Reliability Scorecard0127

Version 1.
0 January 2006
Reliability Program Scorecard

Created by John S. Mitchell; jsmitchell@worldnet.att.net
January 2006
Reliability Program Category Summary
Reliability Program Elements Element Weight -% Category Weight -%

Results / Reliability Program Effectiveness
High plant, system and equipment availability 2.7%
Optimum maintenance costs 2.7%
Minimum Emergency, break-in work 2.6%
Few unexpected failures last two years 2.0%
Failure rate trending down 1.9%
Total 11.9% 17%
Values, Culture, Relationships
Good partnership between Production, Maintenance 2.8%
Reliability culture in place and effective 2.0%
Training and coaching available and effective 1.2%
Change Management process in place and effective 0.8%
Total 6.8% 8%
Charter, Organization, Administration, Training
High level management champion actively involved 1.3%
Skills management, training and certification in place 1.3%
Specifications, procedures and practices documented, up to date and available 1.1%
Risk analysis and ranking established 1.1%
Control plan established for sustainability 1.1%
Reliability champion appointed and active 1.1%
Program business value contribution determined 1.0%
Component, Condition, Cause, Action codes in use 1.0%
Vital facility and and equipment records up to date 0.8%
MTBF determined 0.8%
Document revision / configuration control process in use 0.8%
Total 11.4% 16%
Version 1.0 January 2006
Supporting programs
Lubrication Program 8.0% 8%
Condition Monitoring / CBM Program in place and effective 2.6%
Vibration 2.1%
Lubrication 2.2%
Temperature; infra red imaging and measurement 0.7%
Process / operating performance 0.7%
Motor electrical analysis 0.5%
Air and gas leakage; out, through and in (hazard, waste, lost efficiency) 0.4%
Ultrasonic -- active (thickness measurement), passive (leak detection) 0.3%
Steam trap performance 0.3%
Transformer oil, gas and temperature 0.2%
Total 10.0% 10%
Time based Preventive Maintenance (PM) Program 8.0% 8%
Maintenance Requirements Analysis and Program Development — RCM FMEA 5.0% 5%
Proactive Maintenance
Lubrication system integrity 1.5%
Clean and orderly plant and workspace 1.1%
Precision shaft alignment utilized effectively 0.9%
Total 3.5% 6%
Maintenance, Maintainability for Capital Projects
Comprehensive maintenance strategy in place and followed 2.0%
Comprehensive procedure followed to assure optimum reliability and maintainability 1.3%
Total 3.3% 5%
Activities
Failure Analysis — RCFA
Implementing procedure established and followed 1.1%
Failure analyses accomplished 1.1%
Corrective action reviewed, applied and checked for effectiveness 1.1%
Total 3.2% 7%
Reliability Improvement
Reliability improvement teams chartered and active 2.1%
Continuous reliability improvement program active and effective 1.9%
Participation by Production and Maintenance 1.6%
Total 5.6% 8%
Reliability Modeling, Prediction, Lifetime Analysis 2.0% 2%
Version 1.0 January 2006
Total 79% 100%

Version 1.1 January, 2006
Reliability Program Detailed Scorecard

Created by John S. Mitchell; jsmitchell@worldnet.att.net
January 2006
Necessity, Comparative Requirements Element Program Quartile Spread

Reliability Program Elements Definition Metrics Weight - % Weight - %
Results / Reliability Program Effectiveness 100 17% 1 2 3
Values, Culture, Relationships 100 8%

Charter, Organization, Administration, Training 100 16%
Supporting Programs
Lubrication 100 8%
Plant wide lubrication program in place. Compliance with Quality

best practices including determination of coverage, assurance, Procedure written,
yes 80 6.4 cmplete some, not all
optimum type, requirements for receipt, storage, testing, maximum published and followed
transfer, delivery to equipment and sampling reliability
Lubrication sidestream filtering / polishing in place and in

20 1.6 yes
use
8.0
Condition Monitoring, Condition Based

100 10%
Maintenance
Time Based Preventive Maintenance 100 8%
Maintenance Requirements Analysis and

100 5%
Program Development — RCM FMEA
Proactive Maintenance 100 6%
Maintenance, Maintainability for Capital Projects 100 5%
Activities
Failure Analysis — RCFA 100 7%
Reliability Improvement 100 8%
Reliability Modeling, Prediction, Lifetime

100 2%
Analysis
Total score 100

World Class Performance >80 >80 60-80 40-60
ogram Detailed Scorecard

. Mitchell; jsmitchell@worldnet.att.net
January 2006
Quartile Spread
4
no
no
<40

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Version 1.

Reliability Program Scorecard

Reliability Program Category Summary

Reliability Program Elements Element Weight -% Category Weight -%

Total 79% 100%

Reliability Program Detailed Scorecard

Necessity, Comparative Requirements Element Program Quartile Spread

Values, Culture, Relationships 100 8%

Charter, Organization, Administration, Training 100 16%

Plant wide lubrication program in place. Compliance with Quality

Lubrication sidestream filtering / polishing in place and in

Condition Monitoring, Condition Based

Time Based Preventive Maintenance 100 8%

Maintenance Requirements Analysis and

Proactive Maintenance 100 6%

Maintenance, Maintainability for Capital Projects 100 5%

Reliability Improvement 100 8%

Reliability Modeling, Prediction, Lifetime

Total score 100

ogram Detailed Scorecard

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