Your Reliability Engineering Professional Development Site
A listing in reverse chronological order of these article series:
Reliability programs often suffer from “Catastrophe Bias.” We spin up an intensive RCA for the big turbine failure, but we ignore the pump that trips once a week or the sensor that needs a “quick reset” every shift.
Because these events are small, they don’t trigger a formal investigation. However, when you aggregate the labor, parts, and lost uptime, these chronic issues often cost significantly more than the rare, sporadic catastrophes.
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OPERATIONAL EXCELLENCE REQUIRES BEST-PRACTICE PHYSICAL ASSET MANAGEMENT, MAINTENANCE MANAGEMENT, AND WORLD CLASS RELIABLE EQUIPMENT, WHICH YOU GET WITH A PLANT WELLNESS WAY EAM SYSTEM-OF-RELIABILITY
Successful Operational Excellence requires a business-wide, life-cycle asset management system with the methods and practices that ensure utmost productivity and top-of-class operational performance
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In Unit 6, we explore the next steps in the Reliability Centered Maintenance (RCM) process: Step 5, assessing Failure Consequences and Step 6, Proactive Maintenance and associated intervals. Building on our previous work in identifying Failure Effects, we now analyze whether these failures have safety, environmental, operational, or non-operational consequences. From there, we delve into step six of the RCM process: proactive maintenance, which includes both Condition Based Maintenance (CBM) and Preventive Maintenance. Through practical examples, such as monitoring bearing vibrations or scheduling oil changes, we illustrate how to develop technically appropriate and cost-effective maintenance tasks. We also examine the P-F interval and its role in determining CBM task intervals, ensuring that maintenance is performed only when necessary, maximizing the useful life of components. Join us as we demystify these essential concepts and learn how to apply them.
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In many RCA programs, investigations consistently stall at the “who” instead of the “why.” A technician misses a step, a operator turns the wrong valve, or a mechanic over-torques a bolt.
The investigation concludes that “Human Error” was the cause, and the file is closed with a recommendation for “Retraining” or “Increased Awareness.”
This creates a revolving door of failure. Leaders see the same incidents recurring every six to twelve months because the underlying vulnerability remains untouched.
If your RCA program relies on people never making mistakes, your reliability system is actually a “fragility” system.
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POSTED IN ASSET MANAGEMENT, ASSET PORTFOLIO, MRBP FRAMEWORK, RELIABILITYX BLOG
BY ANJELICA SEPTEMBER 15, 2025
Understanding Asset Portfolio Management in Asset Management
In the world of asset management, the concept of an asset portfolio is crucial. Organizations that rely on physical assets—whether in manufacturing, energy, transportation, or utilities—must manage them strategically to maximize value, minimize risk, and ensure long-term sustainability. Just as investors manage a financial portfolio to balance risk and return, businesses must manage their asset portfolio to align with operational and financial goals.
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In Unit 5, we transition to the RCM Decision Diagram, focusing specifically on identifying Evident and Hidden Failure Modes. This unit demystifies the process of using the RCM Decision Diagram, a pivotal tool in the Reliability Centered Maintenance (RCM) process. We begin by analyzing each Failure Mode from our FMEA by putting it through the Decision Diagram to determine if its effects are Evident or Hidden during normal operations. Through some examples, we illustrate how to navigate the RCM Decision Diagram.
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There are only two ways to get high system reliability: meeting outstanding task quality performance standards so excellence is done everywhere, and by building parallel arrangements where the failure of one has no impact on system performance. Both are done in a PWW EAM System-of-Reliability
Equipment can be configured in series or in parallel arrangements. A series arrangement is when one item or task connects sequentially to the next. It takes only one item to fail in a series arrangement and the whole system will fail. Exceptionally reliable individual equipment is needed to experience a high-reliability system with a series arrangement.
Parallel arrangements are when each item is arranged as a companion, one duplicates another. In this circumstance, exceptionally reliable systems can be formed even if individual equipment has poor reliability.
A system is formed when equipment is combined to do a duty. For example, when a pump, coupling, and electric motor are connected they form a series system used to move liquid through pipes from one point to another.
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5-Why is it popular because it’s simple—and that’s exactly where it can fall short.
Teams ask “why” five times, land on a familiar answer, document it, and move on.
The exercise feels efficient, but the thinking is often shallow.
