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HRO'?

  • 1.  HRO'?

    Posted 08-08-2022 03:23 PM
    Hi all,

    I've heard mentioned Highly Reliabile Organisations (HRO's) but never a actually heard of a company that is regarded as such, anyone know?

    Also, would it be possible to spend time with an HRO' to see how they accomplish higher reliability results?

    Cheers
    Derek 


    ------------------------------
    Derek Brown
    Grangemouth
    ------------------------------


  • 2.  RE: HRO'?

    Posted 08-09-2022 09:01 PM
    If we tried to name an HRO we'd probably get into an endless argument about the definition of an HRO. Some people have tried it though:
    https://www.ncbi.nlm.nih.gov/pmc/articles/PMC3388695/

    Seems like most discussions list nuclear power, navies, power generation/distribution, and specialty medical teams. I'd also add high-performing sports teams. Of course, there are plenty of disasters to study from these groups too. My HRO experience was as a nuclear power technician and engineer in a navy. Being an HRO is something no one should claim, because the moment they did, they start the process of devolution. The best HROs try to learn from themselves and other HROs constantly. It's a journey, not a destination.

    At first, I thought you asked what it's like to be in an HRO. I thought up an answer while cooking dinner so I'll offer it up.

    It's always a struggle. It's satisfying, though, to come off an operation where everything went well. Then you do it again only a few hours later.

    There is a lot of excess, at least to the eyes of an efficiency-minded management guru:
    • Excessive preparation for tasks you have repeated many times.
    • Excessive training. Repeated training. Aggressive testing to prove the training was effective.
    • Excessive oversight and supervision.
    • Excessive record keeping.
    • Self-assessment and audits are routine...daily. The corrective actions are real and get tracked to completion.
    • Drills are similarly frequent. We had small fire drills every shift, and more complex drills weekly up to daily (depending on the situation.) You'd meet immediately after, do a self-assessment and assign corrective actions.
    • Root cause investigations are not just for failure. Operations that are successful get self-assessments or after-action reviews, too.
    • Actual accidents and near-misses got investigated. Supervisory layers could and did send it back if it didn't hold water. The lessons were driven through the organization...no lawyers were involved in suppressing the ugly parts of the RCA findings.
    • Reliability isn't just a machine thing and requires a really good organization. People are not inherently reliable, but can be trained and organized to form an organization that is more reliable than the individual. This requires layers of self-checking..."forceful backup."


    This gent was one of my mentors and has become an HRO thinker and author:

    https://www.ralphsoule.com/ralph-soules-blog
    https://www.talkingaboutorganizations.com/author/ralph-soule/

    ------------------------------
    Karl Burnett
    General Electric
    Anderson SC
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  • 3.  RE: HRO'?

    Posted 08-10-2022 10:05 AM
    Karl,
    The regard of management efficiency gurus likely ignores that the issue is the design and operation of logistics support in an organization with structure that includes integrated logistic support (ILS). In the design of LS, the issues in your list are considered in the context of the need for which the plant or weapon system was being acquired and is now being managed. Depending upon logistic support analysis (LSA), what is too much, too little or just right is determined. We should also note that maintenance as the core process of system support is formed in the context of an overall LS scheme. This is an important distinction because history outside the recognition of logistic support thinking treats them as if maintenance were a primary rather than support system.

    I like your comment about good organization. It starts with analysis of the entire support scheme and the roles of ILS as an organizational entity. Merely drawing up an organizational chart does not work well because the dynamics of what is called social psychology are ignored resulting in hidden fatal dysfunctions






  • 4.  RE: HRO'?

    Posted 08-13-2022 02:11 PM
    Here's a resource for Derek specifically about HRO:

    This gent has a podcast and some books out:
    https://www.linkedin.com/in/jonscottrennie/

    He worked under this gent, who also consults on HRO:
    https://www.linkedin.com/in/bobkoonce/

    You'll find they both talk a lot about good organization and leadership. If they talk about maintenance, it's the same theme. I guarantee you they are both plenty competent in maintenance. To Richard's point, maintenance, repair, and reliability of fixed assets is simply a function within a larger support scheme. The support scheme itself needs maintenance, troubleshooting, and repair. When an organization invests in troubleshooting and tuning itself by using self-assessments even when nothing went wrong, then you're headed toward being an HRO.


