Reliability means your roster of assets are available and performing how they’re supposed to, for as long as possible. When you invest in assets that aren’t performing, you waste resources and lose returns. Having an effective reliability program makes financial sense even before accounting for the costs of reactive repair or potential replacement of machines that have been run to failure.
A roadmap to success for reliability should correspond precisely to your organizational direction. If you’re serious about long-term returns, optimizing production values, and minimizing reactionary capital flows, then maintenance is the key. As professional reliability practitioners, we know what drives success and it’s built on foundational knowledge and personnel at all levels driving reliability best practice. We build this core organizational strength around the four pillars of reliability.
Improve Organizations for Reliability
Creating a productivity-centered work environment requires a core understanding of the importance of reliability at the leadership level. Naturally everyone wants reliability, the assurance that equipment will do what it’s supposed to when it’s supposed to for as long as possible, but not everyone is aware or committed to implementing the strategies to deliver that reliability. The right training equips those in leadership positions with the knowledge to drive reliability and consistency in their organization.
Building Reliable, High Performance Teams
High performance teams that adhere to professional reliability standards build organizations and working environments where reliability is an assured constant rather than an afterthought when something’s gone wrong. These teams have an understanding of how machine and process reliability is ensured and can instill this throughout the organization. At Reliability Solutions, we help develop leaders of professional reliability teams through a number of highly targeted training courses.
Introduction to Reliable Manufacturing
Consistent asset availability driving consistent and sustainable profits is the goal for organizational leaders. To deliver that, leaders need to understand how reliability happens, which we explore through identifying industry best practice, teaching effective measurement methodologies and providing practical real-world tips.
Manufacturing Reliability Boot Camp
The formal education most in leadership positions receive may do little to inform them of the practicalities of a technical workplace. We aim to solve this divide by giving anyone a solid foundation in what “good” reliability and technical practice looks like. Participants in this hands-on, professional reliability bootcamp will also return equipped with hard skills and a capacity to perform their own observations of process reliability.
Essential Reliable Manufacturing Skills & RMIC Certification
Equipping your organizational leaders with greater skills through professional reliability and maintenance training delivers greater value for your business through enhanced assessment capacity, earlier identification of issues and implementing more effective processes. Over 18 months, targeted classes provide technical information and hands-on project experience to level up your reliability leadership. This is confirmed through the Reliability and Maintenance Implementation Certification they receive upon completing their training.
Improve Precision Maintenance
Your organization needs professional reliability personnel that can implement strategies advancing your roadmap to success. This pillar is focused on improving the hard skills and capabilities of the craftsmen and mechanics engaged directly with maintenance. Becoming best in class doesn’t happen overnight but hyper-targeted training in the areas that make a difference will deliver results and empower your maintenance teams.
Achieving Precise and Reliable Equipment Performance
This set of courses focuses on equipping your maintenance and reliability technicians with an understanding of how critical equipment and processes work, the knowledge to identify issues, and the hard skills to resolve and maintain equipment at peak performance.
Essential Craft Skills Assessment
Discovering where gaps exist, or where hard skills can be improved, requires effective assessment of the current capabilities of your teams. Your ability to maintain asset reliability and overall productivity comes down to their capacity to implement strategies, so this course gives you a baseline of where you’re at and where you can move forward.
Implementing Precision Maintenance Workshop
An intensive 2-day session designed to get to the root of what Essential Craft Skills are and how they apply to teams and individuals. The course outlines KPIs, expectations and timelines that define industry best practice and guide professional reliability teams in strategies for achieving those aims.
Essential Craft Skills Core Proficiencies
Upskilling maintenance teams to understand machinery failure and implement best practice reliability principles happens through combining theory with hands-on practice. This course sees technicians work through the logic and practicalities of motor, pump, gearbox and power transmission lifecycles.
Assembly and Installation
As much as 70% of equipment breakdown and downtime comes from a number of common faults and errors. This course looks at developing strategies and hard skills to address and reduce these.
Bearings and Lubrication
This course focuses on two of the most important elements contributing to equipment failure yet are so basic they are often overlooked. Participants are trained to reduce downtime and improve reliability through guaranteeing core reliability.
