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.
Original Message:
Sent: 8/18/2022 9:49:00 AM
From: Henry Kocevar
Subject: RE: HRO'?
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.
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Hank Kocevar,CMRP
Consultant
Guardian Technical Services
hkocevar@guardiantech.org
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Original Message:
Sent: 08-17-2022 12:03 PM
From: Richard Lamb
Subject: HRO'?
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?
Original Message:
Sent: 8/16/2022 5:56:00 PM
From: Henry Kocevar
Subject: RE: HRO'?
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.
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Hank Kocevar,CMRP
Consultant
Guardian Technical Services
hkocevar@guardiantech.org
Original Message:
Sent: 08-16-2022 01:24 PM
From: Richard Lamb
Subject: HRO'?
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.
Original Message:
Sent: 8/16/2022 10:28:00 AM
From: Henry Kocevar
Subject: RE: HRO'?
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.
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Hank Kocevar,CMRP
Consultant
Guardian Technical Services
hkocevar@guardiantech.org
Original Message:
Sent: 08-16-2022 07:25 AM
From: Derek Brown
Subject: HRO'?
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
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Derek Brown
Grangemouth
Original Message:
Sent: 08-10-2022 10:04 AM
From: Richard Lamb
Subject: HRO'?
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
Original Message:
Sent: 8/9/2022 9:01:00 PM
From: Karl Burnett
Subject: RE: HRO'?
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/
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Karl Burnett
General Electric
Anderson SC
Original Message:
Sent: 08-08-2022 03:22 PM
From: Derek Brown
Subject: HRO'?
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?
CheersDerek
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Derek Brown
Grangemouth
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