    ------------------------------
    Karl Burnett
    General Electric
    Anderson SC
    ------------------------------



  • 5.  RE: HRO'?

    Posted 08-13-2022 03:25 PM
    It seems that HRO is another acronym for handwaving generalities about how to do great  things. Logistic support to the primary production system is a rigous system of terminology and design issues all of which are integrated to the primary system and each other. The profession of maintenance and relliability engineering will be forever marginal until we can move into dealing with the maintenance and reliability as integrated logistic support. Worse, I don't see much interest for making the transition. One more speech about leadership and all the other platitudes will never get us there.





  • 6.  RE: HRO'?

    Posted 08-14-2022 11:33 AM
    Derek: In the US, anywhere that has an enthusiastic Process Safety Measures program (OSHA 1910.119, but I don't know the UK or EU equivalent) has some elements of being an HRO, because you're supposed to anticipate and evaluate risk, document it, prioritize it, and come up with solutions. Not just equipment modifications, but things like awareness training with objective evidence that is retained, and revision-controlled standard operating procedures. Mechanical integrity programs also have these elements. Quality systems also have these characteristics: under AS9100, I've used the required risk register essentially as an organizational FMEA, made preventive corrective actions for things like personnel turnover, and shown year-over-year reductions in residual risk. That's all HRO practice. You may be in an HRO and not even realize it.

    Richard: No doubt HRO will get watered down for consulting advertisements, but I don't agree it is just another acronym. It's a different approach than the lean/Toyota/6-sigma but also results in operational excellence.

    As I recall, we used to call HRO by something like HRHO....high-risk high-reliability organizations. The high-risk part is an important part of the outlook... the Wikipedia article on HRO is very good and discusses attitudes about risk, but it does not mention maintenance at all. HRO is risk-focused. Operational Excellence is resource-focused.

    Effective maintenance, asset management, and ILS are just one ingredient. If an HRO-style organization doesn't have them, they will eventually get them naturally as part of the HRO process.

    The Wikipedia article also references wildfire incident command systems, which would not have occured to me. That's using HRO in a non-asset intensive organization.


    ------------------------------
    Karl Burnett
    General Electric
    Anderson SC
    ------------------------------



  • 7.  RE: HRO'?

    Posted 08-14-2022 11:47 AM
    Derek, my point is that we can't just recite it like a boy scout oath. We have to design it. And for it and all other generally equivalent acronyms competing for our attention, we are mostly reciting rather than designing. Regardless of name and acronyms, the doing it always entails systems engineering. All of those things in the found slide, if they exist in an organization do by virtue of methodical systems engineering. The system in our domain for engineering is ILS. And to quote the HRO scout oath and expect the systems design to naturally ocurr is a bit optimistic.





  • 8.  RE: HRO'?

    Posted 08-14-2022 11:03 AM
    Thanks Karl. 

    I would be intrigued to know if anyone has spent time within an HRO, or visited an HRO as part of a learning opportunity.

    ------------------------------
    Derek Brown
    Grangemouth
    ------------------------------



  • 9.  RE: HRO'?

    Posted 08-14-2022 11:32 AM
    I found this on line. We over the decades have fallen into slogoneering. We can say these things 10 times every day but if we do not design the orgnanizatial elements we ar only making motor noises. To get past the motor noise with respect to maintenance and reliability we need to get into the detials of ILS (integrated logistic support) which conduct system design for maintenance activity and the support logistics to delivering activity and the organizational superstructure to assure that they succeed in their mission with firm business success.

    image.png





  • 10.  RE: HRO'?

    Posted 08-15-2022 10:43 AM
    Ha, Ha.  Slogoneering, nice one Richard.  IMHO, that is pretty much where most organizations are at these days.  

    No one wants to commit the time, resources (money and people) to do the work it really requires to achieve this HRO.  We want the cheap knockoff artificial version that we can quickly window dress in front of the VP. 

