the 5th advancing reliability through leadership · iso14224 collection and exchange of reliability...
TRANSCRIPT
The 5th AdvancingReliability Through Leadership
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Terrence O’Hanlon, CEO and Publisher of Reliabilityweb.com and Uptime Magazine 150 feet below London at the Crossrail UK Paddington Station site
• Co-Author: 10 Rights of Asset Management
• Executive Director, Reliability Leadership Institute Community of Practice
• Asset Management Strategy Advisor to Fortune 500 firms
• Recipient 1st Veteran CMRP of the Year Award
• Voting member ISO55000 Asset Management TC251 and ISO TC56 Dependability Advisory Group
• Asset Management expert ISO WG39
• Executive Producer for Conferences like IMC, MaximoWorld, The RELIABILITY Conference
• Judging Panel Uptime Awards
• Judging Panel Year In Infrastructure Awards and Emerson Reliability Program of the Year
• Co-Founder: IAM USA
• Member: AMP, STLE, AFE, IAM, SMRP
• I am a CMRP, have an Asset Management Certificate (IAM)
• Prosci Change Management Professional/ Immunity to Change Facilitator
• I am excited and enthusiastic about the people who are seeking to advance Reliability and Asset Management
Three Reliability Business Lines
IMC/TRC/MaximoWorld
Conferences
Uptime Magazine
Reliabilityweb Publishing
Publishing
Training
Certification
Reliability Leadership
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Who are we?
We work with these personal and business values:
✓ Integrity – by doing what we say we will do and cleaning up the mess at the earliest possible opportunity when we cannot or don’t
✓ Authenticity – as a team we share our most important values with each other and support each other to work with them and toward them
✓ Responsibility – we take a stand to be work with responsibility to create/generated the outcomes we want to see
✓ Aim – working to make the people we serve safer and more successful is an honor and drives us
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Influenced Uptime Elements Change Management: Becoming a Learning Organization
Deming to Senge
Influenced Uptime Elements Change Management: Becoming a Learning Organization
Deming to Senge to O’Hanlon
Influenced Uptime Elements Change Management: Becoming a Learning Organization
Deming to Senge to O’Hanlon
Is Reliability at the level you want it?
”besides having to get through the non-intuitive thinking process required in reliability, the process requires a rare systematic blend of cross-functional experience, judgement, decision making, leadership,
empowerment and engagement enabled by enlightened executive sponsorship. Wonder why it's rare? It is consequence driven when it really needs
to be value driven." -Terrence O’Hanlon
© Copyright 2019 Reliabilityweb.com ® All rights reserved
© Copyright 2019 Reliabilityweb.com® All rights reserved
© Copyright 2019 Reliabilityweb.com® All rights reserved
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Discipline One: Systems Thinking
✓ Introduced 2013 with an aim to transform the prevailing style of technical Reliability and Asset Management implementation with powerful cultural leadership centered implementations
✓ Based in Systems Thinking
✓ Empowers cross-functional collaboration from stakeholders across the organization
✓ Human values as the Cornerstone for Uptime Elements Leadership Foundation
✓ Align Technical Activities to Business Process
✓ Introduces the Domain of Generation
✓ Core belief: Leadership creates Culture/Culture creates performance – focus on leadership to create performance
Systems Thinking
The Organization as a System with an Aim to provide benefit to all
stakeholders
Reliability and Asset Management as a System
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved
Systems Thinking
Reliability and Asset Management as a System
Uptime Elements places human value at the cornerstone of the system
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
2002Preventive
Maintenance Best Practices
2005CMMS
Best Practices
2005Reliability Centered
MaintenanceBest Practices
2005RCM Project
Managers Guide1st Edition
2011CMMS
Best Practices
2011Asset Health
Management Best Practices
2014Asset
ManagementPractices,
Investment and Challenges
2015RCM Project
Managers Guide2nd Edition
2015Acoustic
Lubrication Guide
2015Work Execution
Project Managers Guide
2016Asset Condition
Monitoring Project Managers Guide
2017MRO Best
Practices Guide
2017Reliability Leadership Leadership
Best Practices
Uptime Elements Reliability Framework and Asset Management System is based on the industries deepest research on best practices
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved
Uptime Elements is aligned to a Framework of International Standards
✓ ISO55000 Asset management -- Overview, principles and terminology:
✓ ISO55001 Asset management -- Management systems –Requirements:
✓ ISO31000 Risk management -- Principles and guidelines:✓ ISO14224 Collection and exchange of reliability and
maintenance data for equipment:✓ ISO17359 Condition monitoring and diagnostics of machines --
General guidelines✓ ISO13372 Condition monitoring and diagnostics of machines –
Vocabulary:✓ ISO18436-8 Condition monitoring and diagnostics of machines✓ Requirements for qualification and assessment of personnel✓ IEC60300-3-11 Dependability management -- Part 3-11:
Application guide -- Reliability centered maintenance:✓ SAE-JA1011 Evaluation criteria for reliability centered
maintenance (RCM) processes✓ Many more…
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
CHANGE OR DIE
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
9:1 odds says bet red
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Operating Domain Maturity
Reactive Domain
Planned Domain
Precision Domain
World Class Domain
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Operating Domain Maturity
Department Thinking
Isolated Ownership:Maintenance Department
Preventive Maintenance ApproachMoving from Reactive Domain to Planned
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Traditional Approach to Reliability Through Maintenance
Department Thinking
Everyone adding defects faster than maintenance/inspection
can remove
Maintenance (Only) Approach
Up to 72% of premature failures may be considered “infant mortality” and not time/usage related in pattern. Maintenance may not be the most cost effective way to deal with the elimination or prevention of these issues. © Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
You Can’tPlan
BreakDowns
Who is causing these failures?
