How often are small, seemingly minor jobs instigated with only verbal instruction or the simplest of hand sketches and with no detailed Engineering Drawings for the minor works? Why is it so? – To use a well known phrase or saying
Well…… There are many reasons given –
It’s a very simple, basic job and doesn’t need a drawing
We don’t want to spend time or money on a detail drawing for such a small job – it is not justified
Why spend time, effort and money on a small job which the fitter/millwright/skilled worker/contractor can do without a detail drawing and in fact they have done similar jobs many times before
We don’t have a drafter or the ability to produce an Engineering Drawing
All of our Engineering staff are currently fully occupied on other major work
We don’t know what we want – but its pretty simple and we want it fixed and we are sure that the fitter/millwright/skilled worker/contractor can come up with something – they always have in the past
We always use contractors – we tell them the issues and they figure it out and fix it
And other similar reasons
The reasons all follow a similar pattern.
However the bottom line is – If there is no Engineering Drawing – How on earth do you know what you are going to get – it’s just like signing a blank cheque. You may get a very good fix or you may not.
And that fix will come at a cost – and not always in money.
Verbal instructions with no detailed Engineering drawings can have widely differing interpretation
I fully expect that there will be some people who will say – “its all very minor stuff – not worth spending much time or money on – JFDI (Just Flipping Do It) –
However, there are many potential traps and follow up questions – such as –
Does the finished work ……
Comply with all of the relevant statutory external Standards
Comply with all internal company standards
Comply with all of the relevant OH&S requirements
Suit the ergonomic requirements
Actually provide a suitable solution to the problem
Provide an “ongoing fix” or will it fall apart very quickly
Become a “band aid “fix for a problem which will keep returning
Become a temporary fix which “looks like a temporary fix” and will never get a proper fix – the problem with these types of fixes is that it becomes the accepted norm and they can get progressively worse.
Verbal instruction with no Engineering Drawings for Minor Works. Who knows what the “fix” will be
And of course – There is no permanent record of specifically what has been done, so that if there is a recurring or similar problem – a different fitter/millwright/skilled worker/contractor will need to start again from the beginning. Maybe a different fix – maybe better – maybe worse – who knows? as the work is not being recorded or managed
With no detailed Engineering Drawing there is every chance that a Band Aid solution could be put in place and stay in place until the next breakdown
Most companies are trying to instill a culture of excellence and continuous improvement in their staff. However, it can be counterproductive when questionable fixes are put in place for small jobs and particularly if they stick out like the proverbial sore thumb.
Sometimes all work is done by outside contractors – I have seen major companies close down all of their internal engineering capabilities and outsource everything – as a cost saving measure.
Whilst this may show a cost saving in one area of the financial accounts in the short term – it is very likely to create a much larger expense in other areas of the financial accounts. And this cost is quite often not captured or immediately obvious.
This can be a very dangerous practice for a number of reasons – However the people who make these decisions are generally very removed from the day to day running of the business and can be quite oblivious to the problems and costs encountered by the people “at the coal face”
I have worked as a contract Engineer/Drafter at a number of companies over the past 50 years or so and have seen many of these issues “first hand”
I will briefly touch on a few areas.
Does guarding which was fabricated and fitted “on the run” comply with statutory standards
Temporary repairs to pressure piping which have been in place for years – just forgotten about – but will burst eventually with the possibility of serious ramifications.
Machine Guards which have been fabricated and installed “on the run” which do not comply with safety standards.
Stairs, Steps, Hand Railing and Platform repairs etc are all likely candidates for non complacence and in danger of being trip or fall hazards
Some companies have regular safety audits and these get picked up.
In other companies these dangers are just part of the working environment – until something goes wrong and there is an incident.
I would also comment that in several companies I did contract work for, the maintenance fitters would keep their own detailed records of machine issues and repairs, typically hand written in note books. Generally they were very protective of this information. In their eyes they owned this data and it was not to be shared with anyone. This went some way to protecting their positions at the companies. And as long as the machines ran OK – this was not an issue with senior management who generally where focused on other issues. I my view it was poor practice – but it seemed to work for them. – Most of the time!!
Verbal Instruction to replace “Like with Like” has many traps…….
Not Only – But Also……
When there is a need to take a deep breath and take a break
Looking for “A Better Way” – Go to – Engineering the 3R Way for an overview of the 3R PhilosophyReview – Refresh – Reset and link to the full list of topics
Then Take A Break – With the List Of Pages – Engineering Nostalgia for pages of Old Engineer Memories from Engineering practice in the 1960’s/70’s/80’s – with a bit of armed forces and medieval trivia thrown in
Or check out Engineering Odd Bits for more odd subject matter – including humor and comment
Hi, Slide is the name, Slide Rule that is. For years I was the biggest thing in the world of Engineering, Science and Commerce,
Hey, there was hardly a calculation done which didn’t involve me, the Slide Rule. I was the King. I’d been around for hundreds of years and I RULED (excuse the pun). My powers are based on a clever logarithmic scale and it was all me, Multiplication, Division, Involution, Evolution, Trig Functions, Logs, I did it all and I was loved by all.
