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Nobody likes maintenance, except those who make a living from it. Car servicing and repairs not only cost you money—while your wheels are in the garage, your mobility and convenience take a hit, too. There’s just one thing worse than maintaining your assets. Not maintaining them.
[Listen to audio version, read by David Hodes]
This is Part 4 of our series on Asset constraint management: Part 1 | Part 2 | Part 3 | Part 4 | Part 5
Whatever value your assets generate, they’re not much good to anyone when they’re broken or unexpectedly in the repair shop. It’s the job of maintenance to support production, and we often lose this idea both in the executive suite and within the maintenance function itself. Some beancounter, aided and abetted by a reputable management consultancy, looks to save some beans by deciding that, for example, the interval between major maintenance events can be extended, with the effect of reducing short-term costs.
Things go well for a while. Then Murphy comes to pay a visit—when you least need or want him around. Your production losses turn out to be catastrophic, with rehabilitation of the ailing plant costing twice as much as it would have had you done the work when originally called for. Or perhaps operations falls behind in their production numbers and insist they cannot hand over a particular piece of kit for routine work until they have overcome their backlog. Maintenance shrugs, knowing that they are a cost, and cannot hold sway over moneymaking production, so they stand down or reassign their crews. Murphy once again turns to mock the optimists.
“Murphy comes to pay a visit—when
you least need or want him around”
But, there’s another systemic problem we need to address. No one can know when a particular piece of equipment is going to fail—it’s a matter of probability. Furthermore, even if you have a reasonable handle on the interval between failures, and set your maintenance routines to align within those intervals, you rarely get to run a maintenance event which deals with only one item.
For example, you take your car in for a service. The very friendly mechanic says he’ll phone once he’s done the diagnostics. You get the call and he tells you the tyres all need changing. You give him the OK and, keeping a tally of the cost, you ask if there’s anything else. Adopting a tone of sincere regret, he lets you know that the brake linings, while good for now, have probably got only another couple of thousand kilometres left on them. The frugal you wants to get every last millimetre of wear from your brakes, but the practical you knows that this will mean taking the car back to the garage in a few weeks, with all the hassle that entails.
The truth is that there’s not a maintenance function in the world that can afford all the resources they require to deal with every contingency afflicting production. The real issue is about changing, from the shop floor to the boardroom, the prevailing mindset about maintenance. What is seen by many as a ‘regret cost’ must be seen, through a new lens, as a ‘throughput enabler’. You simply can’t optimise production without accounting for maintenance.
The starting point is to appreciate that, whatever you’re producing, the value created is a consequence of innumerable interactions in a complex system of buying, making, distributing and selling. No matter how complex the system, the Theory of Constraints (TOC) can help simplify sense- and decision-making through its fundamental premise that all systems have a constraint which governs the rate at which value flows.
“All systems have a constraint which
governs the rate at which value flows”
From TOC, we can use the 5-Step FOCUS to find the constraint, optimise its contribution to the goal and collaborate around that proposition, both now and in the future. Appreciation for a system lets ‘maintenance’ and ‘production’ understand that collaboration is a prerequisite of outsized success. TOC provides the practical means by which these two functional silos, together, turn the intention of productive collaboration into reality.
Industrial enterprises need to tightly synchronise how they apply resources to the challenges of production. Are the right people with the right skills mobilised and ready to do the work? Do we have the materials, by way of parts and equipment? Are our finances in order to pay in a timely way for all the products and services provided as vendor inputs? Do our information systems provide us with everything we need to plan the work and work the plan?
TOC has in its armoury three ‘proven’ solutions to deal with the complexity of scheduling: Critical Chain project management, Drum Buffer Rope production management and Dynamic Buffer Management for replenishment. They are proven in the sense that they are grounded in sound reasoning and also have a treasure trove of empirical evidence supporting the claim to delivery of outsized results.
How would a transformation to systems thinking and its practical partner, TOC, be delivered? I have been doing this kind of work for decades now and, unfortunately, there’s no easy off-the-peg solution. It’s as much about cultural and org design changes as about operations. So, you start with a discovery. What’s the context within which your business is currently operating and what are the drivers of success? What are the formal and informal methods you use for planning and controlling both routine and heavy maintenance? What do the people who use the current systems think about it?
Bring a cross-section of maintenance and production folk together into a room and explore the issue from all perspectives: planners, operators, maintainers, asset strategists, engineers, inventory managers, procurement officers, finance people and the like. Be bold and get some of your critical contractors into the room and involve them in the conversation.
