When it comes to working on machinery in the plant, the saying ‘If it ain’t broke, don’t fix it’ comes to mind. In other words, don’t work on something until it needs to be worked on. The challenge is that everyone has a different definition of ‘broke,’ so everyone has a different idea of when something needs to be worked on. From the perspective of reliability, a machine is broken as soon as a defect enters the system that will lead to a functional failure and potentially a catastrophic failure. A process is needed to understand the current state of the machine and to detect the presence of a defect in a system. Once the current state is understood, decisions can be made about how to work on the machine and when to perform this work.

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