6 HIGH-LEVEL ELEMENTS TO GUIDE YOUR ASSESSMENT
We don’t lead the journey to improve equipment reliability just for the sake of improving equipment reliability. We lead the journey to improve equipment reliability because it is required to achieve, and sustain, productivity gains.
A successful reliability journey results in sustained productivity gains. Allied believes reliability is best understood as a systems model, made up of levels of elements and processes that help you attain and sustain success. Unless foundational elements and the successive levels are optimized, you will experience inefficiency and lost productivity. But with the right structure in place, you can ensure your organization is integrated and focused on a successful Reliability Journey.
A strong reliability system requires a solid base upon which to build. Effective leadership and organizational structures, with clearly defined roles and responsibilities for all team members, will ensure your organization is aligned for success.
The foundation for a proactive environment requires certain elements to be in place, including an accurate and complete asset catalog, efficient and effective work management processes, failure mode-based maintenance strategies with the proper balance of preventive and condition-based maintenance, and the appropriate performance indicators.
Training, operator care, and craft skills programs help ensure your team has the skills and ownership needed to succeed. Measurement tools such as process audits and FRACAS show your progress towards your goals so you can see, and improve, the effectiveness of your reliability system.
This level of the reliability system is all about making the right decisions to optimize Total Cost of Ownership and ensure that desirable maintenance strategies are executable, through the use of tools such as reliability-centered maintenance, reliability & availability modeling, and reliability-centered design.
The reliability system should be viewed as a living system. The only way to ensure your system is delivering maximum value and success is through continuous improvement – with periodic reviews of system elements, methods, and tools and implementation of new initiatives to meet your needs in an ever-changing environment.
Explore some of our popular Reliability Consulting solutions below. Don’t see what you’re looking for? Contact us for a more comprehensive overview of our offerings.
“Asset health” is a metric that quantifies the overall state of a piece of equipment relative to the presence of an identifiable defect. This metric can be applied to specific pieces of equipment, process systems, plant areas, or the overall health of an entire plant or facility. To know and manage asset health, key foundational elements are needed, including a complete asset catalog with asset criticality rankings and equipment maintenance plans that address the findings of a failure modes analysis. Understanding asset health and managing risk across all of your assets is core to not only understanding your current performance and cost structure, but also being able to project future performance and cost.
Guidance designed to successfully internalize and take control of your reliability initiatives. If you want more than a training solution, but still prefer to implement new processes and standards using your own personnel, Allied offers a combination training and coaching solution. Training classes augmented by a regimen of coaching and mentoring work well when training capabilities exist within the plant and implementation timing is not urgent, costs need to be absorbed over time, and new jobs are welcome. Coaching and mentoring are available for a variety of disciplines, including reliability engineering, planning, and scheduling.
The Equipment Maintenance Plan, or EMP, is the document that communicates the engineered maintenance strategy to the organization. EMP development – the process that is used to determine the most effective approach to maintenance through a failure mode-driven strategy – involves identifying actions that, when taken, will reduce the probability of failure and that are the most cost effective. EMPs are built from a combination of failure mode data, criticality rankings, Reliability Centered Maintenance (RCM) analysis, and/or statistical analysis. Allied offers multiple levels of EMP development ranging from a “Balance of Plant” solution to plans for your highest-ranking assets that incorporate Weibull statistics and Monte Carlo Simulation for a fully customized EMP development support solution.
Employee engagement is the holy grail of any organization. Operators need to have ownership of the assets that they operate. They need solutions to make this ownership less subjective and more quantitative and systematic.
Adding an Operator Care program to equipment maintenance strategies allows an organization to engage a largely untapped resource in a meaningful way to support the asset reliability efforts of the organization. In addition to the tangible deliverables of the process (inspection forms, problem tags, audits, etc.), Allied has found that our approach provides an additional benefit by immediately empowering the operators in an area, focusing their attention on measurable results and simple problem-solving techniques. Operators take increased ownership for equipment with a solid structure around existing informal activities while improving and formalizing lines of communication, increasing the visibility of abnormalities, as well as results, and reducing equipment delays and product quality issues.
Many facilities are losing nearly 10% of their maintenance budget due to a poor oil analysis program and poor lubrication practices that fail to add value. While a solid Reliability-Centered Lubrication (RCL) program will not stop all failures, when RCL is well designed and implemented, at least 50% or more of those lost dollars can be realized in cost avoidance. Reliability Centered Lubrication (RCL) is a logical way of identifying the critical equipment for implementing condition monitoring and preventive maintenance. Allied’s RCL delivery model can be tailored to meet your specific needs and requirements, beginning with an in-depth review of your current lubrication program to develop an implementation plan to help you achieve your overall goals.
An overall reliability strategy must be grounded in a fundamental understanding of how equipment fails. Allied's reliability-centered maintenance (RCM) process is the hub of Allied's integrated approach to designing and implementing failure mode-driven reliability strategies that return results in a fraction of the time of traditional RCM methods. This facilitated process includes Failure Modes, Effects, and Criticality Analysis (FMECA); Process Verification Techniques; Consequence Reduction Tasks; Spare Parts Strategy; and Implementation Strategy.
No organization is immune from equipment failures, operations breakdowns, or human errors. What sets the successful company apart from the rest is its ability to solve problems in a way that prevents recurrence by addressing the root cause of the failure. Root cause analysis (RCA) is the core skill used by maintenance and reliability engineering professionals to resolve problems that impact an organization's ability to meet strategic objectives. RCA is not just a tool, it is a systematic methodology used to eliminate chronic problems that affect an organization. Eliminating the root cause of problems through effective RCA prevents problem recurrence and achieves stronger results for ALL key performance indicators and, ultimately, gives you a competitive advantage in the marketplace.
6 HIGH-LEVEL ELEMENTS TO GUIDE YOUR ASSESSMENT