Library of Congress Cataloging-in-Publication Data
Daley, Daniel T. Reliability assesment : a guide to aligning expectations, practices, and performance / Dan Daley. p. cm. ISBN 978-0-8311-3407-5 1. Reliability (Engineering) I. Title. TA169.D36 2010 620'.00452--dc22 2009046977
Industrial Press, Inc.
989 Avenue of the Americas New York, NY 10018 Sponsoring Editor: John Carleo Copyeditor: Robert Weinstein Interior Text and Cover Design: Janet Romano Copyright © 2010 by Industrial Press Inc., New York. Printed in the United States of America. All rights reserved. This book, or any parts thereof, may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the publisher. 10 9 8 7 6 5 4 3 2 1
To Theresa, Paul, Caroline, Kate and Alex.
Thanks for listening and pretending that
engineering is interesting to you.
Table of Contents
Chapter 1A Fictional Story — What Do You Have a Right to Expect?
• Maintaining or Improving Inherent Reliability during Modification and Renewal
Chapter 3Assessing What You Have a Right to Expect
• Outline for a Wide-Hart Assessment
• Assess Commissioning / Start-Up Processes
• Assess Operating Practices
• Assess Inspection Practices
• Assess PM/PdM Practices
• Assess Maintenance Practices
• Assess Modification Project Practices
• Assess Renewal Practices
• Identify Implementation Program
Chapter 4Conducting the Assessment of Your Reliability Opportunity
• Conducting the Wide-Hart Assessment
• Organizing the Interview
• Tool #1 — List of Questions, Points to Observe, Information, and Measures
• Tool #2 — Alignment Workshop Outline
• Tool #3 — Wide-Hart Assessment Reporting Tool
Chapter 5Developing and Implementing Your Corrective Action Plan
• Articulate Expectations
• Clarify Opportunities and Create Pareto
• Identify the Gap
• Identify the Project Manager
• Study Issues and Create a Detailed Plan and Schedule
• Create a Plan for Installing Each Component of the System, Skills, and Disciplines
• Create a Comprehensive Schedule
• Assign an Implementation Team & Begin Implementation
• Work the Plan and Schedule
• Begin Using the Reliability Process and Harvesting Benefits
Chapter 6Design for Reliability
• The Elements of DFR
• Evaluating the Expected Reliability of a New Plant
• Evaluating the Expected Availability of a New Plant
• Evaluating the Expected Maintainability of a New Plant
• Organizing and Staffing for DFR
Chapter 7Preserving Reliability During Renewal
Chapter 8Everything in Between
• Failure Mapping
Chapter 9Conclusion
AppendixWide-Hart Assessment
References for Further Reading
Index
Climate is what we expect, weather is what we get.
Mark Twain
A number of years ago, I heard someone refer to a concept called the “device mentality.” It was a way of describing a naïve viewpoint of complex devices. For instance, a young driver with a “device mentality” would view a car as simply being a steering wheel, an accelerator, and a brake. You push the accelerator to make it go. You push the brake to 