“You cannot bring innovation to productivity
without introducing new knowledge”
The truth is that you cannot bring innovation to productivity without introducing new knowledge to the people who will be leading and participating in the transformation. Being intentional in educating your team in the principles and practices of systems thinking in general, and more specifically in TOC, will challenge their thinking. They will then be capable of championing the transition from the generalisations of the methods taught, to the specifics of your particular circumstance. Bringing about a new way of thinking is much more than merely training people in the technique of a given method. Providing education encourages the development of critical thinking skills and sharpens the ability to argue any point, grounded in reason.
All of this effort would amount to nothing if it didn’t address the adverse effects of poor performance: unplanned breakdowns, production losses, unbudgeted costs, unnecessarily long turn-times and late return to service. These negatives can severely impact your reputation and hamper your ability to make a case for a change in approach to maintenance: from regret cost to throughput enabler.
In adopting the systems thinking approach to maintenance, backed up by TOC operations management, you can be sure you’ll achieve better outcomes than you previously believed were reasonable or possible. You can effectively minimise backlogs and achieve extraordinary adherence to schedule, with all of its cost and downstream benefits. Having the courage to bring new ways of working to the maintenance domain will burnish your reputation as an inspiring and capable managerial leader and fill you with a deep sense of satisfaction from the multifaceted achievements of doing meaningful work.
Wouldn’t it be something to go from being a hands-on manager, exhausted by having to relentlessly arbitrate the production versus maintenance clashes, to being an inspiring dynamo who encourages those two worlds to learn how to harmonise their efforts by giving primacy to the whole?
This is Part 4 of our series on Asset constraints management.
Part 1: Asset Constraints Management Capabilities
Part 2: Projecting Projects
Part 3: Producing production
Part 4: Maintaining production
Part 5: Controlling contractors
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What’s next?
The change from standard thinking to Theory of Constraints (TOC) is both profound and exhilarating. To make it both fun and memorable, we use a business simulation we call The Right Stuff Workshop.
We’d love to run it with you. To learn more:
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[Background image: man opening valve on large plant, Shutterstock]
“A gain at the constraint is a gain for the system as a whole.”
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Healthcare professionals are central to the patient’s progress from awareness of a therapy to successful long-term use. They identify risk, interpret evidence, diagnose conditions, discuss options, perform procedures, provide training and monitor outcomes.
Yet many medical device development programs treat healthcare professionals primarily as users to be trained or customers to be persuaded.
HCP-Centered Design takes a wider view. It examines the work healthcare professionals must perform, the system in which they perform it and the constraints that limit their ability to move suitable patients through the care pathway.
“If patient flow depends on a healthcare professional, that professional’s available capacity may determine how many patients ultimately receive the therapy.”
A medical device patient journey commonly depends on several healthcare professionals:
Each professional governs a transition in the flow of patients.
If one transition lacks sufficient capacity, information or clarity, the whole pathway slows. More marketing, sales activity or production capacity will not compensate for a shortage of specialist time or a burdensome diagnostic process.
This is why HCP-Centered Design is not simply about making an interface easier to use. It is about enabling the system of care to perform.
A healthcare professional’s work depends on information and actions supplied by others. They may rely on referrals, patient histories, pathology, imaging, electronic records, clinical guidelines and the availability of equipment or trained colleagues.
After reaching a decision, they may need to explain it, document it, arrange authorization, coordinate treatment and prepare the next person in the pathway.
A technically strong solution can still create difficulty if it:
The relevant design question is not merely, “Can the HCP use this product?”
It is, “Does this solution improve the HCP’s ability to complete important clinical work within the conditions in which care is actually delivered?”
“HCP” is not one persona.
A general practitioner, specialist, interventional physician, nurse, technician and clinical administrator encounter different stages of the pathway. Each has different responsibilities, authority, expertise and exposure to risk.
Even within a profession, context matters. An experienced specialist in a major hospital may approach the same task differently from a professional who encounters the condition infrequently or works without immediate specialist support.
Useful HCP personas distinguish factors that influence work:
These personas clarify who performs each job and what support each person requires.
The HCP journey often begins before the visible clinical procedure.
It may include receiving a referral, gathering information, forming an initial view, ordering investigations, interpreting results, deciding whether the patient is eligible, discussing treatment, obtaining authorization, preparing for the procedure, delivering care and arranging follow-up.
At each stage, ask:
The resulting journey map should distinguish processing time from waiting time. A decision may require only minutes of specialist attention while patients wait weeks to access that attention.
This reveals the practical relationship between HCP capacity and patient flow.
