Reliability Based Asset Management

Reliability Based Asset ManagementReliability Based Asset ManagementReliability-Based Asset Management (RBAM) takes a holistic approach to caring for the assets that everyone in your company relies on to produce your end product and earn the revenues that keep your business competitive and profitable. RBAM is NOT simply a maintenance department initiative to attain high asset reliability. It is holistic in that it affects how business is done by all departments, and its success depends on the participation and commitment of all departments to the processes and practices that provide high asset reliability.

Performance Associates can work with you to develop an implementation strategy that allows you to grow a reliability culture in your organization, and reap the benefits that an RBAM culture has to offer. Performance Associates has at its disposal a wide array of tools to help you achieve your reliability goals, including:

• Reliability Maturity Audit• Trade Skills GAP Assessments• Performance Audits and Time Studies• Reliability Engineering Training and Mentoring• Reliability Centered Maintenance Analysis (RCMA) and Failure Modes and Effect Analysis (FMEA)• Preventive Maintenance Optimization (PMO)• Predictive Maintenance Optimization (PdMO)• Root Cause Failure Analysis (RCFA)• Computerized Maintenance Management System Audit and Configuration• Business Process Mapping• Key Performance Indicator (KPI) Development• Master Equipment List Development and Criticality Ranking• Equipment Specific Maintenance Task Training• Change Management• Equipment Bill of Material (BOM) Development• Warehouse Stock Optimization• Sustainability Audits

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Reliability Maturity AuditReliability Maturity AuditOne size does not fit all when it comes to Reliability-Based Asset Management (RBAM) implementations. Different companies have reached different levels of maturity with regard to reliability initiatives. This is why the first step in the process of developing an RBAM culture is to assess your current culture and approach as a part of a site survey.

Performance Associates can conduct a Reliability Maturity Audit to assess your current maturity with regard to RBAM. The results of the Reliability Maturity Audit provide the data needed to form a strategy for Reliability Based Asset Management. The strategy developed may require the use of one, a few, or many of the tools provided by Performance Associates.

Performance Associates can manage all or part of your RBAM implementation, all the while training and mentoring your personnel in the practice of RBAM so that the practices take hold and become a part of your culture. We can also lead or assist with your Change Management requirements to ensure that your RBAM implementation efforts remain focused, on track, and ultimately successful.


Trades Skills Gap AssessmentTrades Skills Gap AssessmentEnterprise reliability goals cannot be achieved if there is a gap between the skills and abilities of personnel and the requirements defined by the goals.

Performance Associates can quantitatively assess the skills of your existing work force by conducting a training needs analysis to determine if they possess the necessary skills and abilities required to support your reliability-based asset management strategy. The outcome of an assessment details the necessary skills, as well as the Skills Gap--where the skills are lacking--including:

• A quantitative ranking scale. • Rolled up results by organizational hierarchy.• Highlighting of critical skills shortfalls.• Priority list of where to focus training.• Development of the most cost-effective approach.

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Trades Skills Gap AssessmentTrades Skills Gap Assessment

Most importantly, the Trades Skills Gap Assessment allows a plan to be developed to close the skills gap.

Oftentimes a large portion of the gap can be attributed to a lack of detailed familiarity with your specific assets. This gap can be easily bridged by Equipment-Specific Maintenance Task Training programs developed by Performance Associates. These programs are customized computer-based or hard-copy maintenance training modules that are targeted to your specific assets. They are not generic. These programs teach your personnel the correct way to perform specific maintenance tasks on your specific assets, thereby improving asset reliability.


Performance Audits and Time StudiesPerformance Audits and Time Studies

Reliability goals cannot be achieved if company resources are not used efficiently. These resources include personnel, as well as support equipment and services. Good reliability-based asset management practices focus on efficient use of all your resources.

Performance Associates can conduct a performance audit of your resource utilization in order to identify opportunities for improvement. The results of performance audits—in the form of Business Process Mapping—can provide valuable data for designing the waste out of your key business processes.


Reliability Engineering Training & MentoringReliability Engineering Training & Mentoring

A key enabler of reliability-based asset management is the skill set possessed by your Reliability Engineering Group—typically comprising Maintenance Planners/Schedulers, Maintenance Engineers, and Reliability Engineers. These roles in your organization have a major responsibility to:

• Ensure that jobs are well planned and appropriately scheduled.

