For the Love of Fools!

First, sorry for a month or more without communication here, my goal was three letters a month and lately I have come up a bit short!

Fifteen years and counting of performing RCM Analyses and Instructing RCM Participants and Facilitators and I still get pressure from people who have never performed a RCM analysis in their life to do one of the following:

1. "Shorten your facilitator’s course; it doesn't need to be five days."

2. "Certify people as some level of RCM expert after a three day overview course."

3. "Forget teaching people about failure modes Doug just hit the magic button and bring the 6000 we invented instantly into the analysis."

If you search the internet you will find 3,370,000 quotes about ignorance and somehow I just don't think that is nearly enough because in searching these quotes I have yet to find one that addresses the ignorant ideas people who have never facilitated a RCM analysis have in regard to the process.

Sometimes I begin to feel old, hardheaded, and stubborn and then I think back to all I have learned about the process in the past fifteen years. I also look back on what I continue to learn as this is what is most important in keeping the RCM Blitz™ process relevant in the world of manufacturing reliability. Just one month ago I worked with a customer in Europe where we struggled to complete their first RCM analysis, the equipment being analyzed was off-shore, the prints were far from up to date, and the people performing the analysis had little experience in running or maintaining this asset. As a result we took some time at the end of the week to look at ways to modify our approach to improve the speed and end result. The process doesn't change, the way we prepare and set ourselves up for success does!

While trying to remain open to ideas on how to improve the process, in being honest I have to say the store is closed when it comes to training and certification shortcuts. People who have never performed a RCM are in my mind are the same people who butcher the process, expect a quick result and in the end ruin its reputation when the experiment falls short.

Looking for feedback from my RCM Blitz™ users.....Is the old guy CRAZY?

Another Successful Conference

Just a quick note to say I really enjoyed the 2009 SMRP conference in St. Louis this past week. The conference gave me a chance once again to see some old friends and meet some new connections. I of course enjoyed Walter Nijsen's presentation on implementing RCM results across multiple sites and his message in regard to the benefits of RCM Blitz.

Looking forward now to IMC in Daytona Beach, Florida next month!

Don't forget to get your copy of Reliability Centered Maintenance using the RCM Blitz Method, they sold out at the show in St. Louis!

Scoring Your RCM Effort

Like it or not we live in a society where we like to keep score. The score provides feedback; it gives those who are not involved information on the progress or success of those who are involved. The score can be delivered in an endless number of formats, the price of your company stock, net profits, unit cost of product, overall equipment effectiveness, or percent emergency/demand maintenance. In the world of Reliability Centered Maintenance RCM Guru Jack Nicholas gathered a team of experts several years ago to develop the RCM Scorecard. The result of this effort was a comprehensive tool that evaluated Key Performance Indicators at various periods before and during an RCM Project.

I have to say I was grateful for being involved with this effort as the finished product resulted in a tool that would deliver remarkable feedback on the maturity of an ongoing RCM effort. If you want detailed information on the progress of your RCM effort the RCM Scorecard would provide that information. In addition to this the scorecard also provided the option to be flexible and simple, anyone who knows Jack understands while he is thorough in his work he has a genuine appreciation for simplicity. The quest to make RCM simple is what made Jack and I friends and nearly ten years after working with Jack on the RCM Scorecard I have decided to write an article in regard to how to score your RCM effort using a few simple yet easy to answer questions. The result is a simple and quick method that will allow one to judge to potential success of their effort as well as identify areas where more coaching and mentoring are needed.

Using the original Scorecard as a template we can view your ongoing RCM effort in four phases:

1. Baseline Decision Metrics - (How are you selecting assets for analysis?)
2. Analysis Phase Metrics - (How did the RCM process change our Pre-RCM maintenance strategy?
3. Implementation Phase Metrics - (How are we doing at implementing RCM tasks?)
4. Benefits Phase Metrics - (Are we seeing benefits from our new RCM maintenance strategy?)


Starting with Decision Metrics let’s cut to the chase and begin this simplification by stating that RCM is not a tool that needs to be used on every asset at your facility. Reliability Centered Maintenance is a tool that will provide a return on investment provided we direct is use to critical assets and assets with poor reliability performance measures. Simplification in my mind also results in asking closed factual questions whenever possible. Closed factual questions elicit yes or no answers, we either use a formal process to select assets for RCM analyses or we don’t. In my mind answers like sometimes, maybe or on occasion open the door for bull, and when bull enters the conversation the truth often walks out.

