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Reliability Improvement Fake News

Published on March 29, 2020

Terrence O.Follow
Asset Management, Reliability, Maintenance 4.0, Digital Twins, ISO55000, IIoT, Digitalization, Machine L
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Fake news is a form of information consisting of deliberate disinformation or hoaxes spread via traditional news m

When it comes to Reliability the world is FULL of fake news.

One of the biggest Fake News reports is about " Improving Reliability".

Reliability Leadership Institute members, some of the largest and most successful organizations in the world, liste

Once you design, build and commission an asset or system, the Reliability is set. It is often referred to as "inheren

In Ten Rights of Asset Management, Ramesh Gulati and I describe ten phases of typical asset lifecycle.  The first 5

Reliability is NOT about continuous improvement, it is about planning, design, build, commission and then ensuri

Why do people and organizations seem to chase post-commissioning asset reliabilit

That is easy - it is because that is what is being taught by the associations, training organizations, consultants, gad
 Misinformation is a contagion itself - in some ways much worse than COVID-19 and costs industrial organization

So what can Reliability Leaders do?

Ten Steps to Achieve Reliability (Not improve it)

1) Do what you need to do in order to understand the function and the Inherent/Operational Reliability of the asse

2) Understand the gap between current reliability performance and Inherent/Operational Reliability of the asset or

3) Ensure that the business context (capacity/production drive or cost reduction drive or both) is well understood

4) Create a technical valid and economically viable Preventive Maintenance Plan based on Reliability Strategy De

5) Lead a culture of empowered and engaged, cross functional Reliability Leaders who collaboration to stop defec

6) Ensure Executive Sponsors are active and knowledgeable about basic reliability (failure) concepts.

7) Ensure a technology framework (EAM/APM/AIM/BIM/AI/ML/Condition Monitoring, IIoT etc...) that effectiv

8) Ensure Performance metrics are in place that drive "realizing reliability" and empowered/engaged, cross-functi

9) Learn, teach, coach, mentor, communicate, clarify and focus on people, people, people.

10) Split investment and effort between technology and people development. Achieving reliability is a well know

"Reliability is People" - Terrence O'Hanlon

Four steps to Improve Reliability

1) Design it right

2) Build it right

3) Commission it right

4) Modify it right when required

I hope you find this post useful.

I am NOT posting as Reliability Expert like many of my colleagues who "know it all" and who teach continuous i

In reality, many of my colleagues, even with 20-30 years experience really have two weeks experience, repeated o
 I am a lifelong student of Reliability and I am hoping some readers will teach me more about this topic as result o

Be safe and please stay healthy.

Postscript

A message from Reliability and Lubrication Guru Matt Spurlock of Delta P Reliability:

I read your article: https://www.linkedin.com/pulse/failure-unsatisfactory-condition-terrence-ohanlon/ and und

In this article, "Reliability Improvement Fake News", you write, "Once you design, build and commission

I look forward to your thoughts.

Great question/discussion Matt!

First allow me to make a distinction. You can almost always improve a Reliability Strategy to achieve inherent Re

In your speciality area, if you modify an asset (adding oil sample ports, desiccant breathers, improved and easier f

In Review: You can often improve the Reliability Strategy to achieve inherent Reliability. You can modify an asse

I hope that makes it a little clearer.

I am very grateful for your comment and it served to expand and amplify my learning around this topic.

