Unleash the potential of your reliability function
It is about time to disconnect the reliability function from maintenance and make it an autonomous external entity, focusing on asset reliability at every level in the Asset Lifecycle Management (ALM).
- RCM: Reliability Centered Maintenance (RCM) program covering seven questions of RCM methodology.
- PM: Develop preventive maintenance (PM) procedures and optimize utilizing failure modes.
- PdM: Implement predictive maintenance technology and develop continuous monitoring program. For example; online/offline vibration monitors, ultrasound measurement devices, thermographs, oil condition monitoring, and smart instrumentation online diagnostics.
- ODR: Operator Driven Reliability (ODR) program focusing on the operations role to enhance asset reliability. This may include detailed operators checklists for visual/audio/smell/feel tests, review and enhancement of standard operating procedures (SOP), accurate integrity operating window (IOW) for all equipment, simple handheld devices to collect data for offline predictive maintenance, and minor maintenance tasks, like tightening up loose bolts with basic tools.
- FMEA/FMECA: Failure modes, effects, and criticality analysis.
- RCA/RCFA: Root cause failure analysis covering effective failure reporting and close tracking of recommendations until fully implemented.
- SJP: Develop standard job plans for better planning and scheduling of work orders with accurate resource handling.
- PHA: Participation in process hazard analysis like HAZOP.
- LOPA: Layer of protection analysis or other qualitative analyses for safety instrumented systems.
- SIS: Safety instrumented system lifecycle management covering all phases from cradle to grave and compliance with industry and company standards. SIF (safety instrumented function) performance like Actual Demand Rate, Detected Failure Rates, Proof Test Compliance, and Diagnostics etc. should also be part of this program.
- Functional testing procedures and relevant documentation for non-SIS related equipment.
- Initiation and tracking of a lessons learned database for reliability.
- Capital project packages review with reliability enhancement recommendations.
- Bad actors identification, tracking and replacement program.
- Advanced reliability analyses including but not limited to Weibull analysis, Markov modeling, Lean/Six Sigma study, and RAM (reliability, availability, and maintainability).
- Obsolete equipment tracking and systematic replacement program.
- Ad-hoc site visits to witness the operations and maintenance work with the intention of issuing recommendations for identified gaps.
- Random checks for CMMS/SAP data entry and quality.
- SPF: Single point of failure identification and enhancement.
- DFR: Design for reliability program and related studies.
- Reliability Performance Metrics: Develop, track, and enhance leading/lagging KPIs. For example: MTBF (mean time between failures), MTTR (mean time to repair), OEE (overall equipment efficiency), Equipment availability, and Equipment PFDs (probability of failure on demand).
When placed correctly in an organization, along with the necessary expertise, resources, and authority, the function of reliability will demonstrate the true potential it has in improving asset reliability during its lifecycle, and in achieving a robust reliability culture throughout the facility.
Disclaimer: The author’s views do not necessarily reflect the views of his employers, colleagues or any professional societies he is affiliated with.
References: The hedgehog concept of 3-Circles is depicted from Jim Collins book, "Good to Great"
– Obaidullah A. Syed, CFSP, CMRP, P.E. has nearly 20 years of experience in the controls and automation industry, primarily serving oil and gas companies. His experience comes from a blend of project engineering, functional safety and reliability engineering work. Since 2007, he has worked in Saudi Arabia. Edited by Joy Chang, digital project manager, Plant Engineering, email@example.com.
Original content can be found at Plant Engineering.