Bluefield 30 in 30 is a podcast intending to capture key learnings from mining professionals with a minimum of 30 years experience in 30 minutes.
Taking a Systematic Approach to Ouput Improvement with Dick Pettigrew
Our guest today has been at the forefront of operational reliability improvement in various industries around the world for many years. Dick Pettigrew joins us today, sharing from his extensive experience as we discuss his integrated approach to design, maintenance and operations.
With a degree in Chemical Engineering and a love for machinery, Dick started out working in process engineering support. As he progressed into design and project management, Dick began to observe fundamental issues surrounding the approach to reliability improvement and maintenance operations. In this episode, Dick shares about his career journey, some of the major learnings of his experience thus far and his holistic approach to problem solving on site, not just within maintenance reliability.
We discuss how output improvement is more valuable than maintenance cost reductions, how there’s a difference between the problem and the cause and that taking a broadened approach from reliability improvement into total manufacturing improvement is what will create sustainable improvements.
Dick talks us through some of his experiences improving outcomes and how the assessment process itself isn’t as important as the commitment from the leadership team and people on site to implement the improvements. We discuss the importance of establishing a good culture and how working with people directly on the floor brings the plant up to standard and restores pride in the operation.
Dick has spent a lot of time creating measurement systems and writing books to take a systematic approach to output improvement. He discusses his asset utilisation model and how combining this with the theory of constraints enabled him to improve the output of many plants he’s been involved in.
We discuss using RCM not as a project but as a way of thinking about plant reliability and how it can make a real difference when utilised this way. Dick shares his advice to aspiring maintenance and operational managers, honing in on the vital component of the human aspect.
Improving Safety and Work Quality Outcomes with Steve Flannery
Our guest today, Steve Flannery, has clocked up just over 30 years working primarily in the mining industry. Starting off as a plant mechanic apprentice to gain hands on experience, completing his mechanical engineering degree and working in numerous large corporations, Steve has vast experience in asset management with a focus on work quality.
Steve’s current role is in Asset Management Services as Manager of Eastern Region (NSW/Vic/NZ) at Bluefield. In this episode, Steve shares his journey in the industry and how having a trade background makes a big difference with people on the ground, understanding the challenges of the job and how to find positive solutions.
Steve shares how good maintenance is all about having the right people doing the right work at the right time and that work quality and safety go hand in hand. He recounts some incidents on site leading to injuries and how in his experience, incidents most commonly involve an asset, design or maintenance element.
When asked about his best outcome from assets, Steve shares about the challenge he faced in 2012 to cut his maintenance budget by 30%. He was able to achieve this target in a sustainable way whilst maintaining fleet performance through strategy and good data. This experience taught Steve a lot and he discusses how he has learnt to focus on the work execution team to obtain the best results.
Steve recounts his worst experience as a maintenance manager and his most difficult time dealing with a GM and how he dealt with it. He also shares about his positive fix mentality and leaves us with his top pieces of advice for those looking to enter into the maintenance managers space.
Listening to your Team to Achieve Results with Dave Archinal
Our guest today is Dave Archinal, the South Australian Manager at Bluefield, and he shares from his wealth of knowledge and experience in the reliability and improvement arena. Having worked in the industry for over 30 years, Dave has travelled the world working on different improvement programs across numerous industries and commodities.
In this episode, Dave talks about how he got started in the industry in a mechanical engineering cadetship and how he worked his way through supervisory and planner roles, eventually finding his niche in reliability and improvement. Dave was encouraged to step up into a supervisory role at the young age of 19 and he shares some of the lessons he learned early on about the importance of asking the right questions, listening and enabling others to perform at their best.
As a young apprentice, David was never satisfied with simply completing transactions. He felt the need to question how the system could be made easier, which led him into maintenance improvement initiatives and eventually into the consulting space. David shares numerous experiences working with companies to improve their systems by asking the right questions and challenging the existing processes in place.
David shares his 3 golden nuggets for those looking to embark on a reliability improvement project and talks about the importance of taking the time to listen to the people around you. You can have all the ideas in the world, but until you know what the problem is, you won’t find the solution.
Website: https://www.bluefield.com.au/en/ (https://www.bluefield.com.au/en/)
Book: The Knowing Doing Gap
Lifting People up to a Common Goal with Richard Blayden Part 2
This episode follows on from last week’s discussion with Richard Blayden as he talks about making change in a workplace by lifting people up to a common overall context.
Richard discusses what is required to make lasting change and shares examples of how he has helped implement such change through his process utilising organisational charts, focussing on relationship, understanding data and asking the right questions. Richard also shares his top 5 pieces of advice for those wanting to get excellent results from their assets.
Lifting People up to a Common Goal with Richard Blayden
Our guest today has quite a few more than 30 years experience under his belt. Recognised as the father of the pipeline model for understanding work management, Richard Blayden was the first to put together a detailed framework for operational readiness processes. His developments have become the standard reference point for many of us in the industry.
Starting out his career as a young apprentice, Richard went back to study engineering and progressed into project management. With a broad range of knowledge and depth of experience, he provides asset management and organisational performance improvement services to the mining industry and other industries.
In this episode, Richard shares from his years of experience and how and why he came to develop the pipeline model. Having been involved in maintenance and project management from early days, he found that a lot of issues on site were due to a lack of information, communication and poor data analysis. Richard discusses common issues on site and how the pipeline model helps to lift people up to a common goal rather than dwelling on their personal thoughts about a particular issue.
Richard discusses his involvement in the BHP maintenance evaluation in the early days and the three key issues that were discovered from that process. He shares his thoughts on why people aren’t good at data analysis, how a character string analysis identified an issue that was costing millions of dollars every year and how identifying and implementing the right process helped to fix it.
Keeping Your Systems Simple with Leigh Jameson
A system is a tool that delivers on business processes to reach strategic goals. A common mistake, however, is when businesses focus on the system instead of the outcome the system is intended to achieve.
Our guest today is Leigh Jameson, Senior Asset Management Specialist at Bluefield, and he shares from his wealth of knowledge regarding data analysis, systems and processes. Beginning his career as a motor mechanic and moving into diesel fitting and numerous roles within the mining industry, Leigh’s vast experience has provided a unique perspective into how keeping systems simple lead to the best performance outcomes.
Throughout Leigh’s experience in the workplace, he discovered a passion for improving systems and asking the right questions to enable better outcomes and work quality. Motivated by his desire to thoroughly investigate issues, Leigh spent nights reading and educating himself which eventually led him into the asset management space.
In this episode, Leigh shares his passion for systems improvement and how quality data underpinned by good business processes leads to work quality and positive outcomes on site. He shares some of his positive and challenging experiences over the years and the lessons learned regarding the importance of simplifying systems.
A great system is only one aspect of achieving great results. Leigh shares about the importance of developing a proactive culture on site where each person has a part to play. When people are valued, motivated, and educated they can work together to look for areas of improvement and reduce administrative burden.