THE 10 STEP METHOD FOR BECOMING A

RELIABILITY LEADER
by Ricky Smith and Brian Pertuit

August 29, 2017

 Preface
This book was designed to provide SMART (1) (Specific, Measurable, Achievable, Relevant and
Time-based) steps with succinct guidance to industry practitioners seeking to become
Reliability Leaders. Being a true “Reliability Leader” is far more than simply studying for and
passing an exam, or gaining a title someone has granted you on a certificate or in a job
description. It’s a peer to peer respect level that must be earned through a body of work that
hard working people are striving to achieve through their concerted efforts around the globe.
We are learning from each other, every day and on every job. Benchmarking and sharing best
practices in safety, environmental awareness and reliability has never been practiced at the
levels we are now experiencing throughout a broad spectrum of industries. It’s through our
desire for continuous improvement in asset and work management that we achieve stellar
uptime performance while becoming more efficient and less wasteful. The added benefits of
reducing injuries, our carbon footprint and repair expenses while leaving our environment
better than we found it is at the heart of it all, unbeknownst to many. It is therefore a fertile
time for Reliability Leaders to strive for Operational Excellence in everything they do within
the span of their control and beyond. Those of us who have come to understand this also have
a responsibility to mentor the younger talent within reach, and help mold our future
Reliability Leaders.

Ricky Smith and Brian Pertuit both served the United States of America in the U.S. Army
throughout varying Battalion Maintenance Operations (BMO) assignments while on active
duty. They’ve both learned asset and work management principals at an early age utilizing a
Preventive Maintenance Checks & Services (PMCS) system approach, once considered “best
practices” in both military and industrial applications. Today, our industry would consider
Reliability Centered Maintenance (RCM) in the same regard. Having lived through, learned,
practiced and taught the evolving asset and work management best practices since then, they
were poised to co-author and release this book in the Reliabilityweb.com “Keeping it Simple”
series as a guide for others who may desire to become true, process driven Reliability Leaders.

(1) From Wikipedia, the free encyclopedia:

SMART is a mnemonic acronym, giving criteria to guide in the setting of objectives, for example in project management, employee-
performance management and personal development. The letters S and M usually mean specific and measurable. The other letters have
meant different things to different authors, as described below. Additional letters have been added by some authors.

SMART criteria are commonly attributed to Peter Drucker's management by objectives concept.[1] The first-known use of the term occurs in
the November 1981 issue of Management Review by George T. Doran.[2] The principal advantage of SMART objectives is that they are easier
to understand and to know when they have been done.
 About the Authors
Ricky Smith, CMRP, CPMM, CRL is a well known expert in Maintenance and Reliability Leadership
as a writer, speaker, and trainer. He’s trained hundreds of Maintenance and Reliability Leaders in the
U.S., Australia, New Zealand, Canada, Belgium, Italy, Saudi Arabia, Oman and many more locations
throughout the globe. He has authored and co-authored many books in Proactive Maintenance and
Reliability Best Practices which have taught millions of readers the fundamentals of Proactive and
Optimized Reliability in over 18 countries around the world; many of whom are considered
Maintenance and Reliability Leaders today including Brian Pertuit, his co-author of this guide to
becoming a Reliability Leader. This book was therefore written from the perspectives of both teacher
and student Reliability Centered Maintenance subject matter experts intended for those seeking to
become reliability leaders.
Other books Ricky has co-authored include: Rules of Thumb for Maintenance and Reliability
Engineers, Root Cause Analysis Made Simple, Lean Maintenance, Planning and Scheduling Made
Simple, Preventive Maintenance Made Simple, Lubrication 101, Metrics/KPI’s 101 and many more.
Ricky is a U.S. Army decorated Iraq War Veteran, having recently served overseas as a Maintenance
Company Commander. Ricky began his maintenance career in 1972 in the U.S. Army as a
Maintenance Professional which established his foundation in Proactive Maintenance at a young age.
Ricky trained new officers in leadership skills for 3 years as a tactical officer at Officer Candidate
School. Ricky has worked as a Maintenance Professional for Exxon Company USA (Maintenance
Technician), Alumax Mt Holly (Maintenance Technician), and Kendall Company (Global Maintenance
Engineer), and other assignments as both an owner representative and a consultant.

Brian Pertuit, CMRP is the Manager of Reliability & Maintenance Planning for the Louisiana
Offshore Oil Port (LOOP LLC). Brian’s Department partners with Operations & Maintenance in
ensuring uptime of highly critical equipment at LOOP and LOCAP including large rotating equipment,
electrical systems, metering equipment and more. LOOP won the Uptime Award for Best Work
Execution Management at the International Maintenance Conference in 2014 based on related
successes after achieving 99.75% uptime on the main oil line equipment and reducing repair
expenses significantly. Brian, along with LOOP’s Vice President of Engineering & Technology, Chris
Labat, CMRP, co-authored a Striving for OpEx in Work Execution Management article in the April /
May 2015 edition of Uptime Magazine. LOOP later won the 2016 Best Green Reliability Award based
on additional environmental and energy efficiency successes which was presented at the
International Maintenance Conference in December 2016. Brian and Chris again published a related
article which was featured in the June / July 2017 Uptime Magazine. LOOP has a great culture with
top industry professionals and technicians focused on continuous improvement. The Supervisor of
Reliability Planning in Brian’s Department is David Martin, CMRP; who also co-authored the
aforementioned Lubrication 101 and Metrics/KPI’s 101 books with Ricky Smith.
Like Ricky, Brian is also a U.S. Army veteran having served stateside and overseas in Battalion
Maintenance Operations (BMO). He started as a soldier and Diesel Mechanic over thirty years ago in
1986, was stationed in Germany and later returned home to Louisiana to attend college while
working as a technician and serving in the U.S. Army’s Ready Reserve. He graduated in 1993 from the
University of New Orleans with a Bachelor of Science degree in Electrical Engineering and received
an Honorable Discharge from the U.S. Army in 1994. After graduation, his career toggled from the oil
field to power and back within the energy industry; both as a consultant and an operator
representative focused on equipment design, QA/QC, reliability, work and asset management.
 Foreword
While we realize anyone in an organization can be a Reliability Leader, and it
takes a team with a shared mindset to make a difference, this book is intended
for those who are seeking guidance in becoming a true, certified Reliability
Leader while gaining peer to peer respect for a body of work above and beyond
their certificate. If this thought motivates you, please read on and enjoy. In
taking on this challenge, you must know that becoming a Reliability Leader
means being willing, ready and able to help move the culture of your
organization to become a pro-active, results oriented business with a clear focus
on reliability centered maintenance, uptime and continuous improvement on
multiple fronts.

