There are many myths about reliability, the most common one being that if we do excellent maintenance, we will have excellent reliability.  We often make assumptions, for example, if I complete the following tasks (and you should):

• A CMMS, work management, planning and scheduling, linked to stores
• Maintenance plans for each equipment
• Specific PMs based on failure modes and consequences (each eqpt)
• Condition monitoring program – all PdM, Operator Inspections
• Precision work tools and practices
• Comprehensive RCA process
• Use of RCM in developing and updating maintenance plans

Then operational reliability will improve, efficiency will improve, costs will come down, and profit will improve.  Everyone will be happy.  Not likely.

This podcast will provide a cautionary tale, and suggest some additional work that must be done to assure a reliable operation, especially in designing, buying, storing, starting up, and operating for reliability, which is where most of the defects originate.  These areas must be managed for reliability and defect elimination in collaboration with maintenance in order to have reliability, and operational excellence.