Professional Documents
Culture Documents
Fitch
International Council for Machinery Lubrication (ICML)
Noria Corporation
Introducing ICML 55
By now most people in maintenance and reliability have heard about ISO 55000 and asset
management. When I first heard about ISO 55000 I was apathetic, cautious and very much
unconvinced. But I kept thinking about it. I thought about the fact that there was a missing
element in what I’ve been doing the past 40 years, i.e., teaching people about methods,
tools, philosophies of lubrication and maintenance.
The missing element was the purpose, the structure and the glue that binds it all together.
It was that special something that makes sure people, in the care of machines, do the right
things right, the first time and every time. It’s the glue that brings it all together into a
single cohesive purposeful system. The glue brings it together and holds it together.
After all, poor machine reliability when driven to the root causes can be associated with
many factors that fall outside the domain of operations and maintenance.
How does maintenance and reliability address root causes that are outside the addressable
bounds of their jobs?
How do we achieve real progress and then sustain that progress? Not allowing a relapse to
the old business as usual?
This awareness has brought things to the current state of asset management; the subject of
my paper today.
Many of you are perhaps at that stage today.
ISO 55000 puts reliability, maintenance and lubrication on a much bigger stage
Is a proper and definable framework for these activities. A critical framework.
Asset Management can best be described by
what it looks like when it is absent …
Of course everything on this list is not caused by poor asset management, but there is
snowballing and collateral damage.
Bad applies spoil other apples
Much of this is the product of bad leadership and business culture
Some organization have excellent asset management but haven’t assigned that name to
what they do instinctively
Others need to have it taught or spoon fed to them.
They know what they want they just don’t know how to get it.
What they want is the opposite of what is listed on both sides
One begets the other
What’s on the left (at a moderate degree or a high degree) causes what is on the right (at a
moderate degree or a high degree)
Let’s define the meaning of a couple terms …
What has Root Cause Analysis (RCA) Taught us?
Failure is a great teacher. But we have to be a good student and apply why we learn.
Because the cause of so many machine failures originate at the top this is a good place for
asset management to begin. An overarching organizational asset management system
gives focus to asset management at all levels. The forest and the trees.
We may be looking for a root cause in the bottom tier to find something or someone to
blame. However, the real problem hides at the top. It radiates its influence downward
causing systemic, chronic problems below.
For instance, if the apparent cause of a gearbox failure is the use of cheap, dirty oil that
didn’t get changed on time. How is that corrected is management doesn’t provide the
budget for better oil, better filters, and training on the importance of changing the oil and
filter on time.
Definition of Key Terms
Asset
An item, thing or entity that has potential (future), or actual, value
to an organization…and can be tangible or intangible, financial or
non-financial.
ASSET
Asset Management
MANAGEMENT
Image
Asset Management
Involves the balancing of costs, opportunities and risks against
the desired performance of assets, to achieve the organizational
objectives.
Accountants define assets as anything that is owned today that has future value. In order
for that future value to be realized it most be managed and cared for today. This is includes
the protection of critical assets by operations and the proactive and reactive care of our
assets by maintainers (inspection and preventive maintenance). Assets are the bedrock of
all organizations.
Asset management is about a plan of action to insure assets have future value. How can
this be done at the lowest life-cycle cost?
It’s all about:
• What we do but shouldn’t do
• What we don’t do but should do
The asset management system executes the asset management plan. This is how asset
management is enabled.
A Crisis of Unconscious Incompetence
(43 Clauses)
ISO 55000 ISO 55001 ISO 55002
Principles and Terms Requirements for Narrative on How to
Certification Achieve Compliance
ISO 55000; sets a foundation. Defines critical terms. Establishes purpose and philosophy
ISO 55001 are the requirements that need compliance. It’s like an engineering
specification for asset management; but it reads like tax code or a book of regulations. It’s
a hard read and lacks example and specificity. It is structured after ISO 9001 and other
similar standards. It is the unchanging rule book. The pinnacle standard.
ISO 55002 is a guidelines book. It reads in more plain English and explains in more practical
terms what organizations need to do to comply with the requirements. It is something like
ISO 55000 for dummies.
PAS 55* is the Predecessor to ISO 55000 for
Physical Assets
Condensed
Structurally Organizational Objective
Derived from ISO and Plan
9001
PAS 55-1
Specification for the
Optimization of Asset Management
Physical Assets Policy and Objective
We started in the middle (PAS 55); we jumped to the top (ISO 55000); I’m going to finish by
bringing us back to basics (ICML 55)
PAS 55-1 shares an almost identical structure to ISO 55001 for requirements
Likewise PAS 55-2 roughly mirrors ISO 55002 (recently revised and expanded)
These standards do not address the all-important life cycle details of the last stage in this
block diagram
They talk about life cycle but don’t address it. No specificity
PAS 55 was withdrawn so as not to compete with ISO 55000, BSI is a national standards
body. PAS 55 was not withdrawn because it was a defective standard. It is still the
preferred asset management standard by many in the reliability community.