To help facilitate a positive cultural shift often means change, and change
must be managed. Management takes leadership, and thus you are called to lead.
By the time you finish reading this book, we hope you’ll gain the confidence to do
just that along with a plan. If you are already a leader, we can only hope that
we’ve given you a new view shed of your leadership responsibilities and some
helpful ideas regarding goal setting for yourself and other leaders in your work
groups for continuous improvement.

The ten steps offered in this book are not sequential, but rather building
blocks to help structure your leadership development. Thus, many of these steps
can be performed in parallel, simultaneously streamlining your path to
reliability leadership.

The Forbes “Quote of the Day” on March 31, 2016 when we began writing
this book was very relevant:

"There is nothing like knowing you have a real opportunity to affect the future in a
positive way.”
by Tisha Johnson Commented [BJP1]: Note to Publishing editor, please instruct
me as to how to obtain approval to use this quote, or if possible
please obtain approval for us. If not, we’ll simply delete it.
 Table of Contents
I. Step 1 – The Motivation, Why become a Reliability Leader?
i. Benefits and Rewards {WIIFM}
ii. Drive, Passion and Strong Work Ethics
II. Step 2 – The Preparation, What will it take?
i. Skill Sets and Credentials
ii. Education and Experience
iii. Certifications
III. Step 3 – The Fundamentals, Blocking and Tackling
i. Funding Initiatives through Justification
ii. Planning the Work
iii. Working the Plan
iv. Managing Metrics / Show the Score Board
IV. Step 4 – Being the Best that you can Be
i. Choose a Path or Multiple Paths
ii. Consultant and/or Trainer
iii. Owner / Operator Representative
V. Step 5 – Work / Life Balance
i. Why is What I do Outside of Work so Important?
ii. A Leader must Allocate Work
iii. The Pitfalls of Micromanaging
iv. Strategic versus Tactical Objectives
VI. Step 6 – Plan/Do/Check/Act for Reliability Leaders
i. Plot the Course {Plan}
ii. Perform the Work {Do}
iii. Lookback on the Body of Work {Check}
iv. Turning Lessons Learned into Corrective Actions {Act}
VII. Step 7 – Being a Leader, not just a Boss
i. Lead by Example / Actions over Words / High Integrity
ii. Teamwork & Collaboration
VIII. Step 8 – Successful Business Relationships
i. Effective Communication Methods, Listening Skills
ii. Conflict Management and Team Alignment
iii. The Importance of Clear Roles & Responsibilities
IX. Step 9 – Continuing Education and Conferences
i. When to Learn What and How Often?
X. Step 10 – A Successful Journey ends with Sharing
i. The Lifecycle of a Reliability Leader
ii. Leave a Legacy
 Table of Contents
{continued}

XI. Appendices
i. Potential for Failure (P-F) Curve
ii. Functional Metrics / KPIs / Score Boards
iii. Recap of Suggested S.M.A.R.T Goals by Step
 CHAPTER I

Step 1 – The Motivation, Why become a Reliability Leader?

 i. Benefits and Rewards {WIIFM}

In today’s world, we tend to focus on “What’s In It For Me?” (or WIIFM).

Often, however, employers view this as a negative attribute as it seems self-
centered. As it pertains to choosing and developing a career path, it is an
appropriate question one must ask. We create our own destiny, and planning is
a vital step that is often missed or not well thought out. Like a ship’s Captain, we
must plot the course before we set sail with a clear direction. This chapter
focuses on the reasons one should consider reliability leadership in their career
path. If you are indeed motivated by the related potential, plot your course
accordingly.

The decision to become a Reliability Leader should only be made, however,

after significant research in the field of Reliability Centered Maintenance is
performed and a candidate is comfortable with the subject matter enough to
make an informed decision. This decision has proven to be a very sound one, and
for many of us has resulted in becoming better employees who are self-
motivated to facilitate continuous improvement through stellar asset and work
management practices along with other leadership initiatives that benefit from a
similar proactive approach.

Some benefits and rewards of becoming a Reliability Leader include;

• becoming a successful leader, proven through metrics and KPIs

(e.g., reduced repair cost, improved uptime, PM schedule
compliance, etc…) thereby adding value to your company
• improving system efficiencies and reducing waste, thereby
increasing related profit margins (there are many of these win-
win opportunities throughout industrial facilities)
• leading your organization on the right path in pertinent
programs such as asset utilization and optimization,
equipment safety, energy efficiency and environmental
stewardship
• researching and adopting the latest technological advances in
condition monitoring and asset health management
• obtaining positive results in assignments from other leaders
and self-implemented programs, adding justification for
employment retention
 • improving your proactive skill sets and credentials making
yourself attractive to employers when seeking employment,
and/or other departments when seeking promotion or transfer
• gaining the respect of your peers and colleagues, not only
within the inner circles at your company, but throughout your
organization and potentially throughout industry
• creating job security, and the foundation for a solid career
• your aspirations and dreams can unleash unlimited
advancement, control your own throttle!

ii. Drive, Passion and Strong Work Ethics

A Reliability Leader must possess these traits to become a true leader. They
will help you succeed in all aspects of life, however, not just with your career.
Throughout your lifetime others will watch and learn your behaviors, regardless
of whether they’re good or bad. A leader creates a pull environment by giving
positive examples, thereby leading others to follow in performing those same
positive behaviors. Becoming a true Reliability Leader will drive you to develop
and cultivate these traits further, thereby improving your individual
performance. Others will in turn follow your lead, improving the overall team
performance. This is what leaders do.

