Asset Reliability Advice

Last couple of years we have seen a number of great success stories from companies that adopted asset reliability as a full process (including various supporting processes) and increased company output and earnings in a sustainable manner.
Others have made at least steps to identify and react on production interruptions and serious threats on company performance.

However in quite a number of companies (in particular smaller and medium size) the role of asset management and processing effort is still considered just a cost and should be reduced as much as possible to ensure company profit. Regularly this “cost-cutting” only results in higher cost, lower production and even loss of company earnings overtime.

Why is that? Curious about the reasons I picked up a number of remarks and assumptions, from maintenance people as well as non-maintenance people, around this subject. But to be honest in most cases these are mainly excuses not to act.

Some examples (but there are way more):
Remark 1:
“We are too busy fixing day to day problems to be able to spend time on Reliability”
Fact:
  • One of the main goals of Reliability is to AVOID day to day problems, and this is NOT only on technical issues like failing processes or machines but also for lagging procedures and communication between departments.
  • This is why Reliability is not just a maintenance thing but includes all functions and all levels in the organisation.
  • Moving from preventive to predictive to pro-active maintenance requires to look outside the box and investigate and invest in new processes and procedures and relentless following these.
Remark 2:
“Reliability is a maintenance thing, they need to fix problems as soon as possible”
Fact:
  • Reliability starts with wel designed processes and assets, capacity and asset capability must fit.
  • These assets and processes must be installed correctly, to make optimal use.
  • The processes as well as assets must be treated according specs, deviations must be reported and handled as soon as possible to avoid unexpected breakdown
  • Maintenance must maintain these assets in the best technical way to ensure possible functional failures are avoided.
  • So Reliability is a process where all departments are involved and have their own responsibility.
Remark 3:
“We do not have funding for expensive projects and possible improvement actions” and “You need a big, expensive consultant company and a project team to implement a Reliability Project”.
Fact:
  • Yes - Reliability implementation and related actions will require a form of investment. The best option is to investigate (through evaluation of the current situation) where the best short term opportunities are, the “low hanging fruit” and focus there.
  • This will benefit, build trust, and could help to reach next goals and levels of reliability.
  • Start with the end in mind but focus on the easy gains.
And NOT TRUE,
  • Reliability must come from inside. This can start with some guidance and support but the main part must be done by the own team anyway.
  • To start this process the required knowledge (and the WHY) is most always already in-house. The most difficult step is to make clear HOW to approach.
  • And Yes, most consulting companies can help you with a start but the actual work must be done by you and your team.
Remark 4:
“You need to have a pool of dedicated resources to implement this, e.g. reliability engineers, project managers, etc”.
Fact:
  • The first step is to raise awareness, Reliability is not a project but a change process to ensure Reliability becomes a Culture in the organisation.
  • This also means that people involved are the same already involved in the day to day processes. They cannot be told to change, this must become part of their job.
  • Actually the main issue is not WHAT must be changed but more HOW the process can be optimised.
  • It will require training (as an investment) and a step by step approach with focus on success stories and improved efficiency.
Remark 5:
“It will take years to get some benefits out and we do not have time to wait”
Fact:
  • One of the goals in the action plans will be to identify and react on the most efficient actions/benefits (the low hanging fruit) and build success stories. This will also build trust, involvement and positive attitude.
Remark 6:
“We are already reliable, at the moment we do better than our competitors”
Fact:
This is one of the best….
  • Stick your head in the ground and expect nobody to change so you will remain the best.
  • Your competitor will also focus, if not already done, on a next level of reliability to be more competitive. No time to waste if you do not want to be at the end of the line in the next period (which will come sooner than you can imagine)
  • And remember just following a “continuous improvement” project does not give you a True Reliability Culture.
Conclusion:
So to answer the question I started with…. is a 100% YES, implementing Asset Reliability is worth while to spend time and effort on.
Also for smaller or mid-size companies it really makes sense to evaluate their existing situation and use a “True Reliability” approach to set a solid foundation for improvement steps on overall performance, optimise output, cost and plant revenues.

The basis:
- a vision for the future and management involvement, local ownership is mandatory for succes.
- clear roles and responsibilities, ensure all functions are involved
- evaluate the current situation and identify opportunities with the most easy benefits to be captured.
- set priorities and measurements to show progress and ensure involvement of all functions
- Involve all functions (management, engineering, procurement, manufacturing, QA, EH&S, maintenance, spare-parts inventory)
and
- realise this is not a project with a begin and end date but a way of life and a Culture to be adopted

This requires belief and commitment from management and relentless effort from everyone in the organisation.
But realise the benefits will be huge.



Berend J. Lindeman, Maintenance and Reliability Expert at “Asset Reliability Advice”
For more info contact me at: info@assetreliabilityadvice.nl
Find more on my website: https://www.assetreliabilityadvice.nl