Corporate Operational Reliability Reliability Center, Inc. © Reliability Center, Inc. 1985-2002.
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Transcript of Corporate Operational Reliability Reliability Center, Inc. © Reliability Center, Inc. 1985-2002.
Corporate Operational ReliabilityCorporate Operational Reliability
Reliability Center, Inc.
www.Reliability.com
© Reliability Center, Inc. 1985-2002
Who is Reliability Center, Inc.?Who is Reliability Center, Inc.?
Began in 1972 as Allied Chemical’s Corporate R & D Reliability Center
Split off as an independent organization in 1985
Pioneered the industry standard, “Reliability Approach to Quality and Productivity”
Developers of the award winning PROACT® Software Suite including the New LEAP™ Opportunity Analysis Software
Providing flexibilty through common Reliability assistance, processes and training platforms worldwide
© Reliability Center, Inc. 1985-2002
A Glimpse at Our Customer BaseA Glimpse at Our Customer Base
Air Liquide
AK Steel
BP/AMOCO
Chevron/Phillips
Coors Brewing
Dominion Virginia Power
Dupont
Eastman Chemicals
Ecopetrol
Eli Lilly
International Paper
Lafarge
Lyondell-Citgo
M&M Mars
PECOM (Perez Companc)
PDVSA
PEMEX
PREMCOR
Shell Canada
Syncrude Canada
Chevron - Texaco
Whirlpool
© Reliability Center, Inc. 1985-2002
Reliability Program InitiativesReliability Program Initiatives
Program Identifies Action Result
RCM Critical Facility Equipment
Develop Preventive/Predictive Maintenance Program
Minimizes Consequences of Events to Critical Equipment
Six Sigma Cost of Poor Quality Determine Confidence Intervals and Hypothesis Testing Requirements
Project Statistical Model
Re-engineering Critical Job Positions and Key Personnel
Elimination of Non-Critical Positions and Personnel
Streamlines Organization to Fit Business Environment
Total Quality Process Variations and Critical Variables
Implementation of a Statistical Process Control Program
Reduction of Defects in Final Product
Root Cause Analysis Opportunities for Improvement
Focus on Priority Issues Using GAP and Opportunity Analysis
Eliminates Risk of Problem/Event Recurrence
© Reliability Center, Inc. 1985-2002
Eliminating the risk of recurrence of undesirable outcomes
Here’s how you start...
PROACT® SystemPROACT® System
© Reliability Center, Inc. 1985-2002
Calculate the "Gap” using FMEACalculate the "Gap” using FMEA
PRECISION
Status QuoStatus Quo
Continuous Improvement
Human RootsAddressed
(Disciplinary Action)
Physical RootsAddressed
Untrusting workforce
Latent Roots Addressed
Problems
© Reliability Center, Inc. 1985-2002
Your targets are now highlighted…This is your money leak!Your targets are now highlighted…This is your money leak!