The words in the boxes are in the vernacular of BSI/ISO standards. The words on the right
more simply stated.
Defining and Benchmarking Cross-
Functional Organizational Excellence
Quality
Occupational Companion
Health and ISO 45000 Standards ISO 41000 Facilities
Safety Management
ISO 21469
ISO 55011
ISO 22000
Food Safety Management of
ISO 55000 Government Assets
Asset Management
An organization that embraces compliance to all these standards protects against the risk
of bad applies corrupting the business and its culture. It achieves sustainability. How does
it make sense to not have a cohesive organizational program across: safety, quality, asset
management, environment, etc. Bad applies propagate. Bad culture propagates. Bad
management propagates.
Key Principles and Attributes of
Asset Management
Holistic: Looking at the Optimal: Establishing the
whole picture. Top down. best value compromise
Alignment to between competing
organizational objectives. factors, such as
performance, cost and
Systematic: A risk, associated with the holistic
documented, assets over their life
programmatic approach of cycles.
consistent, repeatable and sustainable systematic
auditable decisions and Sustainable:
actions. Steadies the ship Sustainability must be
influenced by change. enabled: standardized integrated
work, change
Systemic: Viewing assets management, audits and
as a system working re-assessments, optimal systemic
together to achieve measurement, culture
organizational goals and
objectives. Integrated: Transcending risk-based
the principles of asset
Risk-based: Asset management throughout
management is risk the organization. Cross
management. Focuses on functional. Forest and
understanding risks and trees.
applying resources and
activities to manage and
control risks.
Reliable Maintainable
Asset management has a strong value proposition. The benefits statement is loaded. In
search of the hidden plant. 2 plants at 50%
At the very, very top are measures such as: market cap, earnings per share, shareholder
value, P/E ratio, long-term prosperity.
Tiered down from this are such things as: Better Asset Performance (go clockwise around)
…
Reliability: Utilization, uptime,
Control: Proactive, aspiration driven
Capacity: work done, through put, speed of performance
Efficiency: teambuilding, rowing together, non waste,
The asset management gameplan based on international standards (ICML 55.01, ISO
55001) provides an engineering specification for asset management excellence and
lubrication excellence. It is a global expert consensus of what defines excellence. It
creates believers out of doubters.
The Ground is always Shifting … So must Asset
Management
Industrial
State of Internet Of
Knowhow Things Asset Failure
Economy Modes
Technologies (IIOT) Portfolio
Continuous
Production Improvement Tools
Needs Aging Tasks
Machine
Management
of Change
Materials Staff
Turnover
Loads
Risks Speeds
Procedures Suppliers Throughput
A
B
*Withdrawn standard
These standards describe big-picture requirements and codification of asset
management. They don’t provide a prescriptive game-plan to achieve the Optimal
Reference State or specific benchmarks needed for compliance of lubricated mechanical
assets. Asset management must be enabled.
How do we paint by the numbers to achieve the stated goals of reliability, etc. Note, the
new and revised ISO 55002 brings ISO 55001 closer to PAS 55 for physical assets.
In 2017 the International Council for Machinery
Lubrication (ICML) Began the Construction of a New
Consensus Standard for Lubricated Mechanical Assets
Activities:
Industries: Asset Types:
ICML 55 • Nuclear • Mechanical
•
•
Condition Monitoring
Outage Lower Stratum
Lubricated • Transportation • Electronic Management
• Tactical asset
Mechanical • Food • Infrastructure • Asset Design &
Processing • Rotating
Manufacturing management
Assets • Service Providers
• Government Equipment
• Inspection
• Enablers
• Lifestyle changes
*Withdrawn standard
Many cross-sectional views of the enablers in the Lower Stratum
ISO 55000 is your North Star. ICML 55 commands the ship that gets you there.
Other similar standards are being written along the lower stratum. These include: (read
what’s in the blue blocks}
ISO 55000 is your North Star. ICML 55 commands the ship that gets you there.
Coverage of Standards for Mechanical
Asset Management
Role of ICML 55 in the
Holistic
Asset Management Space
*Withdrawn standard
ISO 55001
• ICML 55.1 does not
replace, complete and
technically conflict with
PAS 55-1* ISO 55001
• Instead, it is an enabling
standard
Strategic • Each clause of ICML 55.1
aligns and supports one
or more specific clauses
ICML 55.1 of ISO 55001
• ICML 55.1 delivers a high
degree of specificity
(detail) at a tactical level
for lubricated mechanical
assets
Tactical
Low Degree of Specificity High
ISO 55001 focuses on the organization and a holistic state of asset management. It
provides no specificity for individual asset types.