• Ensure that non-value-added tasks are minimized.• Ensure a focus on continuous improvement.• Leverage technology to improve asset reliability.• Maintain a database of complete information to allow for

making sound decisions.


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Reliability Engineering Training & MentoringReliability Engineering Training & Mentoring

Performance Associates can perform specialized maintenance engineering and reliability training for your personnel in the areas of:

• Maintenance Planning• Maintenance Scheduling• Maintenance Engineering• Reliability Engineering

All training is supplemented with on-the-job mentoring to ensure that the newly learned techniques are put to work and their benefits are realized.


Reliability-Centered Maintenance Analysis (RCMA) and Failure Reliability-Centered Maintenance Analysis (RCMA) and Failure Modes and Effect Analysis (FMEA)Modes and Effect Analysis (FMEA)

A key activity in the transition to a reliability based asset management strategy is performing:

• Preventive Maintenance Optimization (PMO), and • Predictive Maintenance Optimization (PdMO).

Optimizing your PM and PdM program is no easy task, but it is made much easier by analyzing your plant assets and systems utilizing tools that include:

• Reliability-Centered Maintenance Analysis (RCMA), and • Failure Modes and Effects Analysis (FMEA).


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RCMA is a rigorous analysis of critical plant systems performed in a manner that allows the analysis team to identify:

• All system functions.• Functional failures.• Failure modes.• Failure effects.• Failure causes.• Methods to mitigate potential failures.• Default actions when there is no suitable maintenance task

to mitigate a failure mode.

RCMA considers interactions of the system with the process in which it functions, and it considers the interactions between subsystems and components within the system itself.


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RCMA is both qualitative and quantitative, and when performed, utilizes a combination of:

• Actual plant data • Industry available data • Actual experience of operations and maintenance personnel• Management experience • The knowledge base of third-party subject matter experts


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Whereas an RCMA analyzes an entire system, and considers system interactions with the process, sub-systems, and components, FMEA analyzes only one asset or component at a time without regard to system interactions.

FMEA is preferred over RCMA for:

• Stand-alone assets that do not tie in with major processes.

• Assets not affected by upstream inputs and that do not affect downstream systems.

In essence, RCMA is composed of many FMEA analyses, which have been modified to take into account system interactions.


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Performance Associates can facilitate RCMA analysis sessions on your critical systems to assist you with the start of your PM optimization (PMO) and your PdM optimization (PdMO) initiative. The facilitation of one or more analyses serves as a training session for your maintenance and reliability engineering personnel that are unfamiliar with the RCMA process.

Analyses are progressively taken over by your personnel while we continue to mentor them. As more RCMAs are performed, a library of analyses is accumulated that can be scaled to fit similar systems requiring analysis. This library of RCMAs saves valuable resource time on subsequent analyses by accelerating the process, and further accelerates your overall PMO and PdMO initiative.


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Performance Associates can train your personnel in the application of FMEA by conducting several analyses with your Maintenance and Reliability Engineering personnel, followed by reviews of solo analyses performed by your personnel.

As with RCMA, as more FMEAs re performed, you begin to accumulate a library of analyses that can be scaled to fit several applications, and serve as a starting point for other analyses, which saves valuable resource time. The process of FMEA development accelerates as your library grows.

Your FMEA library also serves as source of base data that can be utilized in RCMA analyses, which again saves time and resources as you analyze more critical systems.


Preventive Maintenance Optimization (PMO)Preventive Maintenance Optimization (PMO)

Preventive Maintenance (PM) programs are one of the principle tools at the heart of successful maintenance management programs. However, much of your valuable resource time can be wasted when following a traditional time-directed PM service program.

Your maintenance resources are more efficiently utilized, and the effectiveness of your maintenance personnel is increased, when your PM program is optimized to better monitor your asset health and mitigate potential failure modes.

An optimized PM program performs only quantifiable and value-added tasks at the correct time intervals to help provide the desired asset reliability.