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Operating Domain Maturity
Pla
nn
ed D
om
ain
Is N
ot
Stab
le
Reliability requires a cross-functional approach to stop adding defects and begin removing them
Don’t Just Fix It –Improve It!
The goal is to engage and empower stakeholders to provide the asset with all the care it needs to run perfectly
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
The Precision Domain
Source: Asset Management Investment Priorities and Challenges, Reliabilityweb.com March 2014
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
AIMShared VisionSet organizational objectivesStakeholder concernsHierarchy of needsWhy Reliability?
Team LearningDraft PolicyDraft Strategy SAMP
Personal MasteryEngage and EmpowerCross-Functional teamsReliability Leadership GameHuman Capital Management
Mental Models Decision MakingUnderstanding RiskLong Term Thinking
System ThinkingReliability NetworkingAssessmentsBenchmarkingBlack Belt Documented ProjectsUptime AwardsAligned people, processes and technology
The Reliability Roadmap
© Copyright 2018 Reliabilityweb.com ® All rights reserved
What is Being A Reliability Leader?
Being a reliability leader is defined as, realizing a future that wasn’t going to happen anyway
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Mental Models
What are Mental Models?
Mental models are deeply ingrained assumptions, generalizations, or even pictures or images that
influence how we understand the world and how we take action. Very often, we are not consciously aware of our mental models or the effects they have on our behavior.
Issue universal PMs for monthly bearing
lubrication – needed or not!
Mental Models Effects on Reliability and Asset Management✓ Entrenched mental models can lead to failure of system thinking efforts.✓ If managers “believe” their views as facts rather than assumptions, they will not be open to challenging those views.✓ If they lack skills in inquiring into their and other’s ways of thinking, they will be limited in experimenting with new ways of
thinking.
It occurs to me that if a little grease is good,
more grease is better
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
BOs
BULK OIL STORAG
E
Mr
gMANUAL REGREAS
E
FffFULL
FLOW FILTRATI
ON
WrWATER
REMOVAL
OmOIL
MISTSpray
Vo
aVISUAL
OIL ANALYSI
S
SplSINGLE POINT
LUBRICATOR
Mpl
MULTI POINT
LUBRICATOR
Ws
lWET
SUMP LUBRICA
TION
POF
fPERMAN
ENT OFFLINE FILTRATI
ONPfPORTABL
E FILTRATI
ON
VmVARNISH MITIGATI
ON
LgLUBRICA
TING GREASE
FgFOOD
GRADE LUBRICA
NTS
OsOIL
SAMPLING
GoGEAR OILS
HfHYDRAULIC FLUID
BoBearing
OILS
CfCOMPRE
SSOR FLUIDS
ToTURBINE
OILS
TsTOTE
STORAGE
DRsdrum
STORAGE
LtLubricant transfer
DslDRY
SUMP LUBRICA
TION
VbVENTS & BREATHE
RS
LUBRICANT SELECTION
PcPARTICL
E CONTAMINATION
McMOISTU
RE CONTAMINATION
ArAERATIO
N
SVc
SLUDGE &
VARNISH CONTAMINATION
LUBRICANT APPLICATION
EmEQUIPM
ENT MODIFICATIONS
CONTAMINATION CONTROL
SAMPLING & INSPECTIONS
VcVISCOME
TRICS
FpFLUID
PERFORMANCE
PROPERTIES
UcULTRASO
NIC LUBRICA
TION
GpGREASE
PERFORMANCE
PROPERTIES
LuMACHINER
Y LUBRICATIO
N
OXi
OXIDATION
TfTHERMA
L FAILURE
HyHYDROL
YSIS
AlADDITIV
E loss
Machinery Lubrication Framework
SsSHAFT SEALS
STORAGE & HANDLING
Lubricant formulation
Lubricant properties
Lubricating Oil types
Application methods
Storage options
Common contaminants
Contamination Prevention
Contamination Removal
Lubricant failure modes
Lubricant monitoring
Condition-based lubrication
FPm
FLUID PROPERT
IES MONITO
RING
CmCONTAMINATION MONITO
RING
WDm
WEAR DEBRIS
MONITORING
A visual framework detailing the steps necessary to establish a precision lubrication program.
