POD5 - Reliability and Maintenance Excellence

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Overview

This POD is used to create a Reliability and Maintenance Excellence strategy that is intimately linked to the unique, high level needs of a business.

We combine the latest views on Total Productive Maintenance (particularly from Tokutaro Suzuki) and Reliability-centred Maintenance (particularly from John Moubray) to create a Reliability and Maintenance Excellence framework that can be cost-effectively applied to the process industry.

Big Client Questions

  • I have invested a lot of money in computerised maintenance systems (or standardised TPM programs and or standardised Lean programs) and training but how do I now prioritise the efforts of operations resources so that we can start making a step change in factory performance?
  • I reckon I need to train some of my really good trades people so they essentially become reliability engineers. Is there a way of doing this so that we get the focused skills without needing to send our key people on a degree program?
  • I understand that small failures can accumulate into a lot of downtime but how do I put that, and all the other data that comes from the maintenance area, into a broader business context?
  • Autonomous maintenance seems to be the big buzzword. What does that mean in a high-technology processing environment and how can we navigate some of our historical industrial issues to make this happen?
  • How would pursuing Reliability and Maintenance Excellence affect my continuous improvement effort?
  • I'm told my maintenance system is cutting edge but how do I stop the incessant supply interruptions which, seem to me, to be equipment related?
  • I have purchased a packaged continuous improvement program that refers to input from an operations research specialist. Where do I get that help?

POD Contents and Useful Business Insights

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Client Commitment

This work must be sponsored by the Plant Manager otherwise it won't work. This is because the Bullant Reliability and Maintenance Excellence framework must be interweaved through many existing systems including Plant Scheduling, Continuous Improvement, Production and Plant Services. These systems don't necessarily need to be modified but the pursuit of Reliability and Maintenance Excellence will mean that these areas will need to be influenced for there to be sustainable change.

We have designed our framework so that it is fully customisable. This means that the implementation strategy can be adjusted to the client's needs, according to resource availablity and business priorities.

In any case our approach is to identify a key evangelist, sanctioned by the Plant Manager, who will be trained and coached to pursue Reliability and Maintenance Excellence. The Evangelist is usually the Reliability and/or Maintenance Manager.

Bullant Capability

Generally, Bullant take on a full coaching role with the Evangelist within the context of a governance process overseen by a sponsor, the Plant Manager.

The top level of the Bullant Reliability and Maintenance Excellence framework is shown below and it is the basis on which progress towards excellence can be measured.

The power of this framework is that it is driven from left to right which is different from more traditional, standardised training approaches which are usually driven from right to left.

In this way we make sure that all the detailed work (which is usually already happening i.e. right to left) can be driven by the priorities of the broader business (i.e. left to right).

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