Asset Reliability Solutions
At a Glance
- Establish Asset Reliability Programs to lower maintenance costs and minimize downtime
- Apply Reliability Based Maintenance and best practices to develop effective and sustainable asset management programs
- Deploy Asset Reliability Programs across industry verticals through a global network of specialists
- Award-winning reliability tool for Asset Criticality Ranking to identify/prioritize most critical assets
Our Asset Reliability services are focused on two drivers at the forefront of every sector where we do business: higher reliability and lower maintenance costs for all key assets. Our other priority focus is people—whether in operations, maintenance, quality, finance, or systems—those who are key stakeholders for asset reliability. Our processes include collaboration through teams to facilitate reliability improvement.
We recognize that one size hardly fits all. Some of our customers have well-developed programs and workflows and want to move up to another level of performance. Others want to improve performance by adding an element to their program. Our team will work carefully with yours to first understand your unique needs and then develop an implementation plan with clear tasks, milestones and deliverables.
Services to Optimize Asset Integrity and Reliability
Our Asset Reliability Program has been deployed around the globe across industry verticals. When fully implemented, the following elements constitute a global best-practice Asset Reliability Program: Computerized Maintenance Management System (CMMS) Utilization, Inventory Management, Organizational Readiness, Performance Optimization, Reliability Strategy and Work Management. To help our customers improve asset performance and reliability, we provide a full suite of services:
Our service model is built on a risk based approach to optimizing asset performance management strategies. To quantify the risk profile across a broad range of assets and facilities, we have developed a robust Asset Criticality Ranking (ACR) tool which was awarded the 2015 Solution Award for Reliability Engineering. Our ACR tool is used to rank assets based on their criticality to the business or operation. Product deliverables include:
- Evaluation of how asset failures impact organizational performance
- Provision of detailed profiles of characteristics that makes each asset critical
- Allowance for systematic ranking of assets for prioritization efforts
Our comprehensive Enterprise Asset Management (EAM) Master Planning process involves applying a DMAIC approach (Define, Measure, Analyze, Improve and Control), which is a Six Sigma quality management tool. We can assist your maintenance organization with EAM master planning using our continuum chart showing progression through the following operating states toward a state of continuous improvement: Reactive (repair after failure), Planned (repair before failure), Predictive (measure and repair), Reliability (not only repair, but improve) and Enterprise (improve and sustain).
The purpose of FMEA is to provide a structured, rigorous method to identify asset functions, asset functional failures, failure modes that cause functional failure, failure effects, and the proper course of action to avoid or reduce failure effects. GenesisSolutions incorporates FMEA as a tool within the Reliability Based Maintenance (RBM) process, using RCM processes compliant with SAE JA1011/12. By linking use of FMEA to asset criticality, RBM is proven to save time and money during asset care strategy development, while providing exceptional risk mitigation. Use of FMEA within the RBM process ensures maintenance strategies are always linked to plausible failure modes, resulting in a lean, focused, yet comprehensive, asset care program that serves effectively to mitigate or avoid the effects of failure.
Asset-intensive businesses must know which work orders to address first at any given time. Reliability based maintenance (RBM) can only perform at its peak when the reasons for a specific repair is clearly outlined and properly ranked along a work order continuum. This ensures uptime remains of the utmost priority throughout all RBM activity. As a first step, we can help you develop a Master Asset List (MAL), or comprehensive catalog of every asset within your organization that is critical to operations. These accounts can help everyone from operators to executives better comprehend the full magnitude of how their high performing assets function. Next, we can assist with Asset Criticality Rankings, an underlying value metric within an asset hierarchy. Learn more about our ACR services listed above.
The maintenance, repair and operating (MRO) supply chain is a complex web of interconnected companies, business processes and physical storerooms–all designed to supply the right spare parts at the right time in the right place. The supply chain offers many opportunities for performance and cost improvement. We can help identify opportunities to lower the total cost of ownership for MRO items. Our reliability team can provide assistance in the following areas: strategic sourcing and supplier rationalization, business process re-design, supply network analysis and re-design, stores inventory optimization, MRO data normalization, supplier performance management and MRO inventory management.