Billy Cox (a famous professional baseball player from 1941-1955) was

quoted as saying “The two things in life you are in total control over are your
attitude and your effort”. Possessing a drive to succeed, being self-motivated to
improve processes, being passionate about your efforts and having a strong
work ethic are all pertinent traits of successful leaders in all aspects of life. This
is especially true in Reliability Leadership, as it’s based on a pro-active approach
to asset health management that is results oriented and has a continuous
improvement component that cannot be ignored or avoided. Status quo is never
acceptable, as today’s success often becomes tomorrow’s stalemate due to
improved technology, changes in operational context and/or aging assets and
systems. We cannot stand aloof while our critical assets run themselves to
failure. Thus, having a strong drive, passion and work ethic is required or you’ll
burn out before you can even make a significant impact.

Transforming lessons learned from failures into corrective actions to prevent

future, repeat failures requires leadership. Thus, a successful reliability program
requires a leader that motivates others to pay attention to detail in failure
reports and PM / PdM enhancements to identify and prevent these common
failure modes on like assets. Needless to say, this type of program will die on the
vine without leadership at every milestone along the journey.

There are leaders in your work groups who are leading by example every day
through their hard work, sense of urgency and attention to detail. Their call to
duty each morning drives them to success. These are the ones who will make the
best Reliability Leaders, bar none, and many currently are; even if they’re not
deemed as such by others. Emulate their work ethics in your work assignments.
Become a high performer, and help to make others better through your own
examples and work practices. Envision yourself as a leader, and stay on course
to lead with a positive example when opportunities arise. Often times, this
means taking the time and energy to be self-taught on many fronts. If there are
reliability centered maintenance topics you’re weak on, buy related books and
read them with focus. Develop a thirst for knowledge, and study the areas you
are not sure about to gain confidence. Always be sure to carry the book learning
to the field or shop application that it’s relative to, so you get a horse sense about
the topic. Implement improvement initiatives as you learn more about them
and/or find such opportunities. Be sure to establish metrics to track related
improvements.

In Step 9 of this book, Continuing Education, we discuss “When to Learn

What and How Often”. Knowing what you don’t know (or figuring that out
through conferences, seminars, webinars, magazines, books, the internet of
things and other media) and focusing your learning on areas that will strengthen
you as a Reliability Leader through proven results in the field is the key to
unlimited potential.

Some leaders may debate the point that the elementary leadership traits of
drive, passion and strong work ethics are attributes that are not coachable. Thus,
from a SMART goal perspective they would argue that you cannot set a timeline
to attain them as one has to somehow be born with them or raised a certain way.
We believe, however, that through hard work and dedication to duty everyone
can do whatever it is they set their mind to do (recall the Billy Cox quote
regarding attitude and effort being within our control).

STEP 1 - S.M.A.R.T GOAL

Set a goal to improve your drive, passion and work ethics towards
becoming a Reliability Leader (as needed in your own assessment) within
six (6) months of reading this book. You’ll be amazed at what clear focus and
self-awareness can do to improve your performance as a developing leader. Put
yourself in a fish bowl within your own mind each work day. Watch how you
interact with others, as well as how timely and efficiently you and your team are
completing work assignments given to you or your group. Continuously strive to
improve as a leader, seek to remove waste from your processes and streamline
work activities to gain efficiency. Become more proactive and less reactive, and
coach others to do the same. Consider developing and tracking related metrics
or Key Performance Indicators (KPIs) to assist you when you find such
opportunities. Become self-taught in reliability centered maintenance topics that
you are anemic in, and attend training when possible to gain both knowledge
and confidence.

Implement what you learn, and teach others. Unleash the Reliability Leader
within you, and lead by example daily. Inspire others to follow in your footsteps,
as that’s what leaders do characteristically.
 CHAPTER II

Step 2 – The Preparation, What will it take?

 i. Skill Sets and Credentials

From a skill sets perspective, we cannot emphasize enough the importance of

understanding the assets you are charged with managing as a Reliability Leader.
Being in person at the factories, in the field and at various repair shops to
experience first-hand the following asset related activities is invaluable:
• asset and system design
• design purchasing specifications
• equipment manufacturing, assembly and testing
• equipment installations and precision alignment
• pre-start up safety reviews (PSSR)
• bench marking, and on-line condition monitoring
• preventive maintenance
• troubleshooting
• root cause failure analysis
• teardown inspections
• failure reporting
• turning lessons learned into corrective actions

These crucial activities help build the foundation of your ultimate success as
a Reliability Leader. If you have not had opportunities to perform any or all of
these asset related work activities, we recommend you start to participate and
learn the intricacies involved when possible and within your work schedule.

One key to being a good reliability leader is understanding failure patterns.

There are various failure patterns as depicted in this chart by John Moubray. Commented [BJP2]: Note to editor; please obtain related
approval of use accordingly…

Commented [BJP3]: …approval of the use of this chart of

failure patterns that is, as recommended by Ricky Smith
 As you get involved and familiar with the recommended asset related work
activities, you’ll come to understand these failure patterns at a detailed level.

If you are currently seeking employment and considering the Reliability field
for the first time, search for job listings that have these roles and responsibilities
as they will most certainly set you up to succeed as a Reliability Leader down the
road. Whether you’re seeking a new related position, or working now in the
Reliability / Maintenance realm, look for leaders who possess these skill sets
within your circle and ask them to mentor you.

While some in industry today believe that back in the “old days”, operations
ran equipment until it broke then maintenance fixed it (so there is limited pro-
active knowledge you can learn from the old timers in their minds), this couldn’t
be further from the truth. Only with the help and insights of the experienced
field personnel have we improved our pro-active approach to asset health
management by predicting and preventing failures. You basically have to know
how equipment breaks before you can fix it properly. You also have to know how
it works to understand how it breaks. The au jus is figuring out how to prevent it
from failing in the first place. That’s euphoria for reliability leaders.

There is a plethora of knowledge in the minds of hard working Maintenance

Technicians, Supervisors and Field Operators that we’ll lose when the baby
boomers retire if they don’t take younger workers under their wing and teach
them these common sense aspects to maintenance and repair. In essence, you
should study how the various assets (especially critical assets) in your facility
work, then strive to gain a better understanding of how these same assets fail.
Don’t stop learning until you, or a team of you, succeed in preventing repeat
failures on all like assets.

