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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.

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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

  • Defects, failures and why order matters
    Knowledge
    2m
  • Bad actors: the vital few that drain the most
    Knowledge
    2m
  • Awareness check: defects and bad actors
    Assessment
    7m
2

Knowledge

  • Finding bad actors with Pareto analysis
    Knowledge
    2m
  • Choosing the response: quick defect elimination or formal RCA
    Knowledge
    2m
  • Knowledge check: Pareto and choosing the response
    Assessment
    8m
3

Skill

  • Running a cross-functional defect elimination team
    Knowledge
    3m
  • Run a bad-actor analysis and defect elimination action
    Assignment
    3m
  • Skill check: teams, causes and actions
    Assessment
    8m
4

Mastery

  • Sustaining the programme: value tracking and closing the loop
    Knowledge
    3m
  • Design and defend a defect elimination programme
    Assignment
    3m
  • Mastery assessment: leading defect elimination
    Assessment
    8m

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