Then one day a few years ago, it all started to change. Along came a cute little number called Cal – Cal Culator to be precise. Sure she was a bit bulky, not as good looking as me and her batteries were prone to failure, but she had a big advantages over me. She was deadly accurate, fast and so easy to use, time after time after time and anyone could use her. No special skill was needed.
I’m sure that people really loved me, but I could never compete with that accuracy, speed and simplicity. I could get close, but my users still had to use mental arithmetic and a degree of approximation.
Cal however, she was just spot on every time and oh so quick and easy.
Then….As time went by….. she got lighter and shapelier and more colorful with more and more features and functions. She was cheaper to buy and her batteries began to just last and last a long, long time.
Man…. I was gone, I tried to fight back but I had nothing and I’ve been out to pasture for quite a few years now, slowly sinking into the sunset.
But those clever guys on the internet have come up with a way to keep the legend alive and have immortalized me with my own web page on numerous web sites which feature an interactive display, where you can go and use me, the way I was designed to be used.
So the legend lives on. If you’re an old timer and can still remember how to do it, a young timer who is keen to learn or just have an interest, click onto the links below and go have a look and a play. The instructions are simple, so give it a try.
When there is a need to take a deep breath and take a break
Looking for “A Better Way” – Go to – Engineering the 3R Way for an overview of the 3R PhilosophyReview – Refresh – Reset and link to the full list of topics
Then Take A Break – With the List Of Pages – Engineering Nostalgia for pages of Old Engineer Memories from Engineering practice in the 1960’s/70’s/80’s – with a bit of armed forces and medieval trivia thrown in
Or check out Engineering Odd Bits for more odd subject matter – including humor and comment
Military Trivia Quiz 101 – Is a challenging selection of MilitaryTrivia questions and answers - sometimes you just don’t know what you don’t know, but you’re sure that you did know or that you should know and when you see the answers you know that once upon a time you probably did know !
Challenge your colleagues – can they answer more than you ?
Go to – Engineering the 3R Way for an overview of the 3R Philosophy and review the full list of topics
Then Take A Break
With the List Of Topics – Engineering Nostalgia for pages of Old Engineer Memories from Engineering practice in the 1960’s/70’s/80’s – with a bit of armed forces and medieval trivia thrown in
Or check out Engineering Odd Bits for odd subject matter – including humor and comment
The name for Shrapnel was derived from the Greek word for “shatter and spread in many directions” – True or False
Shrapnel was named after British army officer Lieutenant General Henry Shrapnel
The Maginot Line was the secure telephone line used between the French President and the British Prime Minister at the beginning of WWII – True or False
The Maginot Line was a series of fortifications constructed along the French - German border during the 1930’s
Mulberry Harbours were temporary portable harbours developed by the British during World War II - True or False
Gunpowder was invented by the Greeks – True or False
Gunpowder was invented by the Chinese in the 9th century
The WWII Manhattan Project was created to produce …
The Bailey Bridge was designed to transport live shells from a stockpile to an artillery field gun thus eliminating the need for manual handling – True or False
The Bailey Bridge was a prefabricated, portable, temporary truss bridge, designed to be used where a permanent bridge had been destroyed
The Gatling Gun is named after its inventor R.J.Gatling – True or False
In the Roman army a Ballista was a …
The Tank is an armoured fighting vehicle designed for front line combat. Designed and first used in WW1, the name “Tank” was used by the British as a security measure to fool enemy spies – True or False
The word Ballistic is derived from the Greek word for violent explosion – True or False
The word Ballistic pertains to the science of motion – specifically under its own momentum
A Hostile Trivia Quiz – Maybe ?
Ouch! Time to hit the books
You need to look on the positive side – from here - the only way is up - try again next week
Share your Results :
A Hostile Trivia Quiz – Maybe ?
You can do better!
You have a base to work from – you just need to raise the bar next week
Share your Results :
A Hostile Trivia Quiz – Maybe ?
You have some knowledge!
You need to improve your trivia knowledge if you want to be a master!
Share your Results :
A Hostile Trivia Quiz – Maybe ?
Trivia Buff!
You’re pretty good – almost a Master
Share your Results :
A Hostile Trivia Quiz – Maybe ?
Trivia Sensei!
You have an excellent trivia mind, you're a know it all! Keep it up and try again next week!