There is also the engineering aspect of how equipment is specified and

designed to operate within its operating context. Some have named this concept
as designing for reliability. There’s another important aspect in designing for
maintainability; when possible installing stairs and landings with hand rails in
lieu of caged ladders, for example. Studying design drawings, operations and
maintenance (O&M) manuals and possibly your companies maintenance manual,
as well as spending time with both field and design staff are all opportunities to
gain knowledge and understanding of the equipment within your span of
control. Use common sense, and never underestimate the knowledge of others
and their ability to add value to your understanding of asset reliability.
 Once you’ve gained a good understanding of how your equipment is
designed, how it works and how it fails, the next challenge is to verify that
related Preventive Maintenance (PMs) procedures are in place to address these
failure modes for all like assets. This historically has been the key to success in
asset health management from a “preventive” measure stand point.

Things like proper lubrication using ultrasonic greasing and improving oil
quality (notice I didn’t say oil changes, as filtering techniques have come a long
way in using oil for longer run time intervals by improving its quality – check into
oil condition monitoring and quality improvement programs using modern filter
carts), standard PM intervals recommended by the O&Ms, cleaning contacts and
other such activities are all routine preventive maintenance measures designed
to prevent failures. Audit your PMs to verify they’re not simply repeating
intrusive maintenance tasks that do not prevent failures. Eliminate the waste,
and lean out the process for your Preventive Maintenance Program. Learn how
to properly maintain the equipment in your facilities to prevent failure.

Today’s best practices take asset health management a step further with the
onset of condition based monitoring and predictive maintenance procedures
(PdMs). Refer to the asset life cycle and Potential for Failure (P-F) curve in
Appendix i. We now understand that assets can fail while in service by not
performing as designed within their operating context prior to reaching full
functional failure. Performance testing (e.g., flow rate for a pump, timing test for
a breaker) and condition based monitoring techniques (e.g., vibration analysis,
oil analysis, thermography, ultrasound, etc…) help to identify early signs of
failure. This allows operators to act by preventing failure before it occurs.

Thus, gaining credentials in predictive analysis is essential to becoming a

true Reliability Leader. Keeping up with on line condition monitoring
technology, leading programs to improve asset uptime and prevent failures are
success stories that many leaders in our industry share in common.

Applying related lessons learned to address like assets in all systems, and/or
facilities, within your span of control is where you really hit pay dirt. Reference
one of Ricky Smith’s (co-author) books which was written with Bill Keeter titled
FRACAS (Failure Reporting, Analysis and Corrective Action System) for tricks to
the trade. Understanding and implementing this system is a key credential you’ll
need to possess as a true Reliability Leader in today’s ever-changing world of
asset health management.
 STEP 2 - S.M.A.R.T GOAL 1

Set a goal to gain some or all (as needed in your own assessment) of
these recommended equipment reliability fundamental skill sets and
credentials along with a good understanding of how your equipment works
and fails within two (2) years of reading this book.

Participate and lead factory, field and shop asset health management
activities as often as possible to gain understanding of how the assets in your
span of control are manufactured, function or work, break, are repaired and
installed properly. Seek to improve purchasing, design and repair specifications,
soft goods and/or metallurgy specifications, preventive maintenance and
predictive applications. Apply FRACAS when appropriate ,and gain a sound
foundation for becoming a true Reliability Leader.

ii. Education and Experience

The benefit of advanced, secondary education (e.g., from colleges and/or

technical institutions, etc…) versus on the job experience or training (OJT) is
often debated. A great answer to the question “Do you get more out of advanced
education or OJT?” is YES! The confused look that results is the opportunity
before you to explain yourself, as they’re both great learning opportunities for
different reasons. Both secondary education and work experience contribute
greatly to the knowledge base for Reliability Leaders, in general.

Some employers actually equate four or five years of OJT to a year of college,
so an employee with say twenty years of relevant experience in mechanical
equipment may be considered for a mechanical engineering position though
they don’t possess an engineering degree. Other employers are more careful
with the word “Engineer” in a job title for liability concerns, but may consider
years of experience when filling Specialist and Technician positions.

The U.S. Army has a rank titled Warrant Officer, given to soldiers who’ve
earned the rank through years of OJT as enlisted personnel and who have
become technical experts, promoted through the enlisted ranks and served with
dedication to duty and exemplary service but may have never been to college.
They’re hand selected because of their technical expertise, and are invited to
attend Warrant Officer Candidate School (WOCS). All other “Officers” in the U.S.
Army have graduated college and successfully completed Officer Candidate
School (OCS). This shows how important OJT is for the U.S. Federal Government,
as they’re willing to promote candidates as Officers without a college degree due
to their technical expertise, having become a subject matter expert (SME) of
sorts in their field and proving themselves as very valuable to the organization.

As you may have caught in the tongue and cheek answer to the related
question earlier, we believe that both education and experience are needed for
true Reliability Leaders to be successful. Technical institutions teach a wide
variety of skills that directly relate to asset health management. There are also
fully accredited colleges today, such as the University of Tennessee (UT) and
others, who offer elaborate Reliability Curriculums that many of us didn’t have
the privilege of attending, but wish we did. We believe, therefore, that this type
of curriculum and degree would be a great foundation for Reliability Leader
candidates to consider, though a 2 year technical degree in the field of choice is
not a bad decision either. Engineering curriculums help as well, in particular the
Mechanical Engineering, Electrical Engineering, Petroleum Engineering (for oil
field or petroleum product careers) and Industrial Engineering disciplines. Just as
with Leadership Certificates, however, degrees of any type are pieces of paper
representing your ability to learn. Applying relative knowledge in field
applications, learning from the OJT you gain before, during and after secondary
education is where leaders are born.

Brian Pertuit (co-author), once worked with a Human Resources

representative to change a credential requirement in job opening descriptions
for Reliability Specialist in his Department to state that a college degree in
Engineering was “preferred but not mandatory” where it once was a
requirement. This opened the door for recruiting, interviewing and considering
existing employees and external candidates who had significant OJT and could
add value to the group, but did not possess an Engineering degree.

