Day 1

The Business of Plant Reliability Management

• What corporate and plant leaders need to know about plant reliability

• A clear explanation of how reliability affects the income statement, balance sheet and share price

• How to find profits in the “Commodity Sandwich” and the hidden plant

• How to beat your competitors and satisfy your customers by improving reliability

• How to quantify the benefits of plant reliability

• Creating proposals for reliability initiatives: what works

• Reliability in the economic value added equation and why the Lean Asset Manager always wins

• The critical connection between lean manufacturing and plant reliability

• How the perception of risk drives reliability investments

• How to align operations, maintenance and design to the same vision for plant reliability

• The strategic and functional domains of plant reliability management

• Why you can’t just buy reliability and how to reengineer your business processes

Plant Reliability Tool Kit

• Why preventive maintenance is not necessarily proactive

• How to build on the foundation of reliability engineering

• How to use weibull distribution to uncover time dependencies in failure rate

• Foundational strategies for increasing reliability

• Six controllable operational and environmental elements that help extend service oil life

• How to build your standardized taxonomy of failure modes

• Understanding root cause analysis – a proven improvement tool

• How to conduct RCA and the seven best identification categories

• How to evaluate time to failure – mode by mode

• How to guard against “corporate amnesia” with procedure-based manufacturing

• How plant operating and maintenance procedures drive consistency, continuity and skills management for best practice

• 7 enablers to make “people + systems = success” work

• Three project evaluation methods: when and how to use them

• How to connect skills management to procedures

• Ammunition for getting workforce training proposals accepted

• Unbiased group decision making - it’s easier than you think

• Plant reliability management case studies

Day 2

Design for Reliability

• Why poor design results in poor operability and maintainability

• 27 point checklist for designing electrical systems for reliability

• 42 point checklist for designing mechanical systems for reliability

• Ways to stop design teams from compromising reliability, operability and maintainability

• 26 principles of designing for maintainability

• Best practice design for reliability case studies
  

Operate for Reliability

• How to increase availability with single minute exchange of dies

• How to reduce changeover time and improve production

• Six steps for managing operator alarm systems

• How circadian rhythms affect human performance and operational reliability

• How to use reliability data to estimate the risk of disappointing your customers

• How to estimate the real operating risk for your plant
  
  Operate for reliability case studies
  

Maintain for Reliability

• How maintenance really affects productive output

• Eight RCM-based equipment maintenance strategies

• How to use precision maintenance to eliminate failures and ensure success

• The 10 most common precision maintenance pitfalls

• How to optimize the deployment of condition monitoring and condition-based maintenance

• How to power up wrench time with planning and scheduling

• Shutdown metrics: the top six KPIs to monitor

• Maintain for reliability case studies

Creating and Implementing Your Plant Reliability Strategy

• How to create a successful cultural change game plan

• The six most important players to have on your team

• How to survive organization change

• How to combat resistance to change, and win

• How to assess your strengths, weaknesses, opportunities and threats

• How to make the reliability initiative last

• How to implement metrics for plant reliability management