The Theory of Constraints directs attention to the factor limiting the performance of the entire system.
In some pathways, the constraint may be the number of qualified interventional specialists. In others, it may be diagnostic capacity, physician confidence, authorization effort, operating room access or the time required to train patients.
The constraint may also be hidden inside the HCP’s working day.
A specialist supporting a therapy must still manage other clinical duties, administration, meetings, documentation and urgent cases. The question is not simply how many specialists exist. It is how much of their usable capacity is available for the activities upon which patient flow depends.
“The scarcest resource may not be the healthcare professional. It may be the few hours of focused capacity available for the critical work.”
Improvement away from this constraint can make performance worse. Sending more referrals to an already overloaded specialist increases the queue. Adding information may increase cognitive burden. Creating another approval may consume the capacity required to treat patients.
HCP-Centered Design seeks to protect and expand the capacity that governs flow.
Policies and procedures describe how clinical work should happen. Observation reveals how it actually happens.
Healthcare professionals routinely compensate for missing information, awkward interfaces and unreliable handovers. These workarounds may become so familiar that nobody reports them as problems.
Gemba research should examine:
The purpose is not to judge the healthcare professional. It is to understand the system surrounding the work.
“A workaround is often evidence that the system has failed to support the person doing the work.”
Healthcare professionals do not simply use devices. They use them to make progress in clinical work.
An HCP may need to identify risk, reach a confident diagnosis, select an intervention, perform a procedure safely, explain options, monitor progress or recognize deterioration.
A structured job map divides this work into eight stages:
This wider view prevents the product team from concentrating exclusively on the procedure.
The greatest value may come from reducing preparation, improving decision confidence, clarifying an exception, simplifying documentation or improving the handover to follow-up care.
Comments such as “the interface is difficult” or “we need better information” indicate dissatisfaction, but do not provide sufficient direction for design.
They should be translated into measurable outcome statements, such as:
“Minimize the time required to identify which clinical information is missing before making a treatment decision.”
Or:
“Reduce the likelihood that a clinically significant change goes unrecognized between scheduled reviews.”
A broader population of healthcare professionals can then assess the importance of each outcome and their satisfaction with their current ability to achieve it.
Highly important and poorly satisfied outcomes provide a rational basis for prioritizing innovation.
“Adoption follows when a solution makes important clinical work safer, clearer or easier to complete.”
The five-step FOCUS process creates a practical improvement cycle.
Find the constraint. Determine which HCP activity or resource currently limits patient flow.
Optimise for it. Protect the constraint from avoidable work, missing information, interruptions and rework.
Collaborate around it. Align upstream and downstream teams so patients, information and resources arrive when required.
Uplift it. Add capacity, redesign responsibilities, improve technology or remove restrictive policies.
Start Again. Identify the new constraint once flow improves.
This approach allows the organization to distinguish activity from value. It also turns HCP engagement into an ongoing management discipline.
HCP-Centered Design must connect clinical reality with patient needs, technology, regulation and business strategy.
A Value Management Office can help coordinate these perspectives across the product lifecycle. Its role is to ensure that projects, resources and stage-gate decisions remain connected to patient flow and business value.
The organization should be able to show:
The goal is not simply a device that healthcare professionals can operate. It is a solution they can confidently incorporate into care and a delivery system capable of getting that solution to more patients.
Use the HCP-Centered Design assessment to determine how well your organization understands clinical work, HCP capacity and the constraints governing patient flow.
The resulting evidence should guide product design, process improvement and investment toward better products, delivered faster, with more lives changed for good.
Medical device companies devote enormous skill and investment to developing safe, effective products. Yet a technically successful device changes no lives while suitable patients remain unable to reach it.
Between a patient becoming aware of a therapy and receiving its intended benefit lies a pathway of referrals, consultations, diagnostics, approvals, procedures, training and follow-up. Every step consumes time. Between the steps, patients wait. At some points, they become confused, discouraged, ineligible or lost to the process.
Patient Centered Design must therefore address more than the design of the device. It must improve the performance of the entire system through which patients reach, receive and live successfully with the solution.
“A life-changing therapy changes no lives while patients remain trapped in the pathway leading to it.”
A typical medical device journey may include:
Companies often manage these stages as separate functions. Marketing works on awareness. Medical affairs supports clinicians. Market access addresses reimbursement. Sales works with specialists. Clinical teams gather evidence. Training teams support adoption.
The patient, however, experiences one journey.
From the patient’s perspective, a delay between two organizational functions remains a delay. A repeated test remains repeated work. An unclear handover creates uncertainty regardless of which department owns it.