    I have worked in one what I'd call HRO organization (at a local level) and here is one thing I saw that I think it requires - the right people leading and executing from top to bottom.  Hire or promote the wrong people and you'll get wrong results every time.  You'll never have 100% of the right people but if you have a strong majority, the culture and peer pressure will push the rest.  If you lose that critical organizational mass, the battle will be lost.

    ------------------------------
    Randy Riddell, CMRP, PSAP, CLS
    Reliability Manager
    Essity
    Cherokee AL
    ------------------------------



  • 11.  RE: HRO'?

    Posted 08-15-2022 12:25 PM
    Thanks Randy, but I have to give credit to Deming. He had a rule, "no sloganeering." One saying I like I got from my old daddy as a kid, "just making motor noises."

    The top to bottom you talk about is actually a systems engineering discipline called integrated logistic support developed by aerospace and defense in the 1950s including the later arriving reliability centered maintenance.





  • 12.  RE: HRO'?

    Posted 08-16-2022 07:25 AM
    Hi Richard,

    Thanks for the detailed replies, however I have absolutely no idea what integrated logistics support/analysis means? 

    Apologies but can you advise please?

    Thanks
    Derek 



    ------------------------------
    Derek Brown
    Grangemouth
    ------------------------------



  • 13.  RE: HRO'?

    Posted 08-16-2022 10:28 AM

    Hello Derek, 

    You can find various sources of information on Integrated Logistics Support online.  I typically rely on DOD references, some are dated but the principles don't change.  ILS is essentially  good asset management, what am I building, the operational requirements, and what is required from "Lust to Dust", had to add the slogan.

    SAE/TA Standard 0017 Product Support Analysis lays out the activities required.

    Integrated Product Support (IPS) Elements: Those critical functions related to product readiness including, but not limited to, materiel management, distribution, technical data management, maintenance, training, cataloging, configuration management, engineering support, repair parts management, failure reporting and analysis, reliability growth tracking, and the logistics elements (e.g., support equipment, spares) required to accomplish the functions. All of these elements shall be considered during the development of the Product Support (PS) strategy.

    You can also check out https://www.aia-aerospace.org/standards/s-series-ils-specifications/ for the S Series specifications.

    The S Series Integrated Logistics Support Specifications is a suite of specifications for product support that will provide the seamless passage of technical data (logistics, provisioning, technical publications/IETMs, scheduled maintenance and maintenance data feedback). 

    ILS or IPS is neither Cheap, Fast or Easy which is why, in my experience, there isn't much interest in full use of the practices outside of Defense or Aviation industry.  Some industries pick and choose what parts of the ILS analysis they use thereby limiting the full benefit of the process.



    ------------------------------
    Hank Kocevar,CMRP
    Consultant
    Guardian Technical Services
    hkocevar@guardiantech.org
    ------------------------------



  • 14.  RE: HRO'?

    Posted 08-16-2022 01:25 PM

    Hank,

    You say that ILS is neither Cheap, Fast or Easy which is why, in your experience, there isn't much interest in full use of the practices outside of Defense or Aviation industry.

    I disagree because it is not a matter of "Cheap, Fast or Easy" but a matter of the reality. These are the elements of support logistics that must happen if the primary system is to deliver on its full potential with respect to its mission in the corporate competitive strategy.






  • 15.  RE: HRO'?

    Posted 08-16-2022 05:56 PM
    Richard,

    I'm not surprised you disagree. So convince me it is the corporate reality.  How about some examples of that Fast, Cheap and Easy Blueprint.
    I firmly believe in ILS practices, just haven't seen that Fast, Cheap and Easy Blueprint, perhaps you can share some success stories.

    ------------------------------
    Hank Kocevar,CMRP
    Consultant
    Guardian Technical Services
    hkocevar@guardiantech.org
    ------------------------------



  • 16.  RE: HRO'?

    Posted 08-17-2022 12:03 PM

    Hank,

    ILS may appear as expensive and cumbersome, thus, impractical. That is a perception that should be seen in context. Ideally ILS is should be incorporated as a discipline in the design stages of the plant. Like all engineering disciplines (e.g., electrical, mechanical) in a capital project the cost of including the ILS discipline requires considerable engineering cost.

