Is your plant a top performer?
To qualify as a top performer, studies show you need
- Unplanned downtime less the 3%, and
- Maintenance cost less than 2% of asset replacement value.
A global study of reliability practices by Solomon Associates measured maintenance costs as a function of asset replacement value. If a top-performing site spends 10 million dollars per year on maintenance, a poor performing plant will spend more than three and one half times.
Get your free copy of Emerson’s whitepaper “Achieving Top-Quartile Reliability Return”
- Are you trying to cost cut your way to reliability?
- Poor performers have high cost with low reliability
- Best performers achieve high reliability at low cost.
Reliability is not a “maintenance” issue. It’s a “business” issue.
Combining predictive intelligence and a forward thinking reliability program, you can drive down maintenance and inventory costs as you are improving safety and availability.
By reducing scheduled and unscheduled downtime, companies can reduce their maintenance spend by 50% or more. – Solomon Associates.
Recently we were asked to help a Fortune 500 company.
The company was experiencing multiple failures on air handlers that supply air for a critical sanitary process.
Failure of the air handing systems causes a loss of expensive product ….. not to mention the room requires re-cleaning to meet FDA standards.
The company was using route based vibration monitoring, but this meant most of time the air handler was not monitored at all.
The customer wanted to investigate the value of continuous online monitoring on the air handler. The base solution included wireless vibration and temperature measurements of the fan bearings and the motor.
During the pilot test period, before the system was fully implemented, a spike in bearing temperature caused an alarm. The plant reliability group notified operations to reduce fan speed immediately and the plant avoided a catastrophic and costly failure.
This single “prediction” resulted in a cost avoidance of $100,000.
With an investment of $25,000, the payback was immediate, even before the solution was fully implemented. Get your free copy of Emerson’s whitepaper “Achieving Top-Quartile Reliability Return”
Change the Culture
Transitioning to a proactive reliability culture can prove challenging.
Accepting a new and unfamiliar approach to an activity you have mastered can prove difficult.
Getting everyone to change at once is even more difficult.
The Reliability Game® from Emerson is a fun way to create a common understanding for your reliability business goals.
It is a learning environment that teaches you how to transition from reactive to a proactive maintenance strategy. By letting players from different departments interact, the game lowers resistance to change and the players often emerge with enthusiasm and the knowledge of a better way to work together.
Many Fortune 500 companies have successfully used The Reliability Game®
You will learn:
- The financial opportunity associated with proactive maintenance
- Where the money goes
- How to stop wasting money
- Boise Paper
- Bristol Myers Squibb
- Bruce Power
- Cleveland Cliffs
- DCP Midstream
- GE/Bently Nevada
- Johnson & Johnson
- Mittal Steel
- Owens Corning
- Salt River Project
- Texas Genco
- TXU Mining
- Westar Energy