Cost reduction opportunities in the MRO supply chain can be significant. We typically see a 20% cost reduction opportunity between leading-edge practices and unoptimized conditions.
We have decades of experience building, operating and improving planning and scheduling processes and the elements that support it. Our reliability professionals bring cross-industry best practices and a methodology to educate, train and implement operations and maintenance to achieve maximum gains. Our services include backlog management, work prioritization, outage planning, post-outage reviews and developing systems usage guides for improved asset maintenance and management.
Our reliability professionals bring cross-industry expertise to preventive maintenance (PM) optimization. Our approach is to work closely with our customers' teams to evaluate all inputs to an effective PM program, including: OEM recommendations, failure history, operator logs and interviews, maintenance logs and interviews, spare parts usage, OEM parts usage, etc. We then enhance, modify and refine PM tasks and also incorporate predictive technologies to substitute for PM tasks whenever applicable and cost effective.
One of the most effective ways to improve critical asset reliability (uptime) and reduce maintenance cost is to change from fixed time maintenance to condition based maintenance. We have partnerships with leading organizations to provide a full-service predictive maintenance program, including technologies and proprietary software to track predictive maintenance performance, conduct problem analysis for critical equipment and perform real-time ROI analysis on solution alternatives. We can also provide certified field technicians to collect condition monitoring data and load these data into our software for analysis and reporting.
A predictive maintenance program can improve equipment availability, uptime, productivity, product quality and reduce cost, all at the same time. The reliability and cost savings are substantial (15-20% or more) compared to fixed-time maintenance.
Our reliability engineers are experts in applying a Reliability Based Maintenance approach using the following six steps: identifying and prioritizing critical assets, optimizing the PM program, analyzing spare parts, monitoring reliability analytics and performing a root cause analysis. Through RBM, we can help you determine the predictive approach that will deliver the most reliability for the least cost and evaluate existing maintenance programs to identify and eliminate non-value-added and intrusive tasks that contribute to downtime.
Through our parent company, ABS Group, we can provide a complete training solution for your organization's investigation and root cause analysis (RCA) needs. ABS Group offers training for root cause analysts, front-line supervisors supporting investigations and managers performing reviews. The Incident Investigation and Root Cause Analysis team has provided investigation and RCA training to more than 10,000 individuals through worldwide, multi-language public and onsite training courses and webinars. ABS Group also provides ongoing support through online resources, Root Cause Analysis Handbook and program support services.
Our Critical Asset Safeguard Evaluation (CASE) tool helps customers determine if their most critical assets are being managed to an acceptable level of residual risk. This applies to assets that have been newly installed and commissioned or legacy assets that have been in operation for extended periods. All assets have an inherent risk profile and our goal as reliability professionals is to determine if our existing safeguards adequately address the potential impact of those risks to health, safety and the environment, regulatory compliance, as well as specified business objectives.
One of the cornerstones of a leading-edge reliability program is a fully developed and streamlined spare parts program. We can help your team manage and optimize spare parts stocking and realign your parts usage and cost in these areas: bill of materials, surplus inventories, purchase costs, spot buys, obsolete inventory and storeroom operations.
We take into consideration the requirements of our customers' CMMS and integrate the appropriate data entry, review and measurements necessary to achieve the expected maintenance goals for workflow optimization.
The full benefit of EAM can only be realized if maintenance is effectively identified, planned, scheduled, executed and evaluated. We understand that all elements of work management must be functional for any to be sustainable. Our work management improvement process begins with assessment of current practices, which are captured in process maps that serve to illustrate specific opportunities relative to best practices. We then examine existing documentation, interview stakeholders, shadow personnel throughout the maintenance workflow and develop a master improvement plan based on proven best-in-class work management practices. This plan is tailored to our customers' specific business needs.
By providing a customized, lean, exacting approach toward realizing full organizational potential, we will work closely with your staff until the a sustainable model is developed and implemented.
Following master plan development, we are prepared to provide a full array of work management implementation support services, from remote consultation to fully embedding with your organization in a staff augmentation role, until your organization's work flows are optimized for maximum efficiency and profitability.