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Preventive Maintenance Optimization (PMO)Preventive Maintenance Optimization (PMO)The main tool that supports the optimization of your PM program is Reliability-Centered Maintenance Analysis (RCMA) and Failure Modes and Effects Analysis (FMEA). RCMA and FMEA support your PM optimization by enabling you to:

• Eliminate non value-added PM tasks

• Identify appropriate PM tasks that will mitigate potential failure modes of your assets

• Eliminate those traditional time-directed intrusive tasks that cause more harm than good

• Identify which Predictive Maintenance (PdM) technologies can be utilized to monitor asset health (typically without having to shut down)

• Identify where a run-to-failure maintenance strategy is appropriate

• Identify where an engineering change may be required to mitigate certain failure modes


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Preventive Maintenance Optimization (PMO)Preventive Maintenance Optimization (PMO)

Performance Associates can help launch your Preventive Maintenance Optimization (PMO) program by facilitating RCMA and FMEA sessions, while at the same time training your Maintenance and Reliability Engineering personnel in the process so that you can continue the process and utilize the analysis tools when required.

Performance Associates can also jump-start your PMO initiative by auditing your current PM program and drawing upon our extensive experience in maintenance program development to quickly eliminate those activities that are not quantifiable, add no value, and are potentially harmful. This is not the end of the process, and RCMA and FMEA should be used to complete the PMO initiative.


Predictive Maintenance Optimization (PdMO)Predictive Maintenance Optimization (PdMO)

Predictive Maintenance (PdM) programs are one of the principal tools at the heart of successful maintenance management programs. However, it is common to find many organizations missing the opportunity to leverage the benefits of PdM technologies while pursuing only traditional time-directed Preventive Maintenance (PM) programs.

Maintenance resources are more efficiently utilized, and the effectiveness of maintenance personnel is increased, when the PM program is optimized by identifying where PdM technologies can be utilized to better monitor asset health and mitigate potential failure modes.

Identifying opportunities to replace PM tasks with PdM technologies where appropriate is what Predictive Maintenance Optimization (PdMO) is centered on.


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Predictive Maintenance Optimization (PdMO)Predictive Maintenance Optimization (PdMO)The main tool that supports the optimization of your PdM program is Reliability-Centered maintenance Analysis (RCMA) and Failure Modes and Effects Analysis (FMEA). RCMA and FMEA support your PdMO initiative by enabling you to:

• Eliminate non-value-added PM tasks.• Identify appropriate PM tasks that will mitigate potential

failure modes of your assets.• Eliminate those traditional time-directed intrusive tasks that

cause more harm than good. • Identify which Predictive Maintenance (PdM) technologies

can be utilized to monitor asset health (typically without having to shut it down).

• Identify where a run-to-failure maintenance strategy is appropriate.

• Identify where an engineering change may be required to mitigate certain failure modes.


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Predictive Maintenance Optimization (PdMO)Predictive Maintenance Optimization (PdMO)Performance Associates can help launch your PdMO program by facilitating RCMA and FMEA sessions, while at the same time training your maintenance and reliability engineering personnel in the process so that you can continue the process and utilize the analysis tools when required.

We can also jump-start your PdMO initiative by auditing your current PM program and drawing upon our extensive experience in maintenance program development to quickly identify opportunities to utilize PdM technologies to replace those activities that are not quantifiable, add no value, and are potentially harmful.

This is not the end of the process, and RCMA and FMEA should be used to complete the PdMO initiative.


Root Cause Failure Analysis (RCFA)Root Cause Failure Analysis (RCFA)

• Far too often we hear stories from maintenance departments recounting how they have “performed the same repair for the third time this month” or something similar.

• Many times the problem is explained away by: “that’s the cost of doing business”. This may indeed be business as usual for many, but it does not have to be.


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In typical reactive maintenance environments:

• We are forced to react to repeated emergencies, and

• To make the same repair again and again in the name of production.

All the while we are also neglecting other important tasks that are due to be performed. When we have responded to our repeat emergencies, our continually neglected tasks eventually sneak up on us and become emergencies as well.

Eventually the old emergencies and the new emergencies:

• Force us to continue to react to repeated emergencies. • Adversely affect overall plant reliability.• Adversely affect Production capability.• Most importantly, affect the cost of doing business.


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Recurring problems can be eliminated by the utilization of Root Cause Failure Analysis (RCFA). RCFA finds the true source of the recurring problems and allows decisive steps to be taken to permanently eliminate them from your operation.