0%
10%
20%
30%
40%
50%
60%
% of Loss
Failure Events80% of loss
PSM - Problem Solving Methods
RCA - Root Cause Analysis
20% of loss
© Reliability Center, Inc. 1985-2002
From your “Significant Few” findings split the eventsto be eliminated by the relevant RCI programFrom your “Significant Few” findings split the eventsto be eliminated by the relevant RCI program
Events
Principal Analyst Required Involves All Levels Part Time/Full Time
Root Cause Analysis Extremely Disciplined/
High Attention to Detail
Significant Few - 80% of Losses
Hourly/Supervisory Level Part Time
Problem Solving SkillsLess Attention to Detail
Random Many - 20% of Losses100% Coverage
RCA Methods
PSM
Advanced For Facilitators - Major Events
Problem Solving Methods - Minor Events
© Reliability Center, Inc. 1985-2002
The RCI Two-Track ApproachThe RCI Two-Track Approach
Root Cause Analysis Methods© (RCA) Advanced Facilitation Methods for Major chronic event elimination
Problem Solving Methods© (PSM)Chronic event elimination at the supervisory and front line level
The Reliability Performance Process© (TRPP)Managing Reliability Systems for Executives
© Reliability Center, Inc. 1985-2002
The Supporting Software forRCI’s Reliability SystemsThe Supporting Software forRCI’s Reliability Systems
LEAP™ SoftwareOpportunity Analysis
(OA) Process
+PROACT® Software
Root CauseAnalysis (RCA)
=Best Practices and
Lessons Learned Database
1 2 3 4 5 6 7 8 9 10
Priority Work Identified
20%
© Reliability Center, Inc. 1985-2002
PROACT® Enterprise VersionPROACT® Enterprise Version
Produces Quick and Quantum ROI’s
Establishes Knowledge Management System forCorporation to Share Successful Logic Trees
Used to Eliminate Failures
Develops World Class Analytical Skills
Results in Drastic Cost Savings and Improved Performance
Ensures Regulatory Compliance
Significantly Reduces Cycle Times to Conduct Root Cause Analyses
Benefits:
© Reliability Center, Inc. 1985-2002
The Basis for your Knowledge Management & Best Practices Transfer NetworkTie-in to your existing CMMS, ERP, EAM systemsThe Basis for your Knowledge Management & Best Practices Transfer NetworkTie-in to your existing CMMS, ERP, EAM systems
Desktop Version
Single-User
VS Enterprise Version
Network (SQL/ORACLE)
Brazil
Argentina
Mexico
Server
Venezuela
Enterprise Version
Enterprise Version
Enterprise Version
© Reliability Center, Inc. 1985-2002
Unfortunately, most companies do not allow the results they achieve to be published…but these did!Unfortunately, most companies do not allow the results they achieve to be published…but these did!
“Root Cause Analysis: Improving Performance for Bottom-Line Results” Latino & Latino, 2002, CRC Press, Boca Raton, FL, ISBN 0-8493-1318-x(See Case Studies in Chapter 11)
Eastman Chemical (World Hqtr.)50% Reduction in Customer Complaints
Weyerhaeuser25% Increase in Prod. Capacity
LYONDELL-CITGO17,900% ROI
(ISPAT) Inland Steel4,000% ROI
Eastman Chemical (TED)3,200% ROI
Alabama Power3,125% ROI © Reliability Center, Inc. 1985-2002
Maintain
Conduct RCA on High Return Event With Trained Team
Demonstrate ROI’s To Fund RCA Effort
Correlate RCA Objectives with Corporate Key Performance Indicators
Establish Performance Target
Set Up Management Support Structure
Train & Roll Out To Analysts
Prove Effectiveness
Keep It Up
How to start and fund your PROACT®Corporate Reliability ProcessHow to start and fund your PROACT®Corporate Reliability Process
Pilot
RCA
Provide
ROI
Establish
KPI’s
Develop
GAP
Set Up
Support
Roll Out
Track/
Measure
© Reliability Center, Inc. 1985-2002
Calculate your company’s savingsCalculate your company’s savings
ROI
Now for the fun part!Click the ROI button below and put in your numbers (not ours.) You will be surprised at the reachable savings still to be had within your company.
(Click Here)
© Reliability Center, Inc. 1985-2002
SummarySummary
The average analysis from start to implementation using the PROACT® System is 5 weeks - 5 months.
RCI offers quick results generated from within your company, not by outside consultants. No massive capital investments or major man hour allocations are required.
In our experience, the elimination of one major failure utilizing RCI’s PROACT ® process will fund ALL of your Reliability Programs.
WARNING! The worst case scenario we see day after day is training of a few individuals and expecting corporate to move from Reactive to Precision Based Reliability.
We invite you to visit our web site at www.reliability.com. There is a gold mine of information for you. If you are serious about a corporate change in your organization regarding improvements to your bottom-line we look forward to hearing from you. Contact Norman Haggie at804-458-0645 x311 or [email protected].
© Reliability Center, Inc. 1985-2002
Thank you for your attention!Thank you for your attention!
Reliability Center, Inc.www.Reliability.com
804-458-0645
804-452-2119 [fax]
501 Westover Ave.
Hopewell, Virginia 23860
© Reliability Center, Inc. 1985-2002