I recently spoke with a friend about an issue that his organization was facing that was causing him significant frustration. They had experienced an equipment failure that caused significant downtime for their production line. In response, the leadership team demanded that all the similar parts on the line be replaced, regardless of condition.
My friend indicated that this particular part was one that could easily be inspected for wear and only be replaced if necessary. They did not typically fail without warning. If all the parts had been inspected instead of replaced, the organization could have saved the cost of the parts and weeks of work.
Unfortunately, the decision-makers were not aware of this possibility. None of the mechanics who knew the equipment shared this information. They knew it was a costly decision, but no one spoke up, not even my friend. Why?