Baseline Decision Metrics
1. Is the asset selected for RCM analysis in the top 5 to 20 percent of your critical assets? (Yes or No) If the answer is yes score 1 point, if the answer is no or you have not performed an asset criticality assessment the score is zero. If you have not performed a formal asset criticality assessment I would highly recommend you do so.
2. Are we measuring OEE for the selected asset? Score 1 point if the answer is yes, zero if the answer is no. Overall Equipment Effectiveness will be one way to determine the success of your RCM strategy. If you are not measuring OEE on critical assets I would recommend that you start doing so.
3. Is the selected asset suffering from equipment based failures in any of the following Key Manufacturing Losses; Operational Losses, Speed Losses, Quality Losses? Score 1 point for a yes answer, zero for a no answer. The key manufacturing losses are a function of Overall Equipment Effectiveness losses resulting from equipment based failures are a good indication of a poor maintenance strategy.
4. Is the percent Emergency/Demand maintenance performed on this asset greater than 25%? Score 1 for a yes answer and zero for a no answer. A high amount of emergency and demand maintenance is a good indicator of poor maintenance practices.



Evaluation of Baseline Decision Questions

A score of 3 out of 4 or 4 out of 4 delivers an excellent candidate for RCM analysis. A score of 2 out of 4 or lower is a good indication that we need to select another asset for analysis.

Analysis Phase Metrics

Analysis Phase Metrics give us a snapshot view of two key items;
Did we do a good job of selecting our asset for analysis?
Did our facilitators do a good job in completing our Up-Front and Facilitating the RCM analysis? This includes RCM estimates, gathering of information, team training and RCM Facilitation.

Analysis Phase Questions

1. Was the analysis time estimate within 10% of the actual time spent to perform the analysis? Score 1 for yes, zero for no. Good facilitators know how to keep the team focused to complete each analysis on time. Finishing too early may be a sign that several failure modes may have been missed or written at a high level. The ability to accurately estimate the time it will take a team to perform a RCM analysis is dependent on the number of Functions and Failure Modes analyzed. Time is money, we ask for your best people when we perform a RCM analysis and we want to utilize this time to bring benefit to your business.
2. Are Failure Modes being written in a three part format? (Part, Problem, Specific Cause? Score 1 for yes and zero for no. I want to point out that answers like sometimes or most of the time does not count here. Good RCM facilitators understand the importance of writing good failure modes all the time.
3. Are the tasks identified applicable and effective in mitigating each failure mode? Score 1 for yes and zero for no. I have to say that the person evaluating this question should have a thorough understanding of RCM, I see hundreds of examples of what some people believe are good analyses, in the end if the task mitigates the failure mode we have wasted our time.
4. Did the RCM Facilitator work with the team to identify all the hidden failures and resulting failure finding tasks for this asset? Answer 1 for yes and zero for no. Again as stated along with question 3 you will need a person with a thorough understanding of RCM to report an accurate answer to this question. Accurate assessment of hidden failures is a critical component of a first class RCM effort.


Evaluation of Analysis Phase Metrics

A score of 3 out of 4 or better is outstanding! The analysis phase of Reliability Centered Maintenance is extremely important. It sets the stage for a successful RCM outcome and if we cut corners here our results will suffer.

A score of 2 out of 4 or less is a good indication that your RCM facilitator is in need of more mentoring or coaching. Chances are if you’re scoring in this range you are wasting both time and money. While I have seen a few people get lucky and post some huge results on a few well analyzed failure modes the odds are against continued success.


Implementation Phase Metrics

I have always loves the phrase “Implementation is the graveyard of RCM”. The phrase clearly describes the importance of good planning and follow through when it comes to implementing the task recommendations from each RCM analysis. As we train RCM Facilitators we try to make it very clear that unless we implement the tasks discovered in the analysis phase we have simply wasted a bunch of money talking about what is likely to happen to our equipment. Implementation is where the work really begins, we now have to take the recommendations of the RCM team and make them an ongoing part of how we now plan to manage this critical asset.

Implementation Phase Questions

1. Have we named a specific individual as the RCM Implementation Manager? Score 1 for yes, zero for no. When I say name I mean a person’s name and not a title.
2. Has each RCM Task been assigned a priority, due date and responsible person? Just like the implementation manager I want names assigned to each RCM task along with a due date’s that match the task priority. Implementing the RCM tasks is simple project management and we need to hold people accountable for implementing their assigned tasks.
3. Is the RCM Implementation Manager communicating implementation progress that includes percent of tasks implemented and implementation schedule compliance? Score 1 for yes, zero for no. We need to know the leaders and laggers in our organization, leaders need to be reinforced and laggers may need more coaching or resources.
4. Are we implementing at least 80% of our RCM task recommendations? Score 1 for yes, zero for no. If we are implementing more that’s great but if it’s less than eighty percent I would begin to worry that we may be cherry picking the results of each analysis. Picking the low hanging fruit can produce results but doing this is a gamble that many times results in temporary benefits. A complete maintenance strategy that ensures the designed reliability of your asset will only come from implementing all the tasks identified by the RCM team.

