Achieving Maintenance and Reliability Excellence Through Asset Management
Achieving Maintenance and Reliability Excellence requires a dedicated focus on best practices and methodologies around Asset Management that provide a holistic and sustainable approach to performance improvement. It bridges the gap from leadership vision and asset strategy to continuous improvement by implementing effective frontline reliability, precision maintenance, work execution, and online monitoring programs. Our holistic approach includes these elements and effectively manages risk in advance through unparalleled maintenance training and equipment inspection and monitoring. You will see significant improvements to OEE while realizing lowered costs and incidents.
Maintenance and Reliability Excellence starts with a clear Asset Management strategy and uses elements of maintenance training, planning and scheduling, and effective monitoring to mitigate and manage risk while building Continuous Improvement and Sustainability across an organization.
The foundation of an effective maintenance training program is a clearly defined leadership vision and asset strategy to attain your business goals. GP Strategies can help you create this alignment by developing or supporting your company’s vision, change management process, maintenance and reliability strategies, maintenance training programs, and justification to engage (ROI planning).
The process starts with the asset strategy to analyze the asset data and identify the criticality of equipment. This criticality assessment will be used to create and prioritize maintenance and training strategies.
Another important element of an effective overall maintenance and reliability strategy is condition monitoring. Monitoring critical equipment and plant processes can help detect anomalies and prevent unplanned downtime. Early warning signals can prevent catastrophes, reduce maintenance costs, and help streamline the reporting process.
GP Strategies uses proper planning and scheduling strategies to establish and sustain an effective work control management program that eliminates non-value-added activities and redirects that time to critical maintenance goals.
Read our white paper: Improving the Work Cycle Through Planning.
Front Line Reliability
The goal of front line reliability is to identify issues before they happen using Failure Modes Effect Analysis (FMEA) data and to ensure optimum equipment operation. This can be achieved through GP Strategies’ operator care programs. Using a streamlined rapid improvement process, GP Strategies can help you create a strong, proactive front line that guards against potential failures.
As today’s skilled workforce ages, the need for multi-skilled technicians and innovative workforce solutions becomes more critical. For over 50 years, GP Strategies has provided companies core craft skills training and documentation services that help reduce unplanned or repeat work, increase Mean Time Between Failures (MTBF), and improve equipment uptime and installation.
Investigation management can range from a simple 5-Whys analysis to a more detailed and complex cause-and-effect approach. The goal of investigation management is to improve processes and procedures to prevent human error and equipment failure occurrence.
Continuous Improvement and Sustainability
The final but most critical piece in achieving Maintenance and Reliability Excellence is creating an environment of continuous improvement and program sustainability. This can be accomplished by standardizing the work performed, ensuring it complies with policies and procedures, and conducting periodic audits to confirm processes are followed. That’s why implementing a program that fits your company’s culture and personnel is so important. The only way true ROI can be attained is through sustainability and continuous improvement of your maintenance and reliability strategies.
Read a case study about how improving operator and maintenance training resulted in increased overall equipment effectiveness from 86.2% to 98.8% in a six-month time span.