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11:00-11:50am
How to Sell Maintenance Improvements
to Top Management - Case Studies on
RONA and Reliability vs. Maintenance
Improvement Initiatives
Tor Idhammar, IDCON
Many maintenance improvement initiatives fail to
deliver sustainable results because they lack long-term
support from inpatient top management and/or follow-through on the improvement initiatives by maintenance
management. This presentation will review case studies
and teach you how to talk the financial language to
change this phenomenon.
1:30-2:20pm
Foundational Elements for Relentless
Process Leadership
Rick Baldridge, Cargill
Effective reliability programs demand relentless process
leadership. In this session, you'll learn what it takes to lead
a plant team and the core foundational elements that must
be in place for success. Performance indicators, leadership
vs. management, asset criticality, timelines and continuous
learning are among the key issues for discussion.
2:30-3:20pm
Turning Your CMMS System Into A Lean Tool
Kishan (Kris) Bagadia, PEAK Industrial
The presentation will explain how you can greatly reduce
waste, cost, inventory and inefficiency through more effective
utilization of your CMMS system. A recent survey by the
author showed that only 5.3 percent of respondents feel that
they are using their CMMS to its maximum capacity (the
other 94.7 percent say they aren’t). He believes that if optimized,
a CMMS can serve as a dynamic lean tool.
4:30-5:20pm
Talent Management for the
Plant Maintenance Organization
John Ha, Reliability Careers
“Get the right people on the bus.” You’ve probably heard
this popular phrase from the book Good to Great by Jim
Collins. But, how do you know if someone is “right” or not?
Can you transform or train a “wrong” person into the “right”
person? This session will focus on the process of identifying,
assessing and selecting the “right” people for your
organizations as part of an overall talent management strategy.
Whether it is a new hire or an internal reorganization,
John will walk you through each component so you can
make the best decision possible. Special emphasis will be
placed on behavior based assessments - the most significant
component of making the “right” hire.
8:00 - 9:50am
How Reliability Helps Drive Our Plants:
Views from the Top
Plenary Panel Discussion.
11:00-11:50am
How Reliability Affects Share Price
Drew Troyer, Noria Corporation
Reliability professionals understand the important benefits
that a well-conceived and effectively executed reliability
program creates for a manufacturing organization. But many
have trouble connecting the reliability processes they manage
to organizational goals that are familiar to senior-level
managers. In this presentation, you’ll learn methods for estimating
the financial contribution of reliability management
initiatives, how to create risk-adjusted pro forma financial
projections (sales, profit and loss, etc.) and how reliability
management affects the income statement, the balance
sheet and, ultimately, the organization’s share price.
1:30-2:20pm
How Coors Brewing Does
Planning and Scheduling
Mike Fognani, Coors Brewing Company
Coors Brewing Company emphasizes continuous
improvement, standardization and improved cost and execution
efficiency through a corporate-wide program called
World Class Operations. The maintenance organization plays
a key role in WCO. In fact, planning and scheduling routine
maintenance work is a critical process needed to achieve
WCO principles. Experienced planners and schedulers using
effective planning and scheduling tools and techniques have
allowed Coors sites to achieve substantial improvements in
reliability and equipment availability.
2:30-3:20pm
A Simplified Reliability Program
for Manufacturing Equipment
Bill Hagen, Ford Motor Company
Traditionally, the general thrust of R&M activities has
been limited to ensuring accessibility for repairs and various
preventive and predictive maintenance techniques. These
techniques are no longer sufficient to ensure effective and
efficient manufacturing processes. The combined effects of
cost reductions and lean manufacturing concepts have
reduced redundancy and extra capacity within manufacturing
systems making them less robust. Reliability and
Maintainability techniques drawn from aerospace, defense
and other high-availability areas were introduced into the
design process for a new automobile engine manufacturing
facility which would produce a similar product using similar
processes as an earlier facility. This comparison demonstrated
that the availability of heavy manufacturing equipment
could be improved using up-front techniques. The
project also revealed several of the more effective ways to
apply these traditional techniques to a new environment
where such techniques had not generally been applied
4:30-5:20pm
Implementing Reliability Excellence
at SMI-Steel South Carolina
Mike Garcia, SMI Steel
and Johnny Maldonado, LCE
This presentation steps through the process used to
Implement and achieve Reliability Excellence – specifically
as it was applied at SMI-Steel South Carolina. Described
within, is the Assessment Process, which is the indicator of
where the organization is presently in their quest for excellence
followed by the explanation of a Master Plan which
identifies the actions needed to improve overall reliability.
Also described is how to develop a Return on Investment
(ROI). It will describe the Change Process required to sustain
the effort as well as the organization structure requirements,
process rollout plans, and the Key Performance
Indicators that will measure the success of the initiative.
The presentation will also contain a case study of a fortune
500 company that has used this process and achieved
tremendous success.
8:00 - 9:50am
Movin’ On Up: Plant Managers
that Get Reliability
Plenary Panel Discussion.
10:00-10:50am
Build Your Own Reliability Professional
Steven E. Boardman and
Robert S. Hill, II,
The Quaker Oats Company
With a high turnover rate in salaried maintenance staff
and a demand to do more with less, the Quaker Oats Cedar
Rapids, Iowa plant had to step up. Exit interviews indicated
that there was no where to go in the maintenance
organization. To build bench strength in maintenance,
something had to change. In this session, you’ll learn how
Quaker Oats turned things around by creating clear paths
of progression, identified qualification and performance
standards, implemented training to coincide with the standards
and performed incremental evaluations of each individual’s
development.
1:30-2:20pm
Reliability Achievements in the
North American Steel Industry
Jack R. Nicholas, Jr., MQS LLC
This presentation will describe validated improvements
in reliability in the North American steel industry as determined
by awards made during the years 1999-2005 by the
Association of Iron & Steel Engineers (AISE) and the
Association for Iron & Steel Technology(AIST). The driving
forces that caused the projects to be initiated and some of
the obstacles overcome by the project teams in achieving
their goals will be discussed. Companies such as Dofasco,
Timken, USS Posco, US Steel Gary Works and Nucor will
be highlighted.
2:30-3:20pm
Academia’s Role in Maintenance
and Reliability Education
Thomas V. Byerley,
University of Tennessee
Traditionally, U.S. universities have shied away from
education and research in the area of industrial maintenance
and reliability. Although some institutions have
developed excellent capability in reliability statistics and
probabilities, there is a significant shortfall in the reliability
and maintenance knowledge and education of graduates.
As recognition of the importance of reliability and maintenance
within industry continues to rise, this fundamental
educational void is becoming more obvious and is raising
the question of how to deal with it. This session explores
the history of academia’s approach to maintenance and
reliability, along with recent trends in the academic world
that impact this void of education. It further explore the
current situation of academic offerings as well as delivery
methods. Finally, it will discuss various and appropriate
roles of both academia and industry in the world of reliability
and maintenance.
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