    However, for the existing plant, the ship has sailed on that cost. Now the need is to align ILS to the existing functioning plant. At this point we are revisiting all of those things that can still and "must happen" before the plant can maximally fulfill its competitive mission.

    Another reason to cause some to assume that ILS is "expensive and slow" comes from the impression we can get from the old military standards that mandated in high detail how the process was to be conducted as integral to the government procurement process. The costly passage through the system of documented analyses, reports and decisions is unnecessary in manufacturing.

    The point to make is that we only need to apply the underlying principles and the practices that the military standards reveal to us as ILS and which together are what "must happen" to best be able to support the plant's competitive mission.

    Most of the principles and practices are actually ongoing in most existing plant. Some important ones are absent and many of those that exist are not well aligned to the remaining support elements nor to the plant's competitive mission.

    In the discussion of "expense," what is more expensive, doing the backfill work of ILS or accepting the persistent business losses of not doing the backfill work?






  • 17.  RE: HRO'?

    Posted 08-18-2022 09:49 AM

    Richard and Karl,

    You both have made great points. As I said I believe in the use and benefit of ILS principles,  I have performed most of the steps from DFMEA's to spares analysis.  To both your points it comes down to the well defined requirements.  This is true whether it is a new or existing plant, aircraft, vessel, or other capital asset.  What is the end goal? Meet the expected performance in most efficient manner possible while minimizing risk?

    To my point of not being fast, cheap or easy.  As you stated Richard "Some important ones are absent and many of those that exist are not well aligned to the remaining support elements nor to the plant's competitive mission." Why are those important principles and practices missed or not aligned? Was is it an oversight, lack of training /trained resources or cost?  It doesn't matter, because to your point Richard it is more expensive to backfit the ILS processes. I think Randy Riddell had it right with his comment about everybody wanting the cheap knockoff.

    Karl is on target with his assessment of military programs "different sized programs get different ILS development requirements for the level of detail that is required."  Except of course when they don't, and the Program Office takes a blanket ILS template, doesn't tailor it and then cost overruns, missed expectations and in Karl's words "the program gets canceled or a remediation plan. Ouch!"

    ILS requires training, experience and definitely a systems approach.   What is an FMEA/FMECA, RCM, LORA, MTA, Spares and EOL analysis? Are engineering and maintenance/support staff being exposed to it?  Back to your statement Richard, "The profession of maintenance and reliability engineering will be forever marginal until we can move into dealing with the maintenance and reliability as integrated logistic support.", I'll add the word system. 
    Doing the planning up front takes time, training personnel and doing the analysis costs. Is it worth the investment, I say yes. However, there will be challenges along the way.
    I use a theme similar to Karl's sports team, we all have to be playing the same tune from the same sheet of music.

    We are on the same sheet of music, I'm just a little off key.



    ------------------------------
    Hank Kocevar,CMRP
    Consultant
    Guardian Technical Services
    hkocevar@guardiantech.org
    ------------------------------



  • 18.  RE: HRO'?

    Posted 08-19-2022 11:12 AM

    Hank, Dereck and Karl,

    In the late 1980's, as an employee of a major engineering and construction firm, I mapped out all the project activities for ILS that must happen as part of the standard interdisciplinary design, construction and startup of operations such as oil and gas, refining, petrochemical and pulp and paper. To do that, I had to translate the content of military and aerospace documents and standards for ILS to the formal project workflow of a capital project. The effort was awarded the Society of Logistics Engineers' 1995 Armitage Medal for outstanding contributions to logistics literature.

    I am currently writing out the approach to align maintenance and its support upon the ILS framework, given that a plant is an existing one for which the capital project never included ILS in the project scope. What will emerge is that the backfill for ILS will lean towards the maintainability parameter of the plant availability parameter. The maintenance and support elements have a great deal of flexibility and, therefore, are still an opportunity for the plant.






  • 19.  RE: HRO'?

