To the CEO, Exec & Manager who wants world class reliability, maintenance and operational excellence in their company
How to put Maintenance, Reliability and Operational Excellence into industrial operations
"Turns your company into a 'system-of-reliability' where world class reliability, maintenance and operational excellence are standard practice across your business lifecycle, organizational roles, departments, and supply chains."
Lifetime Reliability Solutions Global Network: Licensed LRS Global Maintenance and Operational Excellence Consultants and Industrial Maintenance Trainers.
LRS Consultants Global Network: Industrial Maintenance and Operations Consulting, Industrial Process