The skill sets and credentials described in Section i. of this Chapter are
mostly OJT obtained, though these concepts and methodologies are also taught
at modern Universities such as UT, both as a degreed curriculum and in short
term training courses and boot camps. There are many training seminars and
conferences throughout the world that help educate and cultivate Reliability
Leaders. We suggest you attend as many as possible within your work schedule.
 The key to success in training, education and experience is to understand
that we never stop learning. We learn every day, and on every job or assignment.
We learn from our successes and our failures alike. Never assume you know it
all, as none of us do. Be thirsty for knowledge, and hungry for experience. The
bottom line, is to prepare yourself to add value in all you do.

STEP 2 - S.M.A.R.T GOAL 2

Set a goal to obtain both educational knowledge and on the job training
(as needed in your own assessment) within four (4) years of reading this
book. Seek to learn something relative to becoming a Reliability Leader
every working day.

It’s important to note that all learning is relevant, and furthermore that you
“get out” what you “put in” regarding your education. Whether it’s class room
learning or field / shop experiences for those of you currently in the work force,
you must be engaged and in the moment at every step of the way to expect to
take away something value added from each session. Therefore, treat every
situation throughout your career as if it’s your last opportunity to get something
out of it thereby adding to your arsenal of relevant skillsets and credentials.

If given the opportunity, shadow Maintenance and Operations in the field and
learn from existing leaders within your organization. Remember the quote about
your attitude and effort; remain positive, motivated and pro-active.

iii. Certifications

As described in the Preface, the intention of this book is to teach Reliability

Leader candidates what it takes above and beyond a certification, a degree a
passing grade on an exam or two to be a successful leader. However, there are
various certifications within reach of many candidates that they should consider
to help validate their skill sets, credentials, education and experience among
their peers, employers and/or potential employers. Often, while studying for
these exams, candidates learn invaluable information about reliability
leadership they may not have been exposed to prior to embarking into
preparation. As stated previously, you should strive to take something valuable
away from every educational experience, and preparing for an exam most
certainly applies.
 We’ve listed several related certifications in alphabetical order (so they’re not
listed nor weighted by any priority or significance), for reliability leadership
candidates to consider pursuing.

• CMRP – Certified Maintenance & Reliability Professional

• CMRT – Certified Maintenance & Reliability Technician
• CRE – Certified Reliability Engineer
• CRL – Certified Reliability Leader

The internet is a great source of information for these certifications; how to

pursue them, resource materials, related venues and workshops to prepare for
and take the related exams. Here are a few related websites for your
convenience. We apologize for any we’ve left out of this listing, and encourage
the reader to research all of the latest websites via your normal search engines.

CMRP – by SMRP (the Society for Maintenance & Reliability Professionals)

http://smrp.org/Certification

CMRT – by SMRP (the Society for Maintenance & Reliability Professionals)

http://smrp.org/Certification

CRE – by ASQ (the American Society for Quality)

https://asq.org/cert/reliability-engineer

CRL – by AMP (the Association of Asset Management Professionals)

http://www.maintenance.org/pages/crl

CRL – workshops by Reliabilityweb.com

https://reliabilityweb.com/events

STEP 2 - S.M.A.R.T GOAL 3

Set a goal to make a decision to obtain at least one Certification listed

above (as needed in your own assessment) within one (1) year of reading
this book. Seek to learn something relative to becoming a Reliability
Leader while preparing for the related exam(s). These exams are often
offered after or during an asset management related conference. Thus,
seek to gain industry knowledge in asset management while you prepare.
 Always remember that how you are perceived as a Reliability Leader has way
more weight in industry than the piece of paper that you may earn to validate
your knowledge, or your ability to learn. The integrity you display in your
business interactions, your efforts to add value to asset uptime and repair cost
reduction and how you lead (and treat) others will always be weighted more-so
than all other accomplishments including your certifications. Through it all, you
must remain trustworthy, first and foremost.
 CHAPTER III

Step 3 – The Fundamentals, Blocking and Tackling

 i. Funding Initiatives through Justification

Gaining the necessary funding for asset health management and your
reliability centered maintenance initiatives is truly the key required to unlock
doors that may be restricting your organization from uptime improvement and
repair cost reduction. Running critical assets to failure, then spending repair
expenses after the failures occur to restore the equipment back to service is
obviously not the best way to fund necessary repairs as many maintenance
personnel and accountants would agree with. So we should strive to identify
which are our critical assets then address pending failures early, and prevent
them from occurring. Parts of the equation include criticality ranking sessions,
obtaining critical spares, and an overall asset strategy. Regarding the use of
critical spares, we often have to perform a “swap and shop” to refurbish a failing
but in service asset and return it as the new critical spare while minimizing
downtime. All of this takes planning and budgeting for the necessary funds.
Criticality ranking is also a key component of any good critical sparing program.
Work with other cross-functional stakeholders at your facilities to determine
what assets are truly critical, and spare up accordingly.

Often maintenance personnel in a reactive organization will ask, “…how do

we gain the necessary funding to move forward and properly monitor and manage
our assets?”. The trick is to simply listen to what the assets are telling you using
predictive tools. Study trending in mean time between failure (MTBF), vibration
analysis, oil analysis, thermography, ultrasound, performance tests and related
PdMs. Please refer to Ricky Smith and David Martin’s book entitled
“Metrics/KPI’s 101” also offered in the Keeping it Simple Series of
Reliabilityweb.com books. The bottom line is to justify your asset improvement
needs based on the trends you’re seeing in asset condition. Sometimes, the
accountants want you to provide rate of return calculations to further justify
your asset condition improvements. You can find IT tools on the internet to help
by searching the web for acronyms like IRR, and/or ROI to accomplish this if and
when necessary for those who’ve never had to perform this type of calculation.
Asset failures that occur randomly inevitably cause unexpected production
downtime, unplanned repair costs and reputational impacts. Some cost may be
hard to measure, but should be discussed or presented in the case for
improvement funding.