    Posted 08-17-2022 08:09 PM
    ILS should be as hard as it needs to be to get you the results you want. From the military systems acquisition point of view, the office sponsoring the acquisition has to formally set some performance parameters, for a manufacturing analogy, a minimum OEE, minimum production run time, and scrap rate. ILS establishes what needs to be included in the entire lifecycle support plan to ensure the key performance parameters (KPPs) are met over the intended service life.

    Like Richard says, this is done during the design phase so that the full cost of design options can be evaluated. So really, you do basic ILS for each of the major design options. The ILS detail matures as the design matures.

    The KPPs aren't just goals...the system performance gets tested during increasingly realistic exercises. You have to meet the KPPs to be able to progress from a few prototypes to building all of them. If you don't meet the KPPs...the program gets canceled or a remediation plan. Ouch!

    For the military, different sized programs get different ILS development requirements for the level of detail that is required. For expensive, multi-service programs, the KPPs get lots of reviews from above, and so does the ILS plan. For submarines...high readiness, lots of oversight and national command interest results in lots of ILS. For submarine hulls, the condition gets tracked very aggressively and almost nothing gets rescheduled. For berthing barges, true story: you can defer the drydocking and hull painting for years without asking permission...it's all part of the smaller ILS plan.

    For a plant that is already built, I don't see why one couldn't come up with an ILS plan. It's just a systems engineering view of all the support functions. You might not be able to re-design the physical plant, but you can take a new approach to the management: say PMs, outage frequency, MRO, the contracting strategy, etc. A systems view would have you do it all together and think about plant OEE and ROI the whole time. The important thing is to formally lock down the key performance parameters at the beginning.

    In a non-ILS approach, you'd optimize one area at a time on narrow departmental KPIs without thinking about OEE or the effect on other departments. The storeroom has many examples of mis-optimization we can come up with: minimizing the size no matter what, reactively increasing minimums to prevent stockouts, cutting the attendants' hours without thinking about how early the maintenance department starts, etc.  ILS puts all the players on the same team, listening to the same coach, all planning for the greater, long-term good.




    ------------------------------
    Karl Burnett
    General Electric
    Anderson SC
    ------------------------------



  • 20.  RE: HRO'?

    Posted 08-16-2022 01:23 PM

    Derek, 

    Thank you for that question. It is a good one.

    I will first describe ILS from 75,000 feet and then you can ask me the first questions that come to mind for you.

    Think of your plant as a "system" of equipment that produces goods. Around a primary system of production equipment there is also a system of production support that provides all necessary resources (people, inventory, delivery equipment, and so on) for the operation of the primary system. If the production support is not done optimally the primary system will fall short of what it is capable of.

    Now let's extend the idea to include the maintenance of the primary system as needed to be called to serve, remain in service or return to service. In turn, maintenance has a support system to allow it to be able to optimally serve the primary system.

    Accordingly, integrated logistic support (ILS) is the lifecycle management and development of maintenance and its support logistics as a system, integrated with the primary system and its logistics as well as integrated with itself.

    Here is where we are as a profession. The elements of ILS exist in all plants and organizations. They are the best practices that always get press. Unfortunately, they exist piecemeal and partially without being integrated to all necessary elements of ILS. It follows that the overall system then underperforms.






  • 21.  RE: HRO'?

    Posted 08-18-2022 08:25 AM
    Derek,
    Since you said that you have just heard mentioned about HRO, and to better understand what an HRO is, I would start with one of the original written material about HRO, which is the book : Managing the Unexpected: Sustained Performance in a Complex World by Karl E. Weick and Kathleen M. Sutcliffe. The book is in its 3rd edition published in 2015, while the first one was published in 2001. You can find this book in Amazon and for sure in other stores.
    The article in Wikipedia give the origins of HRO studies and it's worthy reading. It also includes several references: https://en.wikipedia.org/wiki/High_reliability_organization#:~:text=HRO%20theory%20flowed%20out%20of,hazardous%20systems%20operated%20error%20free.


    Like many other acronyms in the industry, since since the term "HRO" was first coined, many people have given their own meaning and created variations - usually with some commercial interest behind - and that's the reason I prefer to go to to the original references

    Regards,


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    Luiz Ventura CRE, CRL
    Senior Reliability Manager
    The Dow Chemical Company
    ------------------------------