Defect Elimination & Bad-Actor Management
How to find the equipment and defects that drain the most value, eliminate them with cross-functional teams, and sustain a defect elimination programme. For reliability engineers, maintenance leads and operations professionals.
51m
Total time
4
Competency levels
12
Lessons
What you'll learn
- Distinguish defects from failures and explain why eliminating defects early is cheaper than repairing failures
- Apply Pareto analysis to work orders and downtime data to identify bad-actor equipment
- Select the right response for a problem: quick defect elimination action versus formal root cause analysis
- Set up and facilitate a cross-functional defect elimination team of operators, maintainers and engineers
- Track eliminated defects and quantify the value delivered by the programme
- Feed defect lessons into design, procurement and maintenance strategy so defects stay eliminated
Curriculum
Progress through each competency level in order.
1
Awareness
- 2mDefects, failures and why order mattersKnowledge
- 2mBad actors: the vital few that drain the mostKnowledge
- 7mAwareness check: defects and bad actorsAssessment
2
Knowledge
- 2mFinding bad actors with Pareto analysisKnowledge
- 2mChoosing the response: quick defect elimination or formal RCAKnowledge
- 8mKnowledge check: Pareto and choosing the responseAssessment
3
Skill
- 3mRunning a cross-functional defect elimination teamKnowledge
- 3mRun a bad-actor analysis and defect elimination actionAssignment
- 8mSkill check: teams, causes and actionsAssessment
4
Mastery
- 3mSustaining the programme: value tracking and closing the loopKnowledge
- 3mDesign and defend a defect elimination programmeAssignment
- 8mMastery assessment: leading defect eliminationAssessment
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