Optimize Asset Reliability with RBAM

Reliability Based Asset Management
Reliability-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
Performance Associates International, Inc. EXIT

Reliability Maturity Audit
One 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 Assessment
Enterprise 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.
Performance Associates International, Inc.
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Trades 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 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 & 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 & 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
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 (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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The main tool that supports the optimization of your PM program is
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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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 (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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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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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)
• 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 & 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 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 & 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 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 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) 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 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 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 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 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 Management
Making 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 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) 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 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 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’.

Optimize Asset Reliability with RBAM

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