Reliability is NOT expensive.
Erik Hupjé
Escape the vicious cycle of reactive maintenance: less downtime, less work, lower costs and less stress
Would you believe me if I tell you that…?
Reliability is NOT that expensive as you might think it would be?
Hear me out.?
See, many people think that improving reliability and reducing maintenance costs is expensive. That it requires you to invest a HUGE sum of money upfront… for results in the distant future. “Before you can reduce maintenance costs, you first have to invest a ton of money”. “It’s a good investment down the line”.
“We have to start somewhere”.
Now, I can’t blame them.
Because this is what they usually see—
Expensive maintenance programs that don’t produce any obvious results quickly. No wonder plant managers see maintenance as a bottomless money pit—a necessary evil. They think reliability is something ‘miraculous’ that doesn’t happen in their plant.
And let me show you why.
For a long time, organisations improve reliability through BIG programs. A significant upfront investment followed by a multi-year improvement program.
Payback was long. Returns were always in the distant future.
We’ve all heard the message: It’s a marathon, not a sprint.
That is a hard sell. Especially in organisations that have lived with low reliability and reactive maintenance for a long time.
That is the old way.
It’s slow and expensive. Making it very hard to sell in an organisation where maintenance & reliability are not already a focus area.
A series of smaller, more focused improvements. With much smaller upfront investments and quick ROIs.
It’s easier to sell.
And easier to implement.
And that’s exactly how we encourage our clients to implement their journey to a Reliable Plant.
Not as a marathon, but as a series of ‘Reliability Sprints’.
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These reliability sprints are highly focused, shorter projects, or ‘sprints’, where we train and coach your team to implement key reliability practices and processes.
I recommend you start with what we call a “Reliability Strategy Sprint” to ensure you understand the Road to Reliability Framework and have the necessary tools to drive & sustain the change.
Once that’s in place, your next Reliability Sprint would be to implement Maintenance Planning & Scheduling using our ‘Tool Time Sprint’.
There are many more sprints to follow which I won’t go into detail here.
And if you get these sprints right…
All these in a shorter, more realistic time frame.
Now…
If this is something you’re interested in…
If you want smaller investments with many, quick, and obvious ROI over time…
If you’re tired of investing HUGE amounts of money for ‘promised results’ in the future…
Then schedule a call with me so we can discuss how we can help you implement this.
P.S. Whenever you're ready, here are 3 ways we can help you on your Road to Reliability:
1. Want to train your team on how to improve your plant's maintenance reliability?
Enroll your team in one of our most popular online training courses:
Implementing Maintenance Planning and Scheduling—increase your maintenance workforce by 35% without hiring anyone. Reduce costs, improve safety and increase morale.
Developing and Improving Preventive Maintenance Programs—achieve higher reliability and availability whilst doing less maintenance. Acquire the knowledge and tools needed to create a highly effective and efficient Preventive Maintenance Program.
2. Want to know how effective your Planning & Scheduling really is?
Use our Planning & Scheduling Scorecard?to assess your performance and receive a personalised PDF report with recommendations on how to improve.
Use our Wrench Time Calculator?to easily calculate how much value your organisation is missing out when you neglect your Planning & Scheduling.
3. Want to start your journey on the road to reliability?
Download the Reliability Academy eBook?and discover a simple, proven framework that you can use to achieve a highly reliable plant for your organisation. Unlike other overly complicated models that use 10 to 20 elements, the Road to Reliability framework only uses 4 elements to achieve great results.
Senior Electrical Engineer at Brunei Shell Petroleum I Technical Professional in Electrical & Reliability Engineering I Influencing Organizational Health & Safety Culture Improvements I PiP, IIF, OHR Leadership Coach I
2 个月An excellent article! Reliability improvement initiatives at many places more focus on blanket application of gold-plated processes & programs. This requires time and effort in application of the processes, particularly for existing operated assets. Key is really to have focused approach, focusing on critical systems & equipment and preventing high impact failures through improved preventive & predictive activities. Great example of small sprints as followed in IT projects; focus & fix big ones, learn & improve / standardize improvement to deliver better performance.
Improving maintenance and asset reliability to help industry achieve more for less via a structured asset management approach, assessments and training.
2 个月Reliability is not as expensive as poor reliability in terms of business impact
Innovative CEO @ PPCL | Chemical Engineering, 20+ Patents, Operating Envelopes Expert
2 个月We can predict the beginnings of failure by detecting changing relationships between variables that usually have closely related values and move together such as winding temperatures in a transformer, tray temperatures in a distillation column, temperatures along a tubular reactor. We send an Alert to the operator who can in turn Alert the SME to what may be a developing problem and can use his expertise to decide whether to schedule a repair in the normal flow of work or call out the emergency repair team now. In both cases reducing the chance of an unscheduled process shutdown (very expensive) or emergency breakdown response (very expensive) or even irreparable equipment damage in some cases involving rotating equipment. The super-sensitive monitoring software you need is called CPM. It is part of GPC and you will find it at ppcl.com. This will bring order and calm to your plant maintenance activity and give a better environment for considering longer-term changes to your reliability improvement program such as the methods Erik suggests.
Electrical Engineer
2 个月Reliability can be increased and costs can be reduced, as long as it is carefully checked before repairs according to the plan and postponed if possible.
Managing Director and partner at AMPs
2 个月Reliability comes with a cost and leave with a profit. Make sure it never leaves, and profit will repeat. ??