What are the challenges of applying criticality analysis and ranking in a dynamic environment?

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Criticality analysis and ranking (CAR) is a key component of reliability centered maintenance (RCM), a systematic approach to optimize the maintenance strategy of physical assets. CAR helps prioritize the assets based on their impact on safety, environment, production, and cost. However, applying CAR in a dynamic and complex environment can pose several challenges that require careful consideration and adaptation. In this article, we will discuss some of these challenges and how to overcome them.

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Abhishek G.

Product Engineer at UE Systems | GATE 2024 Qualified | Certified Ultrasound Inspector | Ex-Energy Analyst | Specialist…
Haris Muhammad

TUV-FS Eng | CMRP | ISA-62443 Certified | I&C Engineer with 15 Years Experience | MIEAust

1 Data quality and availability

One of the main challenges of applying CAR is obtaining reliable and sufficient data to assess the criticality of the assets. Data quality and availability can vary depending on the type, age, and condition of the assets, as well as the data collection and management systems in place. Poor data quality and availability can lead to inaccurate or incomplete CAR results, which can affect the decision-making process and the effectiveness of the maintenance strategy. To overcome this challenge, establish clear data requirements, standards, and validation methods. Leverage multiple sources of data, such as historical records, operational feedback, failure analysis, and risk assessments.

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Haris Muhammad

TUV-FS Eng | CMRP | ISA-62443 Certified | I&C Engineer with 15 Years Experience | MIEAust
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Well designed and maintained CMMS are vital sources of data when performing criticality analysis of complex processes. They provide key information like breakdown instances, history, M&R costs, MTTR, condition monitoring data, spares consumption and lead times and so on. All these provide quantitative metrics and parameters that are crucial in determining the consequences of the failure, their likelihood and severity.

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Abhishek G.

Product Engineer at UE Systems | GATE 2024 Qualified | Certified Ultrasound Inspector | Ex-Energy Analyst | Specialist in Ultrasound Condition Monitoring & Reliability Solutions
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Great insights on the challenges of data quality and availability in CAR implementation. Establishing clear data standards and leveraging diverse sources like historical records and failure analysis are indeed crucial for making informed maintenance decisions. This approach not only enhances reliability but also strengthens the overall effectiveness of the maintenance strategy.

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2 Dynamic and complex interactions

Another challenge of applying CAR is accounting for the dynamic and complex interactions among the assets, the processes, and the environment. These interactions can influence the criticality of the assets in different ways and at different times, depending on the operational conditions, the external factors, and the interdependencies among the assets. For example, a change in demand, a weather event, or a failure of a supporting asset can alter the criticality of an asset significantly. To overcome this challenge, use a holistic and systemic approach to capture the interactions and their effects. Update the CAR results regularly to reflect the changes in the environment.

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Abhishek G.

Product Engineer at UE Systems | GATE 2024 Qualified | Certified Ultrasound Inspector | Ex-Energy Analyst | Specialist in Ultrasound Condition Monitoring & Reliability Solutions
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Addressing the dynamic interactions among assets, processes, and the environment is crucial for effective Criticality Analysis and Ranking (CAR). These interactions can indeed shift an asset's criticality based on varying operational conditions and external factors. Adopting a holistic, systemic approach allows for a comprehensive understanding of these interdependencies. Regularly updating CAR results is essential to capture real-time changes, ensuring that maintenance strategies remain aligned with current operational realities. This proactive approach enhances resilience and optimizes asset management in complex environments.

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3 Subjectivity and bias

Subjectivity and bias can affect the criticality assessment and ranking process. Subjectivity and bias can arise from the different perspectives, opinions, and preferences of the stakeholders involved in the process, and from the assumptions, criteria, and methods used to perform the analysis. Subjectivity and bias can lead to inconsistent or skewed CAR results, which can compromise the credibility and transparency of the process. To overcome this challenge, involve a diverse and representative group of stakeholders, and use a structured and standardized process with clear definitions, objectives, and metrics.

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Abhishek G.

Product Engineer at UE Systems | GATE 2024 Qualified | Certified Ultrasound Inspector | Ex-Energy Analyst | Specialist in Ultrasound Condition Monitoring & Reliability Solutions
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Subjectivity and bias are often overlooked challenges in criticality assessment. Involving a diverse group of stakeholders and implementing a standardized process is essential to maintain transparency and credibility. Clear definitions and objectives can definitely help in achieving more consistent and reliable CAR results. Great points highlighted here!!

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4 Resource constraints and trade-offs

It can be challenging to manage the resource constraints and trade-offs that can limit the implementation of the maintenance strategy based on the CAR results. Resource constraints and trade-offs can stem from the availability, allocation, and optimization of the human, financial, and material resources needed to perform the maintenance activities. Resource constraints and trade-offs can affect the feasibility and effectiveness of the maintenance strategy, and the alignment with the organizational goals and priorities. To overcome this challenge, balance the benefits and costs of the maintenance strategy, and communicate and justify the CAR results and their implications to the relevant stakeholders.

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Abhishek G.

Product Engineer at UE Systems | GATE 2024 Qualified | Certified Ultrasound Inspector | Ex-Energy Analyst | Specialist in Ultrasound Condition Monitoring & Reliability Solutions
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Resource constraints and trade-offs are indeed critical factors that can impact the success of any maintenance strategy. Balancing costs and benefits while aligning with organizational goals is a challenging but essential step. Clear communication and justification of CAR results to stakeholders help ensure that these strategies are both feasible and effective. Excellent points!

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5 Continuous improvement and learning

Continuous improvement and learning is essential to adapt to the changing environment, to address the gaps and issues identified in the process, and to enhance the performance and reliability of the assets. Continuous improvement and learning can be hindered by the lack of feedback, monitoring, evaluation, and documentation mechanisms, and by the resistance to change and innovation. To overcome this challenge, establish a feedback loop, a performance measurement system, and a knowledge management system, and foster a culture of learning and improvement.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are the challenges of applying criticality analysis and ranking in a dynamic environment?

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1 Data quality and availability

2 Dynamic and complex interactions

3 Subjectivity and bias

4 Resource constraints and trade-offs

5 Continuous improvement and learning

6 Here’s what else to consider

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