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Terrence O.
Asset Management, Reliability, Maintenance 4.0, Digital Twins, ISO55000, IIoT, Digitalization, Machine L
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#assetmanagement #reliability #assetperformancemanagement #maintenance
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Alfred DeVaux
Independent Consultant at AWD Enterprises
Great stuff Terrence!
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Jesús Ramírez
Asesor de Ingeniería Instrumentación & Control en PDVSA
Good point. I identify with the concepts and I agree.
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Jan Fourie
Engineer at TRANSNET
Semantics
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🎓Georgia Smart
Helping you navigate the nuances and synergies of asset management, reliability and maintenance
Terrence O. I agree here - words do matter, it affects the way we understand things a
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Terrence O.
Asset Management, Reliability, Maintenance 4.0, Digital Twins, ISO55000, IIoT, Digitalization, Machine L
Our political leaders may teach us that words don’t matter but WORDS MATTER. It is
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Twila Galanis
Semiconductor/Electronic Manufacturing Professional
This is a very enlightening article. I've learned a really great lesson about distinguishi
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Twila Galanis
Semiconductor/Electronic Manufacturing Professional
Thanks Dwight. I used to get Uptime and I think I'll re-engage. (Long story why I don't
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Dwight Schneider
Principal WhiteBoard Advisory Partners LLC, Consultant at NG Reliability Services LLC
Twila, he is a great teacher and organizers. If you haven't been to one of his conferen
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Dwight Schneider
Principal WhiteBoard Advisory Partners LLC, Consultant at NG Reliability Services LLC
While reading this I was doing a belly laugh. Did some equipment inspections for a cl
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Terrence O.
Asset Management, Reliability, Maintenance 4.0, Digital Twins, ISO55000, IIoT, Digitalization, Machine L
Wow - truth amplified. Great story - almost seems unreal but I have seen so many lik
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Peter Cholakis
Senior Vice President at Four BT, LLC
Expanded to include competencies, technologies, etc.... relative to FM.
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Terrence O.
Asset Management, Reliability, Maintenance 4.0, Digital Twins, ISO55000, IIoT, Digitalization, Machine L
Great graphic showing lifecycle
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Show more comments.
IIoT, Digitalization, Machine Learning, AI

xes spread via traditional news media (print and broadcast), consultants, trainers or online social media.

organizations in the world, listen for vendors using the code word "Improving Reliability".  They respectfully listen during the call or meet

t is often referred to as "inherent reliability" or "operational reliability" which is inherent reliability minus shortfalls in design, build and co

ypical asset lifecycle.  The first 5 phases or rights offer huge opportunities for reliability improvement, the next 5 phases or rights offer ver

uild, commission and then ensuring reliability can achieved through performance of operations and maintenance in accordance with the desi

issioning asset reliability improvements where the opportunities are so limited rather than focus on ear

organizations, consultants, gadget vendors and the commercial trade press.  Prior to COVID-19 there were conferences from Australia, the
and costs industrial organizations billions of dollars.

perational Reliability of the asset or system. 

tional Reliability of the asset or system.

ive or both) is well understood

based on Reliability Strategy Development (Failure Modes and Mechanisms, Function, Criticality, RCM, FMEA, FMECA)

who collaboration to stop defects from entering the system and actively collaborate to remove existing defects.

y (failure) concepts.

nitoring, IIoT etc...) that effectively supports the Reliability strategy and plan

mpowered/engaged, cross-functional front line leaders.

ieving reliability is a well known technical journey, What is less known and even less practiced is steering an effective people journey.  

all" and who teach continuous improvement for Reliability of brownfield assets.

wo weeks experience, repeated over and over again for the past 20-30 years.  Do not confuse longevity or repetitive process delivery with w
more about this topic as result of this post.

P Reliability:
tion-terrence-ohanlon/ and understand and agree with the definitions of inherent reliability and operational reliability. 

design, build and commission an asset or system, the Reliability is set.".  Does this imply that so long as you follow the OEM recom

y Strategy to achieve inherent Reliability. Performing Maintenance Task Analysis, PM Optimization, Reliability-centered Maintenance, Roo

breathers, improved and easier filtering, etc...) could improve the inherent reliability.

iability. You can modify an asset to improve inherent Reliability.

ning around this topic.

IIoT, Digitalization, Machine Learning, AI

ability and maintenance
e way we understand things and allows us to keep missing the point. when people say they want to improve reliability of an as

IIoT, Digitalization, Machine Learning, AI

tter but WORDS MATTER. It is what separates humans from all other living creatures. Language creates meaning and context.

reat lesson about distinguishing between improvement and achievement. Thanks Terry. Can I call you Terry?

ngage. (Long story why I don't get it now.)

't been to one of his conference or take Uptime Magazine you are missing a real treat. Best conferences I have ever been to. I l

quipment inspections for a client a year ago. The project was almost 8 months behind when they called me to see what I could

IIoT, Digitalization, Machine Learning, AI

al but I have seen so many like your client it is actually cliche at this point. Sad how much money is wasted.

relative to FM.