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In this unit, we delve into the second and third steps of the Reliability Centered Maintenance (RCM) process: identifying Functional Failures and writing Failure Modes. It’s vital to distinguish between Failure Effects and the actual causes of failures. A Failure Mode, often termed a failure cause, specifically pinpoints what specifically causes a Functional Failure. Proper training is essential, as accurately identified Failure Modes are the cornerstone of developing effective failure management strategies. We will introduce the four criteria for including Failure Modes in an RCM analysis. This session uses practical examples, such as bearing failures, to demonstrate how well-defined Failure Modes lead to actionable solutions like vibration analysis or enhanced training programs. Learn to balance the level of detail in your documentation to prevent oversimplification and avoid analysis paralysis, ensuring your RCM process is comprehensive and effective.
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Across every mature RCA program we’ve seen, one pattern is unmistakable: leaders who consistently close the loop win.
Not sponsors who attend kickoffs. Not managers who ask for status updates. Leaders who personally ensure that corrective actions are implemented with the same rigor used to identify root causes have RCA programs that thrive.
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In this unit, we delve into the second and third steps of the Reliability Centered Maintenance (RCM) process: identifying Functional Failures and writing Failure Modes. It’s vital to distinguish between Failure Effects and the actual causes of failures. A Failure Mode, often termed a failure cause, specifically pinpoints what specifically causes a Functional Failure. Proper training is essential, as accurately identified Failure Modes are the cornerstone of developing effective failure management strategies. We will introduce the four criteria for including Failure Modes in an RCM analysis. This session uses practical examples, such as bearing failures, to demonstrate how well-defined Failure Modes lead to actionable solutions like vibration analysis or enhanced training programs. Learn to balance the level of detail in your documentation to prevent oversimplification and avoid analysis paralysis, ensuring your RCM process is comprehensive and effective.
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Is your CMMS cluttered with spare parts and throwaway items? Not sure what qualifies as an asset—or why it matters?
In this video, we walk through the logic behind building a clean, effective asset portfolio. Learn how to define what belongs in your CMMS or EAM system, how to structure your asset hierarchy, and how to avoid the common mistakes that derail reliability strategies.
✅ What counts as an asset
✅ What to leave out
✅ How to build decision logic that lasts
✅ Why this matters for ISO 55000 and long-term success
If you’re tired of second-guessing your asset list, this is your starting point.
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ISO 55001 Certification Bodies are accrediting Service Providers to the ISO 55001 asset management standard in the misconstrued belief that a Service Provider’s ‘asset’ is the Contract with a Client. This misunderstanding is dire for service business success.
Having lots of paying clients is the cause of a Service Provider’s success. For a Service Provider, THE ASSET IS THE CLIENT. The Contract with a Client is not the asset!
There is a wonderful ISO 55001 certification benefit you get when YOUR CLIENT IS THE ASSET: The Contract between you and your Client can become your ISO 55001 Strategic Asset Management Plan (SAMP). After all, the Contract explains how you will provide your services to help the Client achieve their organizational goals. That’s exactly what a Strategic Asset Management Plan is meant to do.
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RCAs often get marked complete, but teams don’t know whether the investigation was actually effective.
Actions are assigned and work moves on, yet the investigation team rarely sees whether conclusions held up, whether actions prevented recurrence, or whether the same failure quietly showed up somewhere else.
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RCM in a Nutshell | Free RCM Overview Course – Understand the RCM Process, what RCM (really ) is, How to Apply it Properly, and What Can Be Achieved
In this unit, we delve into the foundational steps of Reliability Centered Maintenance: defining the Operating Context and Functions. Starting with an Operating Context provides a narrative about what the equipment is, its technical details, its operational environment, and its usage expectations. This story sets the stage for a unified understanding among all stakeholders involved in maintaining the equipment. We then move to Functions, the first of seven steps in the RCM process, where reliability is not just an abstract concept but a tangible attribute defined through specific performance standards of the equipment. Through real-world comparisons of air compressor analyses, I illustrate the stark difference between routine function descriptions and those meticulously crafted to meet precise organizational needs. This segment reveals how detailed function writing not only enhances reliability but also uncovers critical insights about equipment operation, which can correct misconceptions and prevent chronic failures. Join me as we explore how properly written functions are integral to effective maintenance strategies and responsible equipment stewardship.
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