Balancing Tradition with Innovation: The Crucial Role of Formal Training in Machine Maintenance

Anyone familiar with Noria knows our emphasis on training. But what many folks don’t realize is that many of the same people teaching our courses spend a large amount of time in facilities. Some of this time is spent benchmarking reliability programs (with an emphasis on lubrication), and the rest with mechanics, maintenance engineers, and lube techs.

If I have learned anything over my years of doing these projects, it’s to never discount the depth and value of the knowledge these people have about their equipment. (Yes, this includes operators since they'd typically spend the most amount of time with the equipment). We commonly refer to this type of experience and information as “tribal knowledge”.

To elaborate, tribal knowledge, which is also referred to as institutional knowledge, includes:

1. Practical Insights: Tribal knowledge often holds valuable insights that aren't found in manuals or formal training. Maintenance technicians with years of experience share real-world lessons, including shortcuts, best practices, and workarounds that can significantly enhance machine upkeep.

2. Customized Solutions: Every machine has its unique quirks and characteristics. Tribal knowledge offers personalized solutions for specific equipment within a particular facility. Technicians who have spent time working on those machines understand their idiosyncrasies and can provide tailor-made solutions.

3. Rapid Troubleshooting: When a machine encounters an issue, tribal knowledge allows maintenance personnel to quickly diagnose problems. Experience-based insights help identify common root causes and streamline troubleshooting processes, minimizing downtime, and improving operational efficiency.

4. Historical Context: Tribal knowledge provides historical context for the equipment. Knowing the maintenance history, past failures, and repairs can aid in predicting potential future issues. This foresight allows maintenance teams to proactively address concerns before they escalate.

5. Cost Savings: Leveraging tribal knowledge reduces the reliance on external consultants or extensive research, leading to cost savings. The expertise shared among team members empowers them to handle routine maintenance tasks and minor repairs without the need for outside assistance.

6. Continuous Improvement: Tribal knowledge encourages a culture of continuous improvement. Technicians learn from each other's experiences, mistakes, and successes, fostering an environment where the team collectively strives to optimize maintenance processes and minimize downtime.

7. Enhanced Collaboration: Sharing tribal knowledge fosters collaboration among maintenance team members. The exchange of insights, tips, and techniques creates a sense of camaraderie, boosting teamwork and overall job satisfaction.

With all these advantages around tribal knowledge, we sometimes can find ourselves questioning why we would want to take valuable time and money to even have formal trainings. This is where the automatic reliance on tribal knowledge can really hurt us. We can’t just rely on the old-timers to show us how it’s always been done.

Formal training offers benefits not found in our traditional OJT and can be trusted as an alternative to tribal knowledge:

1. Structured Curriculum: Formal reliability training provides a structured curriculum designed by experts in the field. This curriculum covers a wide range of topics systematically, ensuring that participants receive a comprehensive education in machine maintenance and reliability practices.

2. Standardized Knowledge: Formal training imparts standardized knowledge to all participants. This consistency ensures that all team members have access to the same accurate and up-to-date information, reducing the risk of misinformation or outdated practices.

3. Industry Best Practices: Training programs often incorporate industry best practices and the latest advancements in machine maintenance and reliability. Participants learn techniques and methods that have been proven effective across various industrial sectors.

4. Theoretical Foundations: Formal training dives into the theoretical foundations of reliability engineering. Participants gain a deeper understanding of the principles underlying maintenance strategies, enabling them to apply critical thinking and problem-solving skills to complex scenarios.

5. Hands-On Experience: Many formal training programs include practical exercises, simulations, and hands-on experiences. These activities allow participants to apply theoretical concepts in a controlled environment, fostering skill development and boosting confidence.

6. Certification and Recognition: Completing formal training programs often leads to certifications that hold industry-wide recognition. These certifications validate participants' expertise and enhance their credibility when working on complex machinery or in diverse industrial settings.

7. Professional Development: Formal training is an investment in professional development. Participants not only acquire technical skills but also develop soft skills such as communication, teamwork, and project management. These skills are essential for thriving in a modern industrial environment.

But one of the most important things for me, when it comes to the why of formal training, is I get to know why my actions are important and how each action I take affects everything else down the road.

The Final Verdict

Tribal knowledge undoubtedly stands as a valuable resource in the realm of machine maintenance and reliability, serving as a repository of practical wisdom distilled from years of hands-on experience. Its strengths lie in the provision of pragmatic insights and customized solutions that often prove highly effective in addressing specific maintenance challenges.

Moreover, the ability to swiftly diagnose problems and draw upon historical context can lead to reduced downtime, resulting in operational cost savings. Additionally, the collaborative and knowledge-sharing aspects of tribal knowledge cultivate a positive team culture, fostering camaraderie among team members.

However, when evaluating the role of tribal knowledge in the broader context of modern industrial practices, its limitations come to the forefront. One significant drawback is the inconsistency that often characterizes tribal knowledge. This inconsistency can stem from variations in experience, expertise, and approaches among different team members, potentially leading to confusion and errors in maintenance processes.

But let’s face it: it’s not perfect.

Sometimes, the advice can be different from one person to another, which can lead to confusion and errors in work processes. It might not cover all the latest ideas and technologies, so it could fall behind the times. Plus, much of tribal knowledge depends on the expertise and availability of certain experts. So, when these old “tribal leaders” leave, things can sometimes get tricky.

Finally, tribal (or institutional) knowledge doesn't come with the backing of official certificates or qualifications. Many professionals in the reliability and lubrication industries may think that these certifications are unnecessary or excessive. But they help to demonstrate a level of competency and help people with having a common language and accepted standards in the tasks that they are performing. This leads to less confusion and more connectedness in a facility.

So, to wrap things up, while tribal knowledge is handy it's not always the best approach to handle machine maintenance. A better, more effective way is to combine it with formal training.

This gives a technician the best of both worlds — the experience and wisdom of the old-timers along with the latest knowledge, training, and technologies — making a team more complete and better equipped at keeping machines running smoothly, efficiently, and avoiding major breakdowns in all the processes going on in a facility.