The Devils Advocate needs to ask the difficult questions in an unbiased and balanced way in order to find any hidden problems
Regardless of it being a very complex project, a fairly simple/basic job or simply routine management tasks, one of the key elements to success is to apply The Devil’s Advocate In Engineering methodology.
Obviously the complexity of the project or task dictates the level of detail. However the basic principles and fundamentals are always the same.
In simple terms, The Devil’s Advocate is a skilled person or group of people, who can take a critical but balanced approach to the subject in question.
For example, this could be a Management Decision, Engineering Project or Engineering Design. The Devil’s Advocate needs to dissect each aspect, ask probing questions and ensure that the proposal is sound and stands up to scrutiny – with no defects or flaws.
Typically – experienced Managers and Engineers will be their own version of The Devil’s Advocate for routine tasks. However for larger and more involved projects, it becomes very valuable to use an independent entity who has no personal input to the project in question. But have the knowledge
The Devil’s Advocate In Engineering needs to peel back the Layers – Get under the skin and ask the difficult questions without getting tears in the eye
and skill to peel back the layers, in order to understand the proposal. And then to ask the relevant questions in a calm and measured fashion.
For large projects, companies may also have standardized, detailed methodology, for example the HAZOP process.
Not Only – But Also……
When there is a need to take a deep breath and take a break
Open List Of Topics – Engineering Nostalgia for pages of Old Engineer Memories from Engineering practice in the 1960’s/70’s/80’s – with a bit of armed forces and medieval trivia thrown in
Regardless of your current status – always ask the question – Is there a Better Way and
visit the 3R web page for an overview of the 3R PhilosophyReview – Refresh – Reset
Engineering Time Line – The Clock Is Ticking – There is always a need to manage against a realistic preset Time Line and to have progressive measurable milestones
Regardless of it being a very complex project, a fairly simple/basic job or simply routine management tasks, one of the key elements to success is having an Engineering Time Line, with clear and measurable milestones and of course hitting those milestones.
Obviously the complexity of the project or task dictates the level of detail. However the basic principles and fundamentals are always the same.
Overview
There are many Time Line tools available
The Gantt Chart or a variation of the Gantt Chart is always popular for complex projects
For simple tasks or smaller projects it may be that one of the simpler tools or a check list of tasks on a spread sheet with completion dates or other appropriate measures will do the job
Be very aware that tools such as the Gantt Chart can be quite resource hungry to prepare and manage. For smaller projects it may be much more cost effective to adopt simpler methods
Regardless of the task at hand – document and set realistic measurable milestones
It is important to ensure that all parties who are involved, understand and commit to those milestones
Ensure that the commitment is documented
For routine work it may be by “Minutes of Meetings” which are “signed off” or email messages which are clear, unambiguous and recorded
Ensure that the milestones can in fact be measured and recorded
Make sure that outside contractors understand their responsibilities and that their progress can be and will be measured
Be aware that contractors or internal departments may agree to terms and conditions in order to win an order or curry favor without fully analyzing or understanding the details which they have committed to
Ensure that the commitments are well documented in the terms and conditions of Purchase Orders and Contracts and that there may be legally enforceable penalties if these conditions are not met
You hope that you will never need to use them – however, it demonstrates that these terms are important and need to be taken seriously
Always have a contingency plan – in the event that the Time Line or milestones are not being met for any number of reasons
Depending on the project or job at hand, it may be worthwhile to use a Devil’s Advocate to critique the work – To ask the questions – Are those times realistic and to take an objective look at what could go wrong and how to compensate for any delays or similar issues
In an ideal world – once the Scope of Work has been agreed and the Time Line agreed there should be no side issues
However, in the Real World – Scope Creep will raise its ugly head and should be vigorously resisted unless there are critical issues to deal with
Be very wary of Scope Creep.- Invariably there may be a number of “Nice to Have” modifications proposed. In the first instance any variations should be recorded and scheduled for review “On Completion” of the existing project. Proponents of Scope Creep issues will use arguments such as – it is a minor variation or it is a nice to have or there is virtually no extra cost or similar. But of course there can be a range of unknown ramifications which have not been thoroughly thought through or analyzed
Unless overruled by senior managers – resist Scope Creep
If overruled by senior managers – ensure that all variation are well documented so that any future issues will not come back to bite you
Not Only – But Also…..
When there is a need to take a deep breath and take a break
Open List Of Pages – Engineering Nostalgia for pages of Old Engineer Memories from Engineering practice in the 1960’s/70’s/80’s – with a bit of armed forces and medieval trivia thrown in
Regardless of your current status – always ask the question – Is there a Better Way and
visit the 3R web page for an overview of the 3R PhilosophyReview – Refresh – Reset