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Bad Actor Calculation

  • 1.  Bad Actor Calculation

    Posted 01-17-2023 11:37 AM
    Hello- we are standardizing the definition of Bad Actor related to unreliable assets, and developing metrics to calculate what a Bad Actor is. Does anyone have an effective definition of Bad Actor (what constitutes a Bad Actor)? Thank You.

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    Thomas Williams
    Principal Reliability Engineer
    Sanofi Pasteur
    Somerset MA
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  • 2.  RE: Bad Actor Calculation

    Posted 01-18-2023 08:02 AM
    Hello- We are also in process of identifying bad actors and standardizing the definition of Bad Actor. We have started reviewing number of unplanned repair orders affecting OEE, annual cost of operating and repair, age and demand (asset utilization). Mostly equipment reaching end of life cycle and costly repairs/obsolescence.  

    Pranav Desai

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    PRANAV DESAI
    Solvay Chemical Manufacturing
    West Deptford NJ
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  • 3.  RE: Bad Actor Calculation

    Posted 01-18-2023 08:18 AM
    Thank You Pranav. We are considering very similar factors. Thanks again.

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    Thomas Williams
    Principal Reliability Engineer
    Sanofi Pasteur
    Somerset MA
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  • 4.  RE: Bad Actor Calculation

    Posted 01-18-2023 08:19 AM

    I use pareto analysis for BA calculation in our asset (Upstream gas production). I have my plant Reliabilty Engineers to carry out a quarterly CMMS review. They take a dump of all corrective maintenance notifications and carry out a functional location or equipment tag level failure count. They then use the Bad Actor qualification procedure which qualifies  an equipment that failed more than 3 times within a period of 12 months as a potential BA. They also carry out an object type ( equipment groups in SAP) based pareto analysis for standard low criticality equipment groups that fail frequently (i.e. instrumentation such as gas detectors, temp probes etc), if they capture excessive number of failures among in these type of equipment, they also shortlist these as potential bad actors. 

    Then we sit together with our operations team and carry out a risk/impact assessment and select repeat failures with actual or potential high risk for treatment (active BAs). Treatment   is carried out in form of 5WHYs, simple RCA or simply discipline engineering review/assessment by the reliability and/or discipline engineers (hardware improvement, management of change by design out, procedural change, part/component upgrade, OEM feedback through service bulletins etc) 

    We report our agreed and active bad actors during our fortnightly Site Reliabilty Meetings to the asset operations team and get their involvement, budget or resource support. When we resolve a BA and implemented an engineering solution and we then claim BA as eliminated. After that, we report out the value delivered by BA Elimination based on initial risk value calculated, so that we can demonstrate the bottom line business improvement value delivered by the effort of the reliability team.
    It is critical that this process is documented as an approved company procedure and/or guideline and all involved team understand the work process and their leaders support it.
    Noyan Ercan
    Brisbane - Australia 



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    Noyan Ercan
    Reliability Manager
    Oil Search Ltd.
    Paddington QLD
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  • 5.  RE: Bad Actor Calculation

    Posted 01-18-2023 02:37 PM
    Thank You Noyan for the excellent feedback.

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    Thomas Williams
    Principal Reliability Engineer
    Sanofi Pasteur
    Somerset MA
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  • 6.  RE: Bad Actor Calculation

    Posted 03-15-2023 08:55 AM

    Same here. I use Pareto analysis to display the number of failures for example on an air cooler bank. I was able to readily identify the AC-5701-D1 as a bad actor with a number of burst belts over a period of time.



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    KAMARIA DUNCAN
    Mechanical Technician
    P.P.G.P.L
    Point Fortin
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  • 7.  RE: Bad Actor Calculation

    Posted 01-18-2023 09:37 AM
    Not knowing your operation, it's difficult to be definitive, but a few questions come to mind for things to consider in setting this up - 1) Has the asset had multiple failures in a given period of time (you select the period based on your operation; 2) Has it resulted in a substantial production/gross profit loss, either a one time event, or multiple cumulative events? 3) Related to this, has it resulted in a major or multiple delivery failures?  4) Has it resulted in a significant, or multiple, environmental release(s)?  5) Has it resulted in an OSHA injury or created a significant hazard?  Many of these will overlap, and therefore be more serious.  
     
    More over, bad actors may not be limited to machinery, but could entail other acts that result in loss of production or risk of excess costs, e.g., poor changeover practices, de-rates and/or transition losses, poor startup and shutdown processes, poor shift handover, and others, all of which result in degraded performance of the plant processes.  
     
    Some food for thought.  
     
    Ron Moore 
    Author, Making Common Sense Common Practice 
    The RM Group, Inc. 
    Knoxville, TN





  • 8.  RE: Bad Actor Calculation

    Posted 01-18-2023 02:39 PM
    Thanks Ron great feedback that I will be considering for our final definition.

