Reliability Excellence Assessment

Condition Monitoring

Reliability is a word everyone can appreciate.

It's the ability of system or system component to perform its required function under both normal and adverse conditions.

We expect our cars, the electricity in our homes, our friends, our meals and our paychecks to all be reliable.

When it comes to your company, reliability can be the difference between success and failure. Here's why.

Equipment, component and system failures are very expensive.

In many cases, these failures cause production downtime or redcuced rates, which can have a negative impact on almost all parts of the business. Unexpected costs may include:

 

Safety - injuries, property and equipment damage

Environment -  air, land and water releases - response,  clean-up, fines etc.

Quality - product scrap, rework, low yields

Operating Costs - Increase labor, material, equipment and energy costs

 

Reliability Excellence is good business!

For one, it leads to excellence in other critical areas including safety, quality, and costs. Companies with excellent reliability performance consistently deliver products and services with the lowest costs and highest profitability

Reliability excellence also reduces operating costs, reduces working capital requirements and increases return on investment (ROI). Increased production volume with better quality using the same or even less physical assets is achieved.  

Next, reliability excellence leads to increased customer satisfaction. Customers want - and demand - reliable suppliers of products and service. Late or missed orders and shipments create distrust in the supplier. On the other hand companies with reliable facilities and processes consistently deliver high quality products and services on-time...  each and every time. These companies become the preferred supplier - for life.

Finally, reliability excellence improves employee morale. Unreliable equipment and processes cause disruption of normal work and lack of confidence in the company. Employees prefer to work with equipment and tools that are reliable and dependable. It makes both their work life and personal life more predictable and enjoyable.

The OPEX Reliability Excellence Assessment identifies strengths, trends and opportunities for improvement. We use Lean and Six Sigma and Lean techniques - including equipment downtime and cost analysis, field observations  and review of existing reliability programs, processes, policies and procedures, to determine areas for rapid improvement at your facility.



Topics Covered: 

Methodology: 


  • Maintenance and reliability organization
  • Production organization reliability effectiveness
  • Reliability improvement teams
  • Rotating equipment
  • Electrical motors
  • Stationary equipment
  • Condition monitoring
  • Time-based maintenance (PM)
  • Failure analysis
  • Inspection program
  • Maintenance planning & scheduling
  • Shutdown planning, scheduling and execution
  • Electrical & instrumentation systems
  • Maintenance and reliability training
  • Procedures and standards
  • Equipment record-keeping and documentation
  • Analyze reliability data to identify opportunities
  • Identify opportunities for improvement
  •  Review existing reliability programs and processes
  •  Review and visit site locations
  •  Meet and get input from key personnel
  •  Identify key reliability drivers
  •  Develop Achieving Reliability Excellence plan
  •  Present and issue final report
  •  Assist in implementing plan
  •  Assessment of strengths and opportunities for improvement
  • Comparison of company practices with industry "Best Practices"
  • Specific recommendations for improvement
  • Written report and presentation to management
  • Assistance in implementing plan

Deliverables: 

  • Assessment of strengths and opportunities for improvement
  • Comparison of company practices with industry Best Practices
  • Specific recommendations for improvement
  • Written report and presentation to management
  • Assistance in implementing plan
 

Proven Results:

OPEX has the demonstrated experience and ability to significantly improve your companies reliability performance.

Testimonial: 

“OPEX conducted a Reliability Excellence Assessment at one of our major plants to evaluate the existing reliability and maintenance performance and culture. OPEX identified opportunities to further strengthen our reliability performance. These included streamlining and strengthening the reliability organization, improving our Root Cause Failure Analysis process and positively impacting our rotating and stationary equipment maintenance procedures and performance.

-  John C. Day

V.P. Environmental, Health,
and Safety

Henry Company

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