IIoT, Digitalization, Machine Learning, AI

ly listen during the call or meeting and then move on to an organization that demonstrate a realistic understanding of intentional achieveme

hortfalls in design, build and commission.  You can read more about the topic of inherent reliability here.  

next 5 phases or rights offer very little opportunity to improve reliability (see graphic below).  

ance in accordance with the design specification.

rather than focus on early asset lifecycle reliability improvement opportunities?

conferences from Australia, the UK, Canada, Latin America, the United States, Africa, India and the Middle East that focused on "Reliabil
MEA, FMECA)

an effective people journey.  

petitive process delivery with wisdom.

al reliability. 

as you follow the OEM recommendations for the system, the inherent reliability that was designed, built, and commissioned into

ility-centered Maintenance, Root Cause Analysis and Failure Modes and Effects Analysis can almost always improve the Preventive Maint
to improve reliability of an asset/system do they mean make it better than it was, or make it as good as it can be? Do they mea

eates meaning and context.

you Terry?
rences I have ever been to. I laughed pretty hard, pretty sure after his career being called Terry is a treat to him as well.

called me to see what I could do to get fabrication on track. Of course, there was zero chance to Improve Reliability beyond Inh
anding of intentional achievement of Reliability. They know fake news when they hear it.

e East that focused on "Reliability Improvement" for brownfield or installed assets.

 built, and commissioned into the system is what it is and can never be better? I'd venture to say that the 4th step in your "Four st

ys improve the Preventive Maintenance Plan but does not improve the inherent Reliability.
od as it can be? Do they mean make it break down less frequently or run faster or smoother or produce better quality products
a treat to him as well.

mprove Reliability beyond Inherent/Operational Reliability. There were bound to be failures after startup, the writing was on th
at the 4th step in your "Four steps to Improve Reliability" would, in fact, extend the original inherent reliability. If I'm thinking co
oduce better quality products? I think they mean, generally, make it demonstrate and achieve better reliability than it does now
startup, the writing was on the wall. We got their fab work pushed through, but it was mostly about poor planning, poor relatio
t reliability. If I'm thinking correctly, then we actually can change the original inherent reliability for the better. Am I missing som
tter reliability than it does now - but as you say the limiting factor is always its design and installation.
ut poor planning, poor relationships, supply chain, poor contracts and multiple design changes that pushed the project far beh
or the better. Am I missing something here?  
at pushed the project far behind schedule. Afterwards we went to the company with the the steps to put the project together e
to put the project together effectively day 1 to operational, including a bit of upfront design support, fully knowing they had th
ort, fully knowing they had the top engineers in their mind on the job (tried not to be to sarcastic with them on that note lettin
with them on that note letting them know we could help improve) and all the steps to wrap up a successful future project with
successful future project with better reliability and lower costs. They liked it, asked for resumes on our additional people but I k
n our additional people but I knew they gave us the death sentence going out the door, "we'll look all this over!" Well, the reaso
all this over!" Well, the reason this made me belly laugh hard, inside of a couple months we got a call and they were needing h
a call and they were needing help on a repair to a failure! A lack of good installation procedures as well as the poor contract wit
well as the poor contract with the fab company. Surprised? Not the group reading this. Because we put the right people in the
we put the right people in the shop we were able to get the fab company to do the repair in 4 days instead of the 2 weeks they
instead of the 2 weeks they said it would take, saving them emissions fines.We reiterated, how we could help. Two months la
we could help. Two months later they called wanting help to move the fab shop along (poor plan, poor contract, poor relationsh
poor contract, poor relationships, poor supply chain) with a new vessel they had determined they needed to get them in compl
needed to get them in compliance. We asked why did you even go back to them? Well, "they promised they could meet our de
mised they could meet our deadline, and it is a really small job." Belly laugh with a hand to the forehead, again. They again elec
ehead, again. They again elected not to use our services or even some earlier free good advice. Fortunately, we were early eno
rtunately, we were early enough, we got in and got the vessel completed for them in half the time the fab shop quoted.
https://youtu.be/3Zz7dvINzDc UV tecnology discargas parciales trabfos-

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son todos los archivos de Terrence ohalon sobre mantenimiento de transfromadores

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