Performance Associates can assist you in your efforts to permanently eliminate recurring problems from your operation by facilitating RCFA sessions with analysis teams made up of your personnel.

At the same time we will be training maintenance and reliability engineering personnel in the process so that they can utilize this powerful tool continually to help attain asset reliability goals.


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In addition to RCFA, the application of Reliability-Centered Maintenance Analysis (RCMA) and Failure Modes and Effects Analysis (FMEA) provides valuable insight in to how to eliminate recurring problems in your operation.

The results of RCMA and FMEA form an integral part of Preventive Maintenance Optimization (PMO) and Predictive Maintenance Optimization (PdMO). This effort optimizes the tasks needed to maintain asset health and mitigate potential failure modes. The results of RCFA also provide insight into the correct tasks to incorporate into your PMO and PdMO initiatives.


CMMS Audit & ConfigurationCMMS Audit & Configuration

The most powerful tool that all maintenance personnel share is the Computerized Maintenance Management System (CMMS).

A well-configured and implemented CMMS has the potential to put valuable information at the fingertips of everyone in an organization.

The reality of the situation in many companies, however, is that the CMMS is poorly configured and implemented, resulting in a loss of some of the benefits of a CMMS. This is unfortunate, given the time and expense that was invested in the implementation. A poorly configured and implemented CMMS is a problem that can be remedied.


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CMMS Audit and ConfigurationCMMS Audit and Configuration

Performance Associates can perform a thorough audit of your current CMMS configuration and assess the level of utilization by your personnel to determine if all potential benefits are being realized.

The CMMS audit identifies any opportunities that may exist to better leverage the power of your CMMS. The audit provides a framework of understanding from which to develop a strategy to revitalize your CMMS and realize its full potential.


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CMMS Audit & ConfigurationCMMS Audit & Configuration

A well configured and implemented CMMS must be aligned with your Business Process Mapping and your Key Performance Indicator (KPI) Development. Many business processes involve transactions in your CMMS. However, a poorly configured CMMS may prevent you from executing your business processes in the desired way.

Likewise, the data required for your KPIs may be difficult to obtain, especially when the data required is not being collected and maintained in your CMMS as it should be as a result of poor configuration. These are both common situations that force companies to design business processes around their CMMS configuration, and which force companies to measure their performance based on whatever data are available in their CMMS. Your business processes, and your ability to measure your performance must not be made a slave to your CMMS configuration, but rather your CMMS configuration must allow you to design optimized business processes and make the most meaningful and useful performance measurement.


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CMMS Audit and ConfigurationCMMS Audit and Configuration

Performance Associates can also help on the ground floor for new CMMS installations as well. We can develop a strategy with you for your new CMMS implementation so that it is configured in a way that will support your business processes and performance measurements. We can also provide the same assistance if your company is migrating your CMMS and/or management software from one system to another.


Business Process MappingBusiness Process Mapping

It is not uncommon for some people, when performing the same business process as their coworkers, to do so with greater efficiency and with better and repeatable results.

If one person is capable of continually executing a business process better than his or her coworkers, that all the other coworkers should aim to emulate that individual. Such inconsistent performance can be witnessed in companies that do not have formalized business processes for typical tasks such as work request management, work backlog management, warehouse reservations/issues/kitting, planned and emergency purchasing, inventory stock addition request, and management of change.


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Performance Associates can assist in your efforts to accurately map and document your key business processes.

We can facilitate process mapping sessions with development teams made up of individuals within your company having a role in the process being mapped. The formation of such teams brings to the session all the knowledge required to identify any waste in the way the process is currently performed and identify opportunities to reduce the time and effort in executing the process while ensuring the highest quality and repeatable results.

While we facilitate one or more process mapping sessions we will be training your personnel in the process.


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The result of a process mapping is a detailed process flow chart accompanied by a text description of the process.

Such processes become valuable tools for new employees, and serve as a reference to all employees if and when they have doubts about how a business process is to be executed. Well mapped and documented processes should become part of employee handbooks and manuals. Knowledge about how you wish to run your business and execute your business processes can have a significant impact on your CMMS configuration strategy. Such knowledge enables you to configure your CMMS in a manner that supports your business processes rather than having to configure your business process to work within the confines of your CMMS configuration.


