The step-by-step guide to improving reliability and performance in your plant.
For years, people have been trying to improve reliability and achieve higher levels of performance. They have understood the benefits to the organization, and they have bought books, attended conferences and even taken specialist training. Yet the goals of reliability and performance improvement have remained elusive...
Over that same time, a small number of companies have had success. They have avoided (or overcome) the main hurdles, and they have gained the necessary support at all levels of the organization, and they now enjoy working in a plant that is rarely interrupted by breakdowns, and their process achieves the target levels of production output or service dependability.
We have learned from their success (and from others' disappointments) and developed a blueprint for transforming reliability one step at a time. It is not just another declaration of the reliability elements you must implement, or vague directions that don't provide the specific directions you need - it will take you through the process, from the first steps of assessing the value of the initiative to the ongoing execution of "world-class" asset management and operational excellence.
Here are the important steps it will guide you through:
  • Establish the business case
  • Gain senior management support
  • Develop a strategy with a plan
  • Transform the culture - everyone on board, skilled, and pulling in the same direction
  • Break out of the reactive maintenance cycle of doom
  • Establish a disciplined approach to maintenance and operations
  • Ensure that new projects and acquisitions do not compromise reliability
  • Care for your equipment to avoid premature failure or poor performance
  • Employ analytics to achieve data-driven decisions
  • Learn from failures, near-misses, and poor performance to eliminate root causes
  • Continually optimize everything you do in order to achieve higher performance standards

At last, there is a step-by-step process we can follow to achieve a reliable plant.

Not just why, but how to improve reliability.

We have developed a high-level summary of the ART process: we establish the VALUE, develop a STRATEGY, engage with PEOPLE, gain CONTROL of reactive maintenance, ACQUIRE assets to deliver the lowest lifecycle costs, establish a DISCIPLINED approach to maintenance and operations, CARE for the assets, utilize ANALYTICS for data-driven decisions, learn from the end of life EOL phase, and constantly OPTIMIZE everything we do.
Most importantly, we have defined the major steps that must be performed in order to achieve success. Think of it as a project plan. Those major steps are broken down into minor steps that clarify exactly what must be done to ensure the major step is completed.
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We also provide a check-list so the progress of your program can be measured, and so you may perform an additional assessment - recognize what you are already doing well, and identify where improvement is required.
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If you are familiar with the reliability acronyms and terminology, the following illustration indicates where the common elements belong within the Asset Reliability Transformation process. However, we need to make an important point.
One of the main reasons why programs fail is that magazines, conference providers, vendors, and even consultants have presented a list of obvious elements that must be a part of a reliability improvement program: RCM, FMECA, RCA, VA, and many other elements. If you simply attempt to implement each of these technologies/strategies/techniques you will be overwhelmed - you will hopefully do a few things well, but it will take time, it will be inefficient, you will still have reactive maintenance, you will lack proper support, you will have a culture of resistance rather than reliability. This has been the history of reliability improvement initiatives for many years.
But it does not have to be that way. We have developed a process with input from practitioners, consultants and authors to help people enjoy the success they so richly deserve.