1. Select the right lubricant2. Apply the lubricant in the right
amount at the right time3. Keep the lubricant clean and dry4. Keep the lubricant cool5. Inspect, sample and analyze to
ensure machine and lubricant health
EM
gELECTRIC MOTOR GREASE
MP
gmulti-
purpose GREASE
CgCOUPLIN
G GREASE
Grease types
GsGREASE STORAG
E
GaGREASE ANALYSI
S
LUBRICATING OILS
LUBRICATING GREASES
BOTH OILS & GREASES
BoBASE OIL
AsADDITIV
E SYSTEMS
HD
gHeavy Duty
GREASE
HTghi temp
& specialty
grease
BoBase Oil
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Personal Mastery
60% of employees say the ability to do what they do best in a role is “very important” to them.
Does your culture
empower employees
to do what they do
best?
Do you speak Reliability?™️
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Personal Mastery
All things that can be mastered begin with the acquisition of a specialized language that contains words, concepts and ideas. Examples would be a Doctor in medical training begins by studying the specialized words, phrases and concepts related to the practice of medicine.
Terry O’s Second Reliability LawHow reliability occurs to a person is how it will be performed:
Senior Leadership?
Procurement?
Operators?Technicians?
You?
?
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved
© Copyright 2019 Reliabilityweb.com® All rights reserved
A Scheduled Maintenance Program has four objectives
1. To realize the inherent safety and reliability levels of the asset
2. To restore safety and reliability to their inherent levels when deterioration occurred
3. To obtain the information necessary for design improvement of those items whose inherent reliability proves inadequate
4. To accomplish these goals at a minimum total cost, including maintenance cost and the costs of failures or other optimum factor basis for your context
Reliability Strategy Development
Sources: Certified Reliability Leader Body of Knowledge 2016 and Nolan and Heap Reliability-centered Maintenance, Nov 1978
© Copyright 2019 Reliabilityweb.com® All rights reserved
It is important for all stakeholders advancing the reliability journey to have a basic understand of the technical definition of failure.
Failure is an unsatisfactory condition.
✓ A functional failure is the inability of an item (or the equipment containing it) to meet a specified performance standard.
✓ A potential failure is an identifiable physical condition which indicates that a functional failure is imminent
What is failure?
Sources: Certified Reliability Leader Body of Knowledge 2016 and Nolan and Heap Reliability-centered Maintenance, Nov 1978
© Copyright 2019 Reliabilityweb.com® All rights reserved
Sources: Certified Reliability Leader Body of Knowledge 2016 and Nolan and Heap Reliability-centered Maintenance, Nov 1978
Inspect an item to detect
a potential failure
Rework an item before a maximum permissible age
is exceeded
Discard an item before a maximum permissible age is
exceeded
Inspect an item to find failures that
have already occurred
Redesign or Accept Risk
Four Types of Scheduled Maintenance Tasks
from Reliability Strategy Development Review
© Copyright 2019 Reliabilityweb.com® All rights reserved
1
2
34
© Copyright 2019 Reliabilityweb.com® All rights reserved
Each scheduled maintenance task in an Uptime Elements developed Reliability Strategy is
generated for an identifiable and explicit reason.
The consequences of each failure possibility are evaluated, and the failures are then classified
according to the severity of their consequences and the risk to organizational objectives.
