Maintenance & Reliability Excellence
Achieving Maintenance & Reliability Excellence requires a dedicated focus on best practices and methodologies that provide a holistic and sustainable approach to performance improvement by implementing effective frontline reliability, precision maintenance, work execution, and online monitoring programs.
Leadership Vision and Asset Strategy
The foundation of an effective maintenance and reliability 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, and justification to engage (ROI planning).
GP Strategies’ critical analysis software from Uberlytics™ allows us to quickly collect essential data on the most critical systems and assets. This software dramatically reduces the time it takes to complete this first crucial step in the data collection and analysis process.
Front Line Reliability
The goal of Front Line Reliability is to identify issues before they happen using Failure Modes Effect Analysis (FMEA) data and ensure optimum equipment operation. This can be achieved through GP Strategies’ operator care programs. Through a streamlined rapid improvement process, GP Strategies can help you can create a strong, proactive front line that guards against potential failures. Some of the benefits of these programs include:
- Reduced labor and material loss
- Improved Overall Equipment Effectiveness (OEE)
- Reduced unplanned downtime
- Improved overall safety
Planned maintenance optimization, Five S and visual management, standard work, and defect identification and elimination are just some of the services available with GP Strategies’ front line reliability programs.
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.
Our off-the-shelf and customized maintenance courseware and hands-on training may be the blended solution your organization needs. Our blended training includes instructor-led training, eLearning, structured on-the-job training (SOJT), and train-the-trainer sessions. Our training courseware offers mechanical, electrical, instrumentation and control, operations courses available off the shelf or in a customizable format. Industrial equipment trainers and our full-size training facility are available for use as well.
Through proper planning and scheduling strategies, an effective work control management program that eliminates non-value-added activities and redirects that time to critical maintenance goals can be established and sustained. Improved planning and scheduling has various benefits:
- Reduce costs
- Improve performance
- Increase wrench time
- Minimize failures
- Optimize machine life
- Improve use of CMMS application
GP Strategies interactive Planning & Scheduling Training workshops include all personnel, not just planners, involved in the process. It’s crucial to have maintenance workers, supervisors, managers, and production staff present for portions of the training. In addition, GP Strategies’ OUTAGE! game for maintenance planning and scheduling can be used as a standalone learning tool or integrated in the formal training program. This customizable game uses various accelerated learning techniques to reinforce the key concepts of the planning and scheduling process.
Another important element of an effective overall maintenance and reliability strategy is online 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 online monitoring tools include:
- EtaPRO™ APR (Advanced Pattern Recognition) using real-time empirical models that provide early warning of anomalies
- EtaPRO™ Predictor™ – Continuous real-time analysis of critical equipment faults
- EtaPRO™ EPArchive™ – High-performance data historian
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’s in accordance 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.