Focus on the big picture, and elevate yourself to 50,000 feet above your
facilities for a bit. From a philosophical point of view, we further recommend
taking your asset health management funding initiative to both a short term
prioritization and a long term view shed to help with your organization’s cash
flow projections. In order to do this, we suggest that you initiate an Asset
Management Plan (AMP) with some fixed duration (e.g., 3, 5, 7 or 10 years) if
your company doesn’t already have a similar program in place. Your AMP should
have a risk assessment and mitigation component as well. Justify your asset
spending needs by stating “we are asking for X dollars to mitigate a risk that may
cost us Y dollars if we run this asset to failure, or we are mitigating the risk of an
environmental spill and/or downtime to this magnitude”, etc… Be sure to factor in
lead time for replacement equipment in your downtime projections, assuming
you have no related critical spare. It may be the critical spare that becomes your
back up plan if funding is not approved initially.

STEP 3 - S.M.A.R.T GOAL 1

Set a goal to create and deliver an Asset Management Plan within your
companies budgeting process timeline, with both time and risk
components included (as needed in your own assessment) within two years
(2) years of reading this book. Remember to utilize KPIs and Metrics as
well as Risk Assessments and Mitigation as supporting documentation for
funding approval requests.

ii. Planning the Work

“Give me six hours to chop down a tree and I’ll spend the first four sharpening
my axe”.
by Abraham Lincoln

It’s an understatement to merely state that you should plan your work when
it comes to reliability centered maintenance. Doc Palmer’s Maintenance Planning
& Scheduling book is a very helpful guideline to today’s related best practices. Commented [BJP4]: Please obtain approval to use this
reference
The efficiency gained through proper planning helps with the quality of the work
performed, the time spent performing the work, the repeatability of the work
tasks among various workers and the reduction of the necessary downtime of
both the assets being maintained and the interconnecting systems that may be
impacted.

Once the necessary work has been funded, a work order process should be
followed to initiate all planned work activities. We won’t elaborate on
Computerized Maintenance Management Systems (CMMS), as there are many
books that teach related best practices and many software products to choose
from. The point here is that obtaining funding and opening a Project or Work
Order prior to commencing work are some early steps in the planning process.

Creating a Work Plan prior to scheduling asset related work is often

performed by Maintenance Planners and Schedulers or Maintenance
Supervisors. Reliability Engineers and Specialist often review the related Work
Plans, or draft them if the work being performed is within their area of expertise.
Work Plans can be drafted in a document format, or stored in the CMMS system
as PMs and/or PdMs.

PMs should be written in clear, step by step format providing maintenance

technicians or specialists with all of the asset related materials and equipment
they’ll need for their planned work. This is an iterative process, however, and
taking a printed copy of the PM procedures to the field with a red pen for mark
ups is recommended. Carrying these redlines back and having the revisions
vetted by supervision then documenting comments regarding the work
performed in the Work Order closing process are keys to success in asset health
management, an industry wide best practice.

Planning work leads to scheduling work, and proper scheduling requires a

good time estimate in man-hours to perform the related work plan. Factors
considered in the schedule and duration of the work to be performed include the
lock out / tag out and reverse lock out tag out time, in the event of pressurized
systems there are drain downs and filling and venting to consider, the actual
wrench time to perform the work (including simultaneous operations) , the
volume of workers on hand at the necessary skill levels per discipline, travel to
and from the warehouse or store room (if applicable) for parts and pre-job
safety meetings as well as meals and breaks.

Preparatory work, including pre-outage work, should be maximized to

minimize the downtime necessary to perform the work at hand. This should
include, but may not be limited to, getting all necessary parts, tools and
equipment to the job site prior to taking downtime, a work plan review with all
company employees and contractors and a pre-job safety kick off meeting. On
the day of the work, a JSA (Jobsite Safety Analysis) or JSEA (Jobsite Safety &
Environmental Analysis) should also be performed at which time the job hazards
are identified along with mitigative measures to prevent incidents. If a repetitive,
planned job continuously running longer or shorter than scheduled, a red line of
the required man-hours should be considered.

While most PMs and repair work plans involve equipment downtime,
predictive PdM routes are typically performed while the assets are on line and
running. Vibration routes, thermography, ultrasound and more are planned
activities similar to PMs but aren’t intrusive to the assets and don’t require
downtime. The plans should focus more on the “routes” for capturing the most
data you can obtain in a work day, at a work facility or in a process unit, given
the predictive tools and quantity of reliability technicians available. On-line
condition monitoring doesn’t typically require work plans, but installation of
related instruments do justify some level of a plan. If the data trends towards
failure, a planned downtime should be scheduled for troubleshooting though
some level of troubleshooting must be done while the asset is on-line. Work with
field experts to learn these matters and best practices at a detail level, and
prepare yourself to lead as soon as practical.

For Reliability Leaders, the most important thing for planned PMs and PdMs
aside from the safety of the personnel is that the equipment failure modes are
being addressed and prevented during the related work that is being performed.
If not, the redlining process should apply and possibly follow up Work Orders
when necessary, addressing relative failure modes.

STEP 3 - S.M.A.R.T GOAL 2

Set a goal to create or improve your work plan process (as needed in
your own assessment) within one year (1) of reading this book. Involve
stakeholders including supervision, maintenance technicians, reliability
technicians and operations in the planning process. Perform an audit of
your existing PMs and PdMs annually thereafter.

iii. Working the Plan

More often than not, contractors or internal maintenance crews are actually
working the plan as far as field work regarding asset health improvements. The
Reliability Leaders are often the job facilitators who verify the work is being
performed as planned.
 Let’s revisit the phases of asset related work as described earlier in the Skills
and Credentials section, and summarize what the Reliability Leader should
actually be responsible for overseeing at each segment of the asset life cycle.
Through it all, good communications with all stakeholders is the key. Operations
and maintenance leaders must know that the Reliability Leader is trustworthy,
and will take care of all matters within his/her span of control.

