Normalization of Deviance — The Pathway to Disaster
Reliability and Maintenance Bootcamp
In this session, we will discuss in detail the definition of Normalization of Deviance and how it has contributed to major accidents, including both Space Shuttle disasters. Examples will be provided of Normalization of Deviance in operating and maintaining process plants, as well as in our daily lives.
Participants will:
- Gain an understanding of how to stop Normalization of Deviance
- Learn how to identify and correct this behavior
- Take this concept home to apply with their families
Moderator:
Dean Roberts, Ergon Refining, Inc.
Speaker:
Rick Hoffman, Becht
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A First-Principles Approach to Root Cause Analysis and Human Error
Reliability and Maintenance Bootcamp
After more than 50 years of root cause analysis (RCA), you might expect problem solving to be a clear and straightforward process. It’s not. You can find yourself caught in unproductive debates. “Is that a contributing factor, or a causal factor?” “That’s a primary cause, but it’s not the main cause.” The result is frustration, inefficiency, and solutions that allow a repeat of the same problems.
A better approach to RCA is one built on evidence-based cause-and-effect relationships. The steps are simple: define the problem, explain why it happened, and identify solutions to reduce risk. Its focus is on having more reliable work processes, learning, and improving, which helps engage the frontline and minimize blame.
This session will explain the pitfalls of drifting from scientific problem solving and features a case study demonstrating how first-principles RCA leads to tangible improvements in reliability and human performance.
Participants will learn:
- Four common errors that arise when explaining why an incident occurred
- The biggest misconception about RCA
- Why effective RCA does not require any proprietary techniques, terminology, or software
- How RCA can be scaled for low-risk incidents and expanded as needed for higher-impact events.
- How to reduce “human error” by involving those who perform the work
Moderator:
Bill Clark, Phillips 66
Speakers:
Bill Clark, Phillips 66
Mark Galley, ThinkReliability
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Capital Projects: Project Life Cycle Costs
Reliability and Maintenance Bootcamp
This session will introduce an integral part of maintenance and reliability engineers’ responsibilities to capital projects. How this relationship and communication is important to get safe, reliable, and maintainable equipment installed when working with a capital project team.
Participants will learn:
- What a project life cycle is
- What influences cost the most, and
- Industry standards for analysis
Moderator:
Bill Clark, Phillips 66
Speaker:
Dean Roberts, Ergon Refining, Inc.
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Maintenance Common Work Practices
Reliability and Maintenance Bootcamp
In this session, leaders in plant maintenance from two major companies in the fuel and petrochemical manufacturing industry will discuss the advantages of a company-wide standard process for routine maintenance. Gaining alignment on a common work practice across a large and geographically diverse portfolio can be challenging, but the resulting organizational discipline can yield improved efficiency, reliability and decision-making. The speakers will provide a high-level overview of their routine maintenance processes and share key success factors for implementing a common maintenance work practice at multiple facilities.
Participants will:
- Learn the major elements of a routine maintenance process
- Hear examples of strategies for a successful wide-scale implementation
- Ask questions to understand how a common work practice for plant maintenance can be applied at their company
Moderators:
Mike DeHart, Valero Energy Corporation
Speakers:
John Duenckel, Valero Energy Corporation
Tom Golden, LyondellBasell Industries
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