Day 1

The Business of Plant Reliability Management

• The secrets to building wealth, satisfy your customers, and beat your competitors with reliability

• What the Board of Directors and C-level executives need to know about plant reliability management and why it’s important

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

• Compare value-destroying companies to lean asset managers

• The four variables of plant reliability that measure management effectiveness

• How to leverage availability to increase earnings

• How to use strategy to meet unfulfilled demand

• How to connect plant reliability management to your income statement and balance sheet

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

• How to connect plant reliability management to value-based management and executive compensation plans

• Lean Manufacturing: Your process won’t flow if your machines won’t go

• How the 5S System will improve your company

• The four root causes of reliability program break-downs

• How the perception of risk drives reliability investments

• How to align design, operations and maintenance 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

• Principles of total productive maintenance

• 23 words and phrases that characterize transformation to reliability-focused plant management

Plant Reliability Management Tool Kit

• The four components of the Failure Pyramid

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

• Why preventive maintenance is not necessarily proactive

• Understanding failure rate and mean time before (to) failure

• Building on the foundation of reliability engineering

• How to use Weibull Distribution to uncover time dependencies in failure rate

• How to map your threats and opportunities with reliability block diagrams

• Proven strategies for increasing reliability

• Your reliability diary: how to write a living document to improve the bottom line

• 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

• Field data collection: Top 10 things you must collect

• How to create a data collection system

• 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

• The key to the reliability map: people + systems = success

• How employee motivation and job satisfaction are key to your reliability initiative

• How to connect skills management to procedures and outsourcing decisions

• The power of an educated workforce and how it affects plant reliability

• How to quantify the benefits of reliability investments

• How to calculate the risk-based cost of a failure

• Unbiased group decision making – The Delphi Method

• Plant reliability management case studies

Day 2

Design for Reliability

• Why poor design results in poor operability and maintainability

• A new, communications-based model for plant and equipment design

• The critical elements for your systems checklist: electrical and mechanical

• Top five benefits of designing for maintainability

• How to optimize life cycle costs

• How we reward design teams to compromise reliability, operability and maintainability

• 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

• How to avoid common mistakes associated with involving the operator in reliability

• Six steps to managing 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

• The role of maintenance on productive output

• How reliability-centered maintenance can save you money

• Rationalized preventive maintenance

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

• 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

• How to properly manage parts and spares at your facility

• Maintain for reliability case studies

Devising and Implementing Your Lean Plant Reliability Management Strategy

• How to a create successful cultural change game plan for at your company

• 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 manage culture by creating systems that enable people to succeed

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

• How to make the reliability initiative last

• How to implement metrics for plant reliability management