Key Performance Indicator (KPI) DevelopmentKey Performance Indicator (KPI) Development

It is a basic tenet of business management that you can only manage what you can measure. Useful and meaningful measures to make good data-driven business decisions are required. It is for this reason that Key Performance Indicators (KPIs) are required.

Performance Associates can assist you with defining what KPI measurements provide the meaningful data you need to manage your business. Defining useful measures, however, is not enough. The ability to collect the data required to make KPI measurements must exist before any attempt to make such measurements can be made. Your Computerized Maintenance Management System (CMMS) must be properly configured to ensure that the data required to make your desired KPI measurements can be made from the data in your CMMS.


Master Equipment List Development and Criticality RankingMaster Equipment List Development and Criticality Ranking

All your maintenance efforts are designed to care for the assets within your operation.

All the assets that you must care for must exist as a master equipment record in your Computerized Maintenance Management System (CMMS) in order to be able to plan and schedule maintenance activities for those assets.

The master equipment list should not only contain records for individual equipment items or systems, but it should contain records for repairable components for tracking repair histories, and it should contain records at the component and sub-system level of the equipment and systems respectively.

Such granularity in the master equipment list hierarchy supports Key Performance Indicator (KPI) measurement capability by allowing you to analyze maintenance and reliability performance at various levels of your asset fleet.


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Master Equipment List Development & Criticality RankingMaster Equipment List Development & Criticality Ranking

Performance Associates can assist you with defining what your master equipment list hierarchy should look like to support your maintenance management business process, and to support your KPI measurements.

Whether your operation is new or established, whether you are implementing a CMMS for the first time or migrating to a new system, a proper master equipment list can be developed at any time.

Once the required equipment hierarchy structure has been defined, all assets are walked down and all nameplate data are collected so that they can be included in the equipment master record. This activity includes a walk down of warehouse and lay-down areas where repairable spares may be stored. The physical walk down of your assets can be performed by your personnel or by Performance Associates Field Engineering personnel.


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The value of a well-developed master equipment list is increased when all the assets in the hierarchy are ranked based on criticality.

This is accomplished by conducting criticality ranking sessions, at which time criticality values are applied to all assets in the master equipment list. The criticality values are determined for each asset by providing answers to weighted question pertaining to the asset and its potential affect on safety, the environment, maintenance, process, and product quality in the event of a functional failure.

The ranking scale is very granular and typically ranks asset criticality on a scale from 100 to 1,000 (which is far more granular than traditional 1,2,3/ABC/High, Medium, Low criticality ranking methods that are commonly used in a poorly configured CMMS). Such a granular criticality ranking of assets helps take the emotion and ‘gut feel’ out of daily maintenance meetings when maintenance priorities are being set.


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A criticality-ranked asset register helps identify which systems and assets deserve rigorous analysis such as Reliability-Centered Maintenance Analysis (RCMA) and Failure Modes and Effects Analysis (FMEA), and helps determine which assets should be considered first for Preventive Maintenance Optimization (PMO) and Predictive Maintenance Optimization (PdMO).

Performance Associates can assist you with establishing a criticality ranking criteria, and then help facilitate equipment criticality ranking sessions with your personnel.

Criticality ranking sessions are made up of individuals who can accurately rate the affect of an asset failure on the aforementioned criteria categories.

While we facilitate the criticality ranking session for the assets in one or more operational areas, we will be training your personnel in the process so that you can continue the ranking process until it is complete.


Equipment Specific Maintenance Task TrainingEquipment Specific Maintenance Task Training

It is common for trades personnel with good basic skills to lack knowledge of the specific equipment at any given plant.

This can be especially true with newly hired experienced personnel that come from different industries or processes. These persons may have excellent core abilities, but they may lack the knowledge of how to apply that ability to properly maintain your assets.

On-the-job training for new personnel only perpetuates undesirable practices when those providing the training also lack the specific knowledge of how to properly maintain your assets.


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Equipment Specific Maintenance Task TrainingEquipment Specific Maintenance Task Training

Performance Associates can develop customized equipment specific maintenance task training programs to teach your skilled trades personnel the correct way to maintain your assets. These are specialized training programs that target the necessary maintenance requirements of your assets as they operate in the context of your operation. These are not generic programs that try to account for all possible scenarios.

