Reliability Training

Brief.  Most of the top industrial companies in the U.S. are implementing reliability and operations excellence programs.  The reliability wave started about 10 years ago and is growing exponentially.  AF view of a World Class reliability program centers around our Reliability Triangle and the Reliability Circle shown in our icon entitled, “What is Asset Reliability Management (ARM) and Why is it Important to You.”  To summarize, ARM is implemented using the 3 legs of the Reliability Triangle:

  1. Do the right work – there are not enough resources to do everything
  2. Do the work right – planning, scheduling, craft skills, contractor management,inventory management, among others.  How is your scorecard here?
  3. Continuous Improvement (CI) – the evaluation of failures and incorporating lessons learned to prevent failures from recurring.

Most major companies have put a new position in place called Reliability Leader or Manager.  In addition, the term Operations Excellence is used.  The key is to develop "thinkers" with a goal of increasing asset reliability and maintaining it at an optimum level year after year. Their responsibilities are to manage plant reliability with a focus upon reducing downtime, safety and environmental events and reducing maintenance costs.  Advisory First has taught reliability courses to many managers and supervisors and has developed a course tailor-made for the newly selected Reliability Leader.  The course reveals time proven methods to evaluate reliability and how to take effective actions that will impact your bottom line.  Give us a call and we will discuss this very important topic in greater detail.

Benefits.  The wave of the 21st century is to optimize production at minimum cost.  For this to be accomplished, the plant must move out of the “Reactive Zone.”  AF Benchmarking Assessments indicate that the average U.S. plant performs 50-75% of all maintenance in the reactive mode; i.e., after asset or equipment failure.  AF defines a “Proactive Zone” where 60-85% of all maintenance is performed prior to asset failure.  Plants who enter the Proactive Zone are World Class with profits in the top 10% of all plants in their industry sector.  Less than 5% achieve this.  AF does not believe this can be accomplished without a strong reliability program. 

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