🎯

Bad Actor Elimination

Kill Your Top 10 Problems

You know that pump...

The one you've fixed 6 times this year
The conveyor that breaks every other week

These are your Bad Actors

Chronic problems that consume disproportionate resources
and never seem to go away

The Uncomfortable Truth:

50%

of your reactive time on 10% of equipment

What makes a Bad Actor?

🔁 Multiple failures in 12 months
📋 Same failure mode repeating
💰 High total cost
😤 Technicians groan at the work order

Step 1: Find Your Bad Actors

🔢

Failure Count

Most work orders

⏱️

Downtime

Hours lost

💰

Cost

Labor + parts

Pull 12 months of CMMS data → Your Top 10 emerges

Step 2: Eliminate Each One

1
Assign an owner
2
Define the problem clearly
3
Root cause analysis (5-Why, Fishbone)
4
Develop countermeasures
5
Implement with rigor
6
Verify for 3-6 months

Real Example:

The Notorious Pump

The Problem

Failures/year8 times
Each repair4 hours
Maintenance cost€35,000
Lost production€80,000
Total annual€115,000

Root Cause:

🔍 Always the mechanical seal
📉 Pump oversized, minimum flow
🔥 Seal faces overheating

The Fix

Recirculation line€5,000
Right-sized impeller€2,000
Better seal design€800
Total investment€7,800

Result:

0

seal failures in 18 months

ROI in < 2 months

Make It Ongoing

📅 Monthly review - check progress
🔄 Quarterly refresh - update top 10
📊 Annual analysis - measure trend
📢 Post publicly - celebrate wins!

Avoid These Pitfalls

❌ Stopping at easy fixes
❌ Too many at once (stick to 5-10)
❌ No tracking after the fix
❌ Giving up too early
📋

Get the Free Template

Bad Actor Tracking at

reliox.org
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