Productivity enhancement using safety and maintenance integration

Ensuring equipment reliability, preventing human error and preventing accidents are necessary for improving predictable plant capacity. These subjects however, have so far been treated separately whereas an integrated approach is the need of the hour. A typical maintenance system focuses on equipment. However, its goals must include establishment of conditions that reflect an understanding of production plants as a combination of various man‐machine systems. Eliminating accidents and removing causes of production interruptions should be approached from the “man” as well as “machine” side. This paper outlines the relationship that exists between plant productivity, safety, and maintenance activities. An integrated system of activities, which is likely to help in eliminating accidents and maintenance related causes of production interruptions, is presented. This system divides plant operations into “man‐machine” system and management system activities. Activities that assist in eliminating accidents and removing potential causes of production interruptions are presented. Key performance indicators and a methodology for operating a continuous improvement program are outlined.