Pumps and Pumping Systems
Helping your technicians to identify and understand various pump types and what they do and require in different contexts. Being such a critical element of many industry processes having intense knowledge of pumps and how to identify and solve common issues helps your maintenance teams drive reliability.
Instrumentation & Electrical: Core Proficiencies
With instrumentation and electrical control systems so critical for industrial processes we dedicate three courses to giving craftsmen and mechanics the hard skills they need to ensure production reliability. This course focuses on teaching about fundamental techniques like precise measurement and effective installation of components.
Instrumentation & Electrical: Installation and Maintenance of Control
Following the roadmap to success for reliability standards means having the capacity to install and maintain critical instrumentation and control systems. These systems manage processes and help identify reliability issues. This session uses custom simulators and models to deliver practical, hands-on training in installation and maintenance.
Instrumentation & Electrical: Troubleshooting Motors and Motor Circuits
The third session of this section on instrumentation and electrical systems provides a data-driven look at what drives peak performance, demonstrating how static and dynamic measurements can guide the roadmap to success and ensure optimum process reliability.
Fluid Power Systems
This course gives technicians knowledge of the principles of fluid power dynamics, why fluid and pneumatic assets fail and shows them best practice techniques to identify and prevent failure using dynamic measurement tools.
Improve Operator Care
Your machinery operators are at the coalface of all of your industrial processes so they have detailed and real-time knowledge of how they are functioning. This puts them in a great position to contribute to your reliability roadmap to success by equipping them with the capacity to perform machinery inspections, contribute to reliability inspections, perform effective reporting and proactively assist in problem-solving.
Optimizing Industrial Processes for Enhanced Reliability and Efficiency
The machine operator role can see high turnover in personnel, so our courses are designed to create a standard operating model that makes it easy for new hires and existing employees to add to their skills and contribute to your reliability success through targeted training.
Essential Operator Care Assessment
Having a detailed understanding of the existing knowledge level of your asset operators allows the creation of better individual and site training plans that can be focused on your actual needs.
Implementation Workshop
Bringing operations teams into the maintenance mix broadens your organization’s knowledge and creates a first line of defense for reliability. We have created an Essential Asset Care (EAC) series to provide operators with the knowledge and hard skills to be reliable assets. The EAC has four phases: asset operation and troubleshooting, equipment inspections, minor equipment adjustments, and front-line failure analysis and logical thinking.
Reliability & Inspection Fundamentals
Operators being able to correctly identify various issues with their machines can only happen if they properly understand what those issues might be. This course delivers foundational knowledge of poor operation practices and improves reliability through improving knowledge of best practice and asset management.
Effective Reliability Rounds
The Asset Strategy Development (ASD) process helps to identify past failures and the failures most likely to happen in the future. Training your operations teams in ASD gives them a science and experience-based toolkit to deliver greater asset care.
Improve Condition Monitoring
Keeping your assets at optimum condition means they are operating at peak productivity and delivering the best possible returns for your investment. At its most obvious reliability is about preventing costly equipment failure and downtime but poor machine condition can also translate to sub-optimal production and quietly lost revenue.
Proactive Solutions for Industrial Asset Health
This pillar of your roadmap to reliability success focuses on building a condition monitoring program that uses all available data points and best practice strategies to identify failure patterns in your assets. These condition monitoring techniques ensure greater time at optimal operation levels and reduced downtime and potential catastrophic failures requiring equipment replacement.
Prediction Techniques
The most effective prediction for equipment failure brings together as much data as possible, including past machine data, current operator reports, maintenance team inspections and technology such as infrared surveying.
Understanding Data
Collected data is only as useful as the context it is put in and how teams translate this knowledge into action. This involves data gathering techniques and training in how to best use that information in relation to your specific asset roster.
Parameter Estimation
Understanding asset conditions is also going to be relatively unique for your particular facility and environment. Establishing baseline values for machinery operation and building a dataset of acceptable and optimum parameters gives all future maintenance technicians a clear roadmap to reliability success.
Conclusion
We believe that every organization can build a reliability program that drives organizational success and delivers the greatest possible returns on their assets. Our four pillars of reliability give personnel at every level, from executives through maintenance teams to machine operators, the knowledge to identify optimal asset conditions and the hard skills to implement best practice.
To find out more about creating your organization’s roadmap to success built on the four pillars of reliability get in contact with us here.