Evaluation of Implementation Phase Questions

Score 3 out of 4 you are doing a good job, 4 out of 4 and you can start planning a celebration, you have are now managing and implementing the tasks from your RCM analysis and in completing this phase of RCM you will soon see results. Start planning your next RCM analysis because you have proven that you can implement!

Score 2 out of 4 or worse and you had better put the brakes on your effort and start holding people accountable. At this point you have everything you need to make the effort a success but are not willing to do the work to make it happen. As a seasoned RCM practitioner nothing pains me more than to see a fantastic RCM analysis sit on a shelf advertising the money wasted for what could have been! Don’t you dare plan another analysis at this point.

Benefits Phase Metrics

Regardless of the score in all other areas, don’t kid yourself, this is where your RCM effort will be judged. This being said, if you scored high in the first three categories you are very likely to have a high score here as well.

Benefits Phase Questions

1. Are the implemented RCM tasks now part of the regular routine maintenance and operating schedule for this equipment? Score 1 for yes and zero for no. In order to see any benefit from your RCM implementation we must now make these tasks part of our routine schedule.
2. Are 90% of the scheduled RCM tasks being completed as part of our routine schedule? Score 1 for yes, zero for no. Completing these tasks will now ensure the benefit of reliability. Failing to complete them will result in a return to our old habits.
3. Has the Overall Equipment Effectiveness (OEE) for this asset improved by more than 10 percent? Score 1 for yes and zero for no. I have seen way more than 10% but this figure will provide the return on investment needed to keep your RCM effort going.
4. Has the amount of Emergency and Demand maintenance been reduced by more than 10 percent? Score 1 for yes and zero for no. Reducing the amount of emergency and demand maintenance will have a direct impact on maintenance costs as well as efficiency.


Evaluating Benefits Phase Metrics

Score 4 out of 4 any your group has hit a home run! Chances are we now have a long list of assets we now want to perform RCM on.

Score 3 out of 4 and we have done well. In most cases we failed question number 2 and we need to then work to improve on scheduling and completing tasks. It is important to recognize a failing score on number 2 will always impact the result of questions 3 and 4.

A score of 2 or less out of 4 shows that we elected to try and hit but failed to swing the bat! Put some work into questions 1 and 2 and the results of 3 and 4 are sure to follow. If we scored high in the first three phases and low on the last phase it’s because we have not followed through at completing the tasks. At this point we need to ensure operations and maintenance are working together to complete the RCM tasks.
In closing I again want to stress that this is a simple RCM Scorecard when we worked as a team to help Jack Nicholas create the original we were looking for a thorough yet flexible way to help managers evaluate their ongoing efforts and I would encourage everyone to read through the original document to find additional items that might better fit your business.

The Dangers of RCM Shortcuts

When people first begin to learn about Reliability Centered Maintenance and methodologies like RCM Blitz, they get excited about the potential results that can come from performing a RCM analysis and implementing the resulting tasks. Shortly after completing their RCM Training some begin to understand that good RCM takes leadership, structure and discipline, others begin to think of ways to shortcut the process.

One of the curses of being human is the burning desire to do everything faster. From the time we first learn to walk we have a desire to run, the minute the first automobiles hit the road someone had to make a faster one. In the world of manufacturing and maintenance speed can be a good thing but it can also be a bad thing. From the time Nowlan and Heap first designed and implemented RCM people have been in search of ways to make it faster and in most cases they do so by eliminating some of the key process steps. In many cases functions and functional failures are steps that are eliminated or partly eliminated. In each case the result is an incomplete RCM analysis and an incomplete maintenance strategy. The well meaning attempt to save time is usually driven by an inexperienced facilitator who does not have a full understanding of the consequences or an impatient manager with even less understanding. The list below outlines consequences of skipping functions and or functional failures when performing RCM.

Skipping Functions, listing only a main function, or skipping functional failures results in:

1.) Incomplete listing of failure modes (How can one expect a complete listing of failures without identifying each component?)

2.) Incomplete listing of hidden failures (If we don’t discuss each component and its intended function would we expect to discover failures that are not evident?)

