Condition Based Maintenance

TPM's Myth of Zero Unplanned Downtime

One of the goals of Total Productive Maintenance is to achieve zero unplanned downtime. While I understand the value of zero targets, in this case I think it serves to alienate some of the seasoned veterans that we desire to include in our reliability improvement efforts.  Our craftsmen intuitively know that preventing all failure is not possible, this disconnect between goal and reality aids the unfortunate leap to the philosophy that their job is simply to repair the failures quickly.  This problem is often compounded by rewarding reactive behaviors.  For example, when I worked in the trades, I quickly learned that the best troubleshooter and fastest repairman got the most recognition, praise, and overtime.