PAS-1 is also holistic but also provides strategic elements related to physical assets. It
provides no specificity related to reliability, maintenance, condition monitoring, lubrication,
etc.
ICML 55.01 is a companion standard to ISO 55001. It doesn’t repeat the holistic
requirements adequately address in that standard. Instead it provides specificity on
maintenance and lubrication, etc.
ISO 55001: Requirements Overview
Tactical
Lubricated
Mechanical
Assets
Reassess
This is the implementation sequence for ICML 55. The ICML 55 clauses are referenced
above. Not where the certification occurs if compliant. Not also the need for periodic
reassessment to achieve sustainability.
Tactical Asset Management …
in the Context of Machine Criticality and Risk
We have little control over the consequences of machine failure, early warning helps as
does machine redundancy. How do we move the OMC value to a lower value to reduce
risk? This is done from the elements of the Failure Occurrence Factor (FOF). See next slide.
ICML 55 Execution Enables Reliability
& Lowers the Likelihood of Machine Failure
* These elements directly affect machine reliability and rise; the Failure Occurrence Factor (FOC)
What’s addressable? Aligning the gameplan for AM with the benefits we seek.
RCA has taught us why machines fail prematurely and with minimal or no warning. These
lessons have given us great insight to the addressable and controllable conditions that can
sharply reduce the probability of failure (Failure Occurrence Factor). What we can control
on the left (ORS attributes). Across the top are the elements that cause premature
machine failure (sub elements of the FOF). This relates directly to the previous OMC chart.
Note the corresponding ICML 55 clauses on the right.
The Benefits from ICML 55 Transformation
Related to Reliability, Maintenance Costs, Safety, and the Environment
The benefits of the ICML 55/ORS attributes go beyond just machine lifecycle extension.
Other benefits include cost of lubricants and consumption, condition monitoring (early
warning), safety, waste disposal, environment and energy consumption. Controllable
attributes on the left. Benefits across the top. See legend. Corresponding ICML 55 clauses
on the right.
Asset Management Journey Time Horizon
10 20 30 40 50 60
Months
Months
ICML 55 Development of other ICML
Planning 55 Asset Management
Requirements
Assessment Engineering
of Current the Optimum
State Reference State
Full Compliance & Certification
of ICML 55.1
Deploy and Execute
The Optimal Reference
State
Full Compliance & Certification
of PAS 55-1
PAS 55-1 Stages
Example of how to start and sustain the AM journey. Rome was not built in a day. Slow
and steady wins the race.
Maturity Continuum through 12 ICML 55.1
Elements
ICML.55-1
1. Skills. Job/Task Skills,
Training and Competency ICML.55-12 ICML.55-2
2. Machine. Machine Lubrication
and Condition Monitoring
Readiness
3. Lubricant. Lubricant Selection ICML.55-11 State of ICML.55-3
4. Lubrication. Routine and Progress
Periodic Lubrication Tasks
5. Tools. Lubrication Support
Facilities and Tools
6. Inspection. Machine and Start Compliance
ICML.55-10 ICML.55-4
Lubricant Inspection
7. Oil Analysis. Lubricant
Analysis and Condition
Monitoring
8. Troubleshoot. Fault/Failure
Troubleshooting and RCA ICML.55-9 ICML.55-5
9. Waste. Lubricant Waste
Handling and Management
10. Energy. Energy Conservation
and Environment ICML.55-8 ICML.55-6
11. Reclaim. Oil Reclamation and
System Decontamination ICML.55-7
12. Management. Program
Management and Metrics Pre-Assessment 1st Test Assessement Minimum Compliance 100%
Orange line is the minimum required performance to meet compliance (tolerance 10%).
Track maturity from beginning to end. This is your ICML 55 dashboard.
Compliance and Certification
ISO 55001
Certification Scheme*
American National • National Accreditation Body
Accreditation Board • Accredits Certifying Bodies
(ANAB)
What does sustainability mean? Why invest in change if you’re not willing to
invest in the sustainability of that change?
Ever try to break a bad habit or loose weight? It requires change. Ever end up going back
to your old ways? This is what is meant by change without sustainability.
When is Asset Management Achieved?
A?
B?
A + B?
Asset A?
Management
Where should it ISO 55000 / PAS 55
begin? (the forest)
• Top down?
• Bottom up? Managing Assets
(the trees) B?
ICML 55. What’s Achieved? The machine achieves the desired service life. It is
maintainable. It is reliable. It is available. It is energy efficient. It cost of maintenance is
optimized. Maintainers and operators are competent in performing tasks.
You can’t have a world class quality forest without quality and sustainably nurtured trees.
Answer is A + B. Start at the Top and the Bottom.
Additional Information on Asset Management