3.) The inability to recognize when functional failure has occurred (Failure to recognize functional failure is key in beginning to recognize and understand potential failures and the P-F Curve)

4.) Improper applications of Preventive Maintenance and On-Condition Maintenance (Functions, Performance Standards and Functional Failures are all key components in understanding the use of on-condition maintenance and predictive technologies. Failure to identify these key components often results in preventive maintenance being applied where on-condition maintenance would be more applicable and effective)

5.) An incomplete and therefore less effective maintenance strategy (With all of the above being true how would one expect an effective maintenance strategy as a finished product)

A Modern Approach to Risk Management

Fasten your seat belts friends! For years I have been telling you all that RCM Blitz is the fastest and most efficient way to build a complete maintenance strategy for your critical assets.

What if I told you that RCM Blitz™ has been made even faster and more efficient AND it not only covered critical assets but we could develop a strategy for every piece of equipment at your plant?

The TEAM at Allied Reliability, Inc. has been working around the clock to perfect a tool that uses a three tiered approach to build a comprehensive maintenance strategy for every piece of equipment at your facility!

Starting with the Asset Health Matrix we quickly load your complete equipment hierarchy and perform a criticality ranking of your assets the information it then uploaded into the RCM Blitz™ software where within minutes a standardized EMP (Equipment Maintenance Plan) is developed for the engineered failure modes for all equipment regardless of criticality. For the top 10 to 20 percent of your critical assets we then perform a RCM Blitz™ analysis. With the intrinsic or engineered failure modes already covered your RCM Team will now focus exclusively on failure modes that result from the operating context of your assets. The last step of our process uses simulation models to optimize PdM task intervals based on the actual failure rate data following the implementation of your RCM Blitz™ tasks.

Having now utilized this approach and implementing the results at several facilities for three major manufacturing companies we are now ready to publicly offer this one of a kind tool to companies around the world!

Contact Allied Reliability to learn more about The Modern Approach to Risk Management.

RCM Blitz™ - Delivering Results

Someone once told me that you know you have made it in life when someone tries to copy the words you have written or a process you invented. Well, thanks to some folks in Malaysia, I guess I have officially made it. I'm also trying to feel good about the fact that someone has copied material that took me years to develop, and decided to offer it up to companies around the globe without consulting me first.

I guess I should feel honored! For some strange reason I don't.

For my loyal and successful customers over the past seven years I would like to say thank you! Allied Reliability, Inc. is thankful that customers like Whrilpool, Cargill, Invista, and Newmont Mining took the time to search and committed their people to research several methodologies looking for the best RCM Training and mentoring available around the world. Because these companies took the time and invested in RCM Blitz™ they now have successful RCM efforts with results that continue to provide return on the money they invested in RCM Facilitator Training.

For companies interested in RCM Training I would encourage you to read the article in the link and contact the good people at Allied Reliability, Inc.

Instant RCM

I don't know about you, but I have always liked a good training course. A dynamic instructor, well thought out and laid out training materials, solid real life training examples and interactive class examples. Combine all of these things and you're now attending a course where you can really learn how to apply a structured process and improve your business.

When we designed the RCM Blitz process and RCM Facilitator training modules, we worked hard to meet the above listed criteria. We wanted to ensure that the people we trained in RCM Blitz understood the process and were able to apply the techniques learned in training back at the workplace. As a result, the people to elected the attend RCM Blitz facilitator training would in turn become successful RCM facilitators.

Over the past several years, we have been approached several times by companies wanting to put our courses on CD and offer them on line for a reduced price. You all know the gimmick "The Instant RCM Blitz Training CD - for a one time price $599.95 you can now purchase the complete RCM Blitz training series just send us your credit card and we'll send you the CD!" "Complete the slides on our CD and you'll soon be doing RCM all on your own!"

Let me give you some good free advice, if you believe you can learn RCM without formal instruction and mentoring, save your money, buy a book on RCM and read it. You'll save yourself five hundred and fifty dollars and have the same probability of success.

If you really want to learn to become a certified RCM facilitator, attend a RCM Facilitator Training class, sign up to be mentored through a couple of RCM analyses and learn RCM the right way. Companies with successful RCM efforts, invest in RCM training and certification and as a result they experience the benefits delivered from a proven methodology. Even more impressive, every certified RCM Blitz facilitator has completed at least two RCM analyses that provided a return on investment that exceeded the cost of training and implementation and continues to to return on that savings year after year with improved reliability and lower maintenance costs!

Contact Allied Reliability, Inc. today and learn about RCM Blitz Facilitator Training and Certification!