 steps.

  • In DE process every employee should be actively engaged in the defect elimination process.
  • Identified defects must be removed from its root.
  • A good system operated DE process need to be establish.

Bad Actor Management

Bad Actor Management is a process by which harmful and unplanned failures are captured, prioritized and investigated to identify the root cause. Corrective actions are then developed and implemented to eliminate or mitigate a repeat failure.

Arrelic Defect Elimination Process?

  • Step One – Identify Unwanted Events / Defects
  • Step Two – Assessing, prioritization and Selecting Events for Analysis
  • Step Three – Analyzing Unwanted Events
  • Step Four – Decide and Act - Root cause determination
  • Step Five – Implementations of solutions
  • Step Six – Improve and Measure the outcome

Defect Elimination Tools

  • Statistical process control
  • Defects per unit (DPU)
  • Supplier assessments
  • FMEA
  • FRACAS
  • Error proofing
  • Basic Equipment Care (BEC)
  • Failure identification and root cause analysis (RCA)
  • Reliability data analysis

The ABC’s of Failure

Studies have shown that failures are generated from three major sources. They are:

  • Aging: This failure is as a result of over long period of time of assets. Assets within this category can show defects even if not operated at all.
  • Basic wear and tear: Failures of assets within this category have shorter periods of time depending on the equipment’s quality.
  • Careless Work Habits: This is the failure that happens when the equipment is not provided with the appropriate care it needs to function perfectly such as lack of discipline to operate, lack of proper training, etc. Over 80% of defects eventually becomes failures due to careless work habits.

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