• asset and system design – the Reliability Leader must verify that assets
and systems are designed for reliable service; check drawings,
calculations, specifications and field conditions for accuracy and
maintainability

• design purchasing specifications– the Reliability Leader must verify

that assets are specified with good quality metallurgy and soft goods,
sized to meet the design capacity in the proper operating context, and
sometimes dictate the proper rigging during transit to prevent damage

• equipment manufacturing, assembly and testing– the Reliability

Leader must verify that source QA/QC has visited the factory during
critical manufacturing, assembly and testing milestone milestones to
ensure the quality and performance of the equipment prior to delivery
(he/she may self-perform this task, delegate or outsource as needed)

• equipment installations and precision alignment– the Reliability

Leader must verify that the Work Plan addresses precision alignment of
rotating equipment (when applicable), and furthermore that during
installation the field QA/QC inspector is present and the proper tools
(laser alignment or the specified technology) are being utilized

• pre-start up safety reviews (PSSR) – the Reliability Leader (or Project

Manager if a major project) must verify that all pertinent operations
and maintenance stakeholders participate in a PSSR meeting prior to
commissioning assets to ensure safe and reliable service

• bench marking, and on-line condition monitoring– the Reliability

Leader must verify that start up condition monitoring is performed for
bench marking vibration, temperature, full load current, ultrasound
(when applicable) which helps tremendously in future trending
 • preventive maintenance – the Reliability Leader must verify that
proper PMs are in place to maintain the equipment prior to start up

• troubleshooting – the Reliability Leader must verify that assets are

delivered with necessary Operations & Maintenance (O&M) Manuals to
support troubleshooting of failure modes, and should either self-perform
or verify a competent subject matter expert (SME) is resourced to
troubleshoot failure modes

• root cause failure analysis– the Reliability Leader must self-perform or

verify that all asset failures undergo a root cause failure analysis
identifying the cause of failure which should be saved in the equipment
files for future reference

• teardown inspections – the Reliability Leader must verify that SMEs are
present at repair shops during teardown inspections, or in the field
when conditions allow for such work to take place

• failure reporting – the Reliability Leader must verify that all asset
failures are followed by a detailed failure analysis identifying failure
modes along with lessons learned and corrective actions

• turning lessons learned into corrective actions – the Reliability Leader

must verify that all lessons learned from asset failures are properly
communicated, and that corrective actions are applied for all like assets
(FRACAS)

STEP 3 - S.M.A.R.T GOAL 3

Set a goal to improve your efforts to work the plan throughout all
phases of asset related work (as needed in your own assessment) within
two (2) yearS of reading this book. For this goal, you do not need to self-
perform every aspect of the asset related work activities, but verify that
SMEs are in place to do so at each step along the journey. If you are aspiring
to be a Reliability Leader, simply learn from others charged with this
responsibility in preparation for the day you are called to serve in this way.
 iv. Managing Metrics / Show the Score Board

Metrics are truly the topic of an entire book, or volumes of books, for
industry Reliability Leaders. Reference one of the books Ricky Smith co-
authored with David Martin (co-worker at LOOP with Brian Pertuit),
Metrics/KPI’s 101 for relevance and further insight.

This saying has been stated many different ways and may be over a bit over-
used, but is very pertinent here; we must measure things we intend to manage,
and likewise we must manage what we measure or simply stop measuring the
things we don’t intend to manage. When we say things, we are referring to Mean
Time Between Failure (MTBF), Mean Time to Repair (MTTR), Schedule
Compliance, Asset Health Condition (Equipment Uptime), Maintenance Repair
Cost, etc…

While Reliability Leaders may use many metrics captured throughout

his/her facilities, two of the most important metrics in their direct span of
control are the Asset Health Condition (Equipment Uptime) and Repair Cost
associated with the assets he/she is charged with overseeing. Every Reliability
Leader should strive to improve equipment uptime, and reduce repair cost.

By showing the score board, we are recommending that Reliability Leaders

manage and share metrics associated with asset uptime and repair cost
throughout the organization. If the numbers are trending negatively, he/she
must work with stakeholders in engineering, operations and maintenance to
improve uptime and reduce repair cost. If the numbers are trending positively,
attempt to learn from the successes that are taking place and share those success
stories throughout the organization to improve enterprise wide using similar
programs and tactics.

In Appendix ii., refer to the various types of functional metrics, KPI’s and
Score Boards (or Dashboards) recommended for Reliability Leaders to consider.

STEP 3 - S.M.A.R.T GOAL 4

Set a goal to create, audit and improve asset related metrics (as needed
in your own assessment) within six (6) months of reading this book. Involve
stakeholders including supervision, maintenance technicians, reliability
technicians and operations in the audit and improvement process.
 CHAPTER IV

Step 4 – Being the Best that you can Be

i. Choose a Path or Multiple Paths
ii. Consultant and/or Trainer
iii. Owner / Operator Representative
 CHAPTER V

Step 5 – Work / Life Balance

i. Why is What I do Outside of Work so Important?
ii. A Leader must Allocate Work
iii. The Pitfalls of Micromanaging
iv. Strategic versus Tactical Objectives
 CHAPTER VI

Step 6 – Plan/Do/Check/Act for Reliability Leaders

 i. Plot the Course {Plan}

Setting a vision and strategy, as with many endeavors in life, is the key to
becoming a successful leader. The strategy, however, can die like fruit left too
long on the vine if it does not lead to relevant tactical objectives and goals.
Reliabilityweb.com Reliability Leadership travel guide states that “Reliability
Leadership involves managing value delivery and the functional assurance of
assets while minimizing the effects of risk and failure”. Let this be your vision, and
set your strategies and tactical objectives in support of this end goal.
ii. Perform the Work {Do}
iii. Lookback on the Body of Work {Check}
iv. Turning Lessons Learned into Corrective Actions {Act}
 CHAPTER VII

Step 7 – Being a Leader, not just a Boss

 i. Lead by Example / Actions over Words / High Integrity

In Chapter I, Section ii., we foreshadowed the importance for a Reliability

Leader to lead by example characteristically, which is certainly de facto mandate
for leaders of all kinds. This section will focus a bit more on some ways in which
we can and should do just that.

The old adage of “do what I say, not what I do” for parents trying to guide
their children otherwise though they’ve watched them drink too much alcohol,
smoke tobacco products or heard them curse too often comes to mind. Statistics
show that these children in turn often become alcoholics, chain smokers or tend
to abuse foul language. Another relevant saying is that “the apple doesn’t fall far
from the tree”, which is very true when we consider the impacts of leading by
example (good or bad). The point we’re making is how we interact with our
executive management team, direct reports, peers, colleagues, customers,
vendors and contractors will most likely be emulated by our direct reports.
Saying and doing the right thing isn’t always easy, but if we strive to be as
consistent as we can in doing so others will follow our actions.