Reliability Strategy Development
© Copyright 2019 Reliabilityweb.com® All rights reserved
3 LAWS OF SCHEDULED
MAINTENANCE
© Copyright 2019 Reliabilityweb.com® All rights reserved
3 LAWS OF SCHEDULED MAINTENANCE
Law 1
Scheduled maintenance is required for any item whose loss of function or mode of failure could have safety consequences. If one of the four type of scheduled preventive tasks (inspect to detect, rework before maximum age, discard before maximum age and inspect to find hidden failures that have already occurred but are not evident) cannot reduce the risk of such failure to an acceptable level, the item must be redesigned to alter its failure consequences.
Law 1 exists because you cannot leave a safety consequence unaddressed.
Sources: Certified Reliability Leader Body of Knowledge 2016 and Nolan and Heap Reliability-centered Maintenance, Nov 1978
© Copyright 2019 Reliabilityweb.com® All rights reserved
3 LAWS OF SCHEDULED MAINTENANCE
Law 2
Scheduled maintenance is required for any item whose functional failure will NOT be evident to the operating crew and therefore reported for corrective action. Law 2 exists to address two kinds of "hidden failures". Hidden failures are failures that are not evident to the operating crew.
An evident function is one whose failure will be evident to the operating crew during the performance of normal duties.
A hidden function is one whose failure will not be evident to the operating crew during the performance of normal duties.
Sources: Certified Reliability Leader Body of Knowledge 2016 and Nolan and Heap Reliability-centered Maintenance, Nov 1978
© Copyright 2019 Reliabilityweb.com® All rights reserved
3 LAWS OF SCHEDULED MAINTENANCE
Law 3
In all other cases the consequences of the failure are either economic or line of sight to organizational objectives and scheduled maintenance tasks directed at preventing such failures must be justified as economically feasible (just because you can prevent it does not mean it is worth preventing).
Law 3 or the Sanity Law or as Ron Moore calls it - "the Common Sense Law", demands that we ONLY perform scheduled maintenance tasks that can be proven to be beneficial. Tasks that add significantly more value than they cost to perform in time, labor and other factors.
This is not only due to economic factors but due to the fact that unnecessary maintenance can actually induce failures, increase safety risk and reduce environmental sustainability.
Sources: Certified Reliability Leader Body of Knowledge 2016 and Nolan and Heap Reliability-centered Maintenance, Nov 1978
Personal Mastery
The Best Project That You Can Ever
Work On Is You
Organizations learn only through individuals who learn. Individual learning does not guarantee organizational learning; but without it, no organizational learning occurs. - Peter Singe, The Fifth Discipline
Shared Vision
Deming on Aim
Systems must have an aim because without one, no system exists.
The aim of the system must:
✓be clear for everyone in the system,
✓include plans for the future,
✓be a value judgment, and
✓be defined in terms of activity or methods.
AIM – The reason your organization exists
“To organize the world’s information and make it universally accessible and useful.”
Walt Disney Parks and Resorts
“One of the world’s leading providers of family travel and leisure experiences, giving millions of guests each year the chance to spend time with their families and friends, making memories that last a lifetime.”
Reliabilityweb.com
We make the people we serve safer and more successful through Reliability Leadership
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Four key themes of asset managementUptime® Elements™️ framework.
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Asset management is what you do as an organization.
The policies, strategies and plans to realize organizational
objectives
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
✓ Frontline Planning✓ All Groups Acting In Concert✓ Forward Movement
Momentum✓ Plans Become Reality
✓ Plan Made Without Stakeholder Investment
✓ Lot’s Of Energy, Little Movement
✓ No Forward Momentum
✓ Groups Move In Many Directions
✓ No Plan or Coordination
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Aim is the engagement buttonIt is also the disengagement button
Push to engage
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
Reliability Leader Return On Investment
© Copyright 2015-2018 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2018 Netexpressusa Inc. dba Reliabilityweb.com ® All rights reserved
Your BrainMore
maintenance must be the path
to reliability!
© Copyright 2015-2018 Netexpressusa Inc. dba Reliabilityweb.com ® All rights reserved
Leadership Creates Culture
Culture Delivers PerformanceStand as a Reliability
Leader To Improve Performance
Imagine: Every employee in the organization empowered and engaged to think and act like a reliability leader
Trim Tab
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved
Take a look at the work you do to advance
reliability and see for yourself that the
world only moves for you when you act.–
Terry O’Hanlon
Reliability LeaderTM
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved
Create A Better Future Now
Find me :About.me/reliabilityFacebook.com/assetmanagerTwitter: @reliabilityEmail:[email protected]
Fall seven times, stand up eight.~ Japanese Proverb
© Copyright 2015-2019 Reliabilityweb.com ® All rights reserved