If the base abilities of your skilled trades personnel are in question, Performance Associates can perform a Trade Skills GAP Assessment to determine if basic skills training is required in addition to, or instead of, equipment specific maintenance task training.


Change ManagementChange ManagementMaking the move to a Reliability-Based Asset Management (RBAM) strategy is no small undertaking, especially if there is an existing reactive maintenance environment. The difficulty is multiplied if you became ‘good’ at being reactive. The thought of an RBAM strategy makes those who have done well under the old ways skeptical and non-receptive to the new vision of maintenance management. The change management required to move your organization and its personnel down an RBAM path is quite likely the most difficult part of the entire process.

Performance Associates can help you manage this important change by assisting you with:

• Defining your vision of the future, and providing a detailed picture of what you wish your RBAM culture to look like when the journey is complete.

• Defining appropriate goals that support and enable the realization of your vision.

• Defining the initiatives required to make each goal a reality. • Defining the activities needed, and the respective resources

required, to execute each initiative. • Defining on the measures that will be used to track progress

ensure that all activities, initiatives, and goals remain aligned with the vision to ensure its realization.


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Change ManagementChange Management

Performance Associates can continue to assist with your change management process until your RBAM vision is realized. We can provide a valuable outsider’s perspective when gauging the progress and the success of your initiatives, and we can help prescribe corrective actions to get the process back on track should it start to deviate from the vision. The Reliability Maturity Audit is repeated at least once during the implementation of the RBAM initiative to gauge your progress by comparing the results of the more recent audit with the first one performed.


Equipment Bill of Material (BOM) DevelopmentEquipment Bill of Material (BOM) Development

It is important that the assets in the Computerized Maintenance Management System (CMMS) have an accurate and complete Bill of Material (BOM) record indicating what parts and materials required for maintenance and repair of the asset, and of those which are held in your warehouse inventory. Complete and accurate BOM data compliments your reliability initiatives by supporting maintenance planning and scheduling activities, purchasing activities, and warehousing activities.

Performance Associates can provide assistance to create asset BOMs. This is not a task that necessarily must be undertaken for all of your assets. It is OK to have a BOM for all of your assets, but the focus should be on your more critical assets first in order to realize the benefits sooner. Determination of which assets are more critical than others can be accomplished with Master Equipment List Development & Criticality Ranking.


Warehouse Stock OptimizationWarehouse Stock Optimization

It is common to find that warehouse management modules of enterprise management systems are in the same state of disarray as the maintenance management module and the master equipment list in the asset directory.

Poorly configured warehouse management systems can be filled with tens of thousands of records, most of which have little useful description to allow a system user to easily search for and find what they are looking for electronically.

A warehouse management module needs to be configured utilizing a standard taxonomy, which is utilized without exception, to maintain warehouse records that can be easily searched by the end users that need what is in the warehouse.


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Performance Associates can assist you with developing a standard taxonomy to be used in your warehouse so that you can begin to utilize the full potential of your CMMS and other business management modules in your enterprise management system.

Once a standard taxonomy is developed, we can assist you with scrubbing all your existing warehouse data and applying the new standard to all existing records.


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The process of scrubbing warehouse data reveals where there are duplicate stock items under numerous manufacturer part numbers.

Scrubbing warehouse data makes it possible to safely begin to reduce inventory quantities, and thus reduce inventory value and associated carrying costs. A standardized taxonomy that contains all the features recognized by your vendors, suppliers, and manufacturers allows you to open up your warehouse and purchasing systems to e-commerce practices.


Sustainability AuditsSustainability Audits

The work of Performance Associates does not end with the development and initiation of your reliability-based asset management strategy. This is just the beginning of sustaining your new reliability initiative, and Performance Associates will be there to ensure that it succeeds.

Sustainability visits and audits ensure that our combined hard work is being put to good use and that the program is delivering the expected results. Performance Associates can also continue to provide training and mentoring services as your reliability initiatives take hold and your strategy is deployed across your entire enterprise.

The work or Performance Associates is considered complete only when the expected results of your reliability-based asset management strategy have been realized, and when reliability-based asset management is engrained across your enterprise as your new ‘business as usual’.


Reliability Based Asset Management

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