Avoid giving “lip service” to others by saying what they want to hear when
you’re not sincere. If we “say all the right things” when in meetings, then go
behind the walls of the conference room and downgrade those we were just kind
to in front of our direct reports, we can expect that they will in turn do the same
thing. If we feud with leaders of other Departments in the office, we can expect
that those we’re charged with leading will in turn butt heads with those same
Departments in the field.

Reliability Leaders, on the contrary, should strive to treat all personnel in all
venues with respect and professionalism. Lead by example in a positive way,
always. We must partner with Maintenance, our vendors and contractors to
meet the needs of our internal customers in Operations. We should be open
minded to the ideas of others, respect their opinions and not downgrade them to
others. It’s okay to debate topics when it comes to equipment reliability, but
we’re encouraging you to do so respectfully and professionally.

A Reliability Leader must also have High Integrity as a strong, unwavering

trait. We must tell the truth, regardless of the outcome. Being the bearer of bad
news is not always the popular thing to do especially with highly critical
equipment health matters, so we often strive to offer both a problem and a
solution whenever possible. If we shoot straight on all fronts, our peers,
colleagues, partners, direct reports and customers will all know exactly where
we stand. Full disclosure goes a long way to a leader’s proven integrity.

ii. Teamwork & Collaboration

Reliability Leaders must create a fertile environment for teamwork and

collaboration within their group and throughout their organizations across
Departmental lines. This is especially true as it pertains to continuous
improvement. Often, that means looking at our equipment performance closely,
or even at our own group’s performance, finding existing problems that must be
addressed then leading a team effort to address those problems after
communicating the plan to all stakeholders.
 CHAPTER VIII

Step 8 – Successful Business Relationships

 i. Effective Communication Methods, Listening Skills

There is an old adage reminding us that “God gave us two ears and only one
mouth for a reason”. The relevant point for becoming a strong Reliability Leader
is in order to be effective at communicating with your peers, direct reports,
partners and Executives, you must be able to listen.

Speaking succinctly is another trait that is often under rated.

ii. Conflict Management and Team Alignment
iii. The Importance of Clear Roles & Responsibilities
 CHAPTER IX

Step 9 – Continuing Education and Conferences

i. When to Learn What and How Often?
 CHAPTER X

Step 10 – A Successful Journey ends with Sharing

i. The Lifecycle of a Reliability Leader
ii. Leave a Legacy
Appendices
 i. Potential for Failure (P-F) Curve

In this graph, we see that involvement of reliability leadership begins during

initial asset design, indicated by the D for R (Design for Reliability), and D for M
(Design for Maintenance). This includes overseeing specifications to meet both
standard design and operational context, related purchase order documents,
metallurgy, oil type and soft good selections when applicable, manufacturing or
source QA/QC inspections and of course factory acceptance or witness testing.
Reliability Leaders should remain involved throughout the life cycle of the asset
as well, from how to properly secure the asset during delivery to offloading to
initial installation where precision alignment is so important throughout the PM
and PdM cycles.

The key is to know when the asset will fail functionally, and pull it before it
fails – often swapping it for a critical spare while the asset is refurbished in the
shop (assuming its repairable), thereby resetting the clock to time zero on the
asset life cycle and returning it as critical spare in climate controlled storage
when possible. This methodology, known in some circles as a “swap and shop”
program, not only wins the battle but helps true Reliability Leaders win the war
of asset health management by reducing downtime for repair and increasing
uptime and theoretical capacity.
ii. Functional Metrics / KPIs / Score Boards
 iii. Recap of Suggested S.M.A.R.T Goals by Step

STEP 1 – The Motivation, Why become a Reliability Leader?

STEP 1 - S.M.A.R.T GOAL

Set a goal to improve your drive, passion and work ethics towards becoming a
Reliability Leader (as needed in your own assessment) within six (6) months from the
time you started reading this book.

STEP 2 – The Preparation, What will it take?

STEP 2 - S.M.A.R.T GOAL 1

Set a goal to gain some or all (as needed in your own assessment) of the
recommended equipment reliability fundamental skill sets and credentials along
with a good understanding of how your equipment works and fails within two (2)
years of reading this book.

STEP 2 - S.M.A.R.T GOAL 2

Set a goal to obtain both educational knowledge and on the job training (as needed
in your own assessment) within four (4) years of reading this book. Seek to learn
something relative to becoming a Reliability Leader every working day.

STEP 2 - S.M.A.R.T GOAL 3

Set a goal to make a decision to obtain at least one Certification listed (as needed in
your own assessment) within one (1) year of reading this book. Seek to learn
something relative to becoming a Reliability Leader while preparing for the related
exam(s). These exams are often offered after or during an asset management related
conference. Thus, seek to gain industry knowledge in asset management while you
prepare.

STEP 3 – The Fundamentals, Blocking and Tackling

STEP 3 - S.M.A.R.T GOAL 1

Set a goal to create and deliver an Asset Management Plan within your companies
budgeting process timeline with some time component to your budgeting program
(as needed in your own assessment) within one (1) year of reading this book.
Remember to utilize KPIs and Metrics as well as a Risk Assessment as supporting
documentation for funding inquiries.

STEP 3 - S.M.A.R.T GOAL 2

Set a goal to create or improve your work plan process (as needed in your own
assessment) within one (1) year of reading this book. Involve stakeholders including
supervision, maintenance technicians, reliability technicians and operations in the
planning process. Perform an audit of your existing PMs and PdMs annually
thereafter.

STEP 3 - S.M.A.R.T GOAL 3

Set a goal to improve your efforts to work the plan throughout all phases of asset
related work (as needed in your own assessment) within two (2) years of reading
this book. For this goal, you do not need to self-perform every aspect of the asset
related work activities, but verify that SMEs are in place to do so at each step along
the journey. If you are aspiring to be a Reliability Leader, simply learn from others
charged with this responsibility in preparation for the day you are called to serve in
this way.

STEP 3 - S.M.A.R.T GOAL 4

Set a goal to create, audit and improve asset related metrics (as needed in your own
assessment) within six (6) months of reading this book. Involve stakeholders
including supervision, maintenance technicians, reliability technicians and
operations in the audit and improvement process.