Patient Centered Design begins when the organization sees and manages this journey as a connected system.
Every step contains some necessary processing time. A consultation takes time. A diagnostic test takes time. An authorization must be assessed. A procedure must be performed.
The patient’s total lead time, however, also includes the waiting between these activities.
A consultation may take 30 minutes, but the patient could wait six weeks for it. A diagnostic test may take an hour, followed by another delay before a specialist reviews the result. Prior authorization may require little actual work while adding weeks to the pathway.
This distinction matters because organizations often improve processing time while leaving the larger queues untouched. Saving five minutes during an appointment produces little benefit if the patient waits months to reach it.
Patient Centered Design therefore asks:
The answers reveal the true performance of the patient system.
Theory of Constraints teaches that the performance of any system is limited by a constraint. Improving a part of the system that is not constraining flow may create more activity without increasing results.
If diagnostic capacity is the constraint, generating more awareness may simply produce a longer queue for diagnosis. If specialist capacity is the constraint, accelerating authorization may move patients more quickly into another wait. If training after first use is inadequate, increasing procedures may produce poor experiences and avoidable follow-up demand.
“More activity at a non-constraint creates work in process. More capability at the constraint improves the system.”
The constraint is not always a physical resource. It may be a policy, an eligibility rule, missing evidence, a fragmented handover, an information delay or the cognitive burden placed on the patient.
The most important question is therefore not, “How do we improve every step?”
It is, “What currently limits the flow of suitable patients to successful use of the therapy?”
Numbers show where patients are lost. Patient research helps explain why.
Two patients with the same diagnosis may respond very differently. One may actively seek new treatment options. Another may delay action until symptoms become severe. A third may want help but lack confidence in navigating the healthcare system.
Meaningful patient segmentation considers characteristics that influence behavior:
These differences affect whether patients enter the pathway, remain engaged and successfully adopt the solution.
The Gemba is the place where work actually happens. For patients, this includes the home, clinic, hospital and all the places where they manage their condition between formal encounters.
Interviews alone may miss important evidence. People normalize inconvenience, forget workarounds and simplify their past decisions. Observation allows the development team to see what patients actually do.
Good research combines three activities.
Observe. Watch how patients obtain information, prepare, use the solution and respond when something goes wrong.
Immerse. Understand the physical, emotional and practical conditions surrounding the experience.
Engage. Ask open questions that allow patients to describe their goals, fears and frustrations in their own language.
The purpose is to discover the patient’s reality before asking them to evaluate the organization’s preferred answer.
Patients rarely want a medical device for its own sake. They want the progress it may enable.
They may want to recognize deterioration earlier, preserve independence, reduce pain, avoid repeated visits, return to work or prevent a disease from controlling daily life.
A useful job map examines eight recurring stages:
This reveals opportunities beyond the immediate use of the device. The most valuable improvement may involve helping patients prepare, confirm readiness, recognize an exception or understand what happens next.
Stories create understanding, but investment decisions require structured evidence.
Patient observations and comments should be converted into outcome statements that identify:
For example:
“Minimize the time required to recognize that my condition has changed sufficiently to require clinical help.”
Patients can then assess the importance of each outcome and their satisfaction with their current ability to achieve it.
Highly important and poorly satisfied outcomes represent genuine opportunities. This prevents teams from prioritizing attractive features that do not materially improve the patient’s life or progress through the pathway.
“Innovation becomes valuable when it improves an outcome that matters and remains poorly served.”
The Patient Centered Design pathway can be improved through a repeating discipline:
Find the constraint. Identify what currently limits patient flow or successful use.
Optimise for it. Make the best possible use of existing constraint capacity.
Collaborate around it. Align functions and partners so their actions support the constraint.
Uplift it. Add capability, remove restrictive policies or redesign the pathway.
Start Again. Once the constraint moves, identify and address the next limiting factor.
This prevents improvement from becoming a collection of disconnected initiatives. It directs scarce resources toward the factor that most strongly governs the result.
Patient insight should influence more than early product design. It should shape clinical evidence, regulatory strategy, reimbursement, manufacturing, education, market development and post-market support.
The organization should be able to show:
The goal is not simply to place the patient at the center of a diagram. It is to organize the enterprise around delivering better products faster, so that more lives can be changed for good.
Use the Patient Centered Design assessment to determine how well your organization understands its patient journeys, priority outcomes and constraints to patient flow.
The result should be more than another collection of patient opinions. It should provide evidence that directs strategy, investment and execution toward the changes that matter most.
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