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    Thomas Williams
    Principal Reliability Engineer
    Sanofi Pasteur
    Somerset MA
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  • 9.  RE: Bad Actor Calculation

    Posted 01-18-2023 12:10 PM
    Many have commented on the various catagories that could be used to define "bad actor".  I don't know of an industry standard for the term.   It is similar to me to criticality models where each business or plant may have specific/custom elements that are important and critical to defining "bad actor".   Those elements some have already mentioned are environmental, # failures in 12 months, cost of failures, # of repair WOs, # failures which caused machine downtime, any repeat failure in 12 months, etc.

    I've used # of repair WOs over a certain dollar amount in 12 months in the past to serve as an indicator of "bad actor".   This is good because you can mine your CMMS and get your listing of assets and repeat WOs. 

    One other element that your reliability engineers and maintenance professionals can help with on bad actor lists is understanding what the failure mode is for each failure or repair.  In some cases it doesn't matter but in some it can.  You will need that information anyway when the bad actor assets gets to a problem solving phase. 

    Two other tips on bad actor lists.  Don't discount feedback from maintenance techs and operators.  A WO scrub may or may not show all bad actors due to documentation errors, etc.

    Also vibration or other predictive maintenance history is another good source of identifying bad actors.  A machine may always have very high vibration and not fail in 12 months but fails in 15-18 months when it should last 5-10 years.  This too is a bad actor but only shows up in some predictive maintenance data for the asset.​

    Good topic with a lot of potential.​​

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    Randy Riddell, CMRP, PSAP, CLS
    Reliability Manager
    Essity
    Cherokee AL
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  • 10.  RE: Bad Actor Calculation

    Posted 01-18-2023 02:41 PM
    Thanks Randy for the feedback. I like the suggestion of reviewing PDM Technolgies for negative trends.

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    Thomas Williams
    Principal Reliability Engineer
    Sanofi Pasteur
    Somerset MA
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  • 11.  RE: Bad Actor Calculation

    Posted 01-23-2023 10:52 AM

    INTERNAL


    In my opinion, the term Bad Actor, is a wrong term. Bad Actor implies something doing a bad thing. Working with my colleagues in Enel, we have adopted the term, defect. A defect is anything not performing as intended. Whether a widget, process, system, procedure, management, training or even personnel related which usually stems from something else such as training.

     

    Intention does not equate design. Defect does not equate stopped and can be expanded as a functional failure. A temperature transmitter, indicating close but false data is a defect. A Work Order completed outside the Scheduled duration (high or low) is a defect. A process originally capable of 100% reliability and less than 100% today is a defect. If a training program is expected to provide a qualified person in six months but personnel are devoting more than six months or are not able to meet the minimum standard after training, those are defects.

     

    I hope this helped.

     

     

    1.  Personnel Safety     2.  Environmental Safety     3.  Equipment Safety     4.  Revenue

    Lockout Larry EBoK

     

    Larry Wade James II CMRP

    Head of Knowledge Management Solar/BESS/Geo US & CA

    www.enelnorthamerica.comwww.linkedin.com/company/enelnorthamerica/mycompany/

     

     

     

    Enel Green Power North America

    200 South Virginia Street, Suite 400

    Reno NV, 89501, USA

    Tel +1 775-250-1260

    Larry.James@enel.com

     

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  • 12.  RE: Bad Actor Calculation

    Posted 01-28-2023 12:24 AM
    Thanks James, great learning for me. In our organization we define bad actors in terms of number of corrective work orders, cost of repair, cost of LPO. However, top 3 bad actors are defined as worst actors and they are resolved.

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    Ashis Bar BSc
    Reliability Engineer
    Chevron Global Upstream
    Dhaka
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  • 13.  RE: Bad Actor Calculation

    Posted 01-30-2023 08:58 AM
    Edited by PRANAV DESAI 01-30-2023 09:01 AM
    Thank you Larry. I agree with you. It is important that correct terminology is used for maintenance and reliability of assets. If 'Bad Actor' is what industries now a days are using, what would be the correct definition of it and how to calculate 'Bad Actor'? It appears to me that term 'Bad Actor' is used more to justify for allocation of capital funds to replace costly equipment due to repeat failures. Not sure if there is even a KPI fort his.

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    PRANAV DESAI
    Solvay Chemical Manufacturing
    West Deptford NJ
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  • 14.  RE: Bad Actor Calculation

    Posted 02-13-2023 04:24 AM

    Hi, i think there many way to define a bad actor, for the most part you don't even need to run a CMMS report to know which equipment is giving you the most issue, Ops/Maintenance will instinctively know, but a Parato would be the data to prove it.

    A good measure is annual maintenance cost/RAV (replacement asset value). The RAV is used in the denominator to normalise the measurement given that equipment varies.  

    SMRP advises for best in class - generally less than 3%; top quartile range is 0.7% to 3.6%, varying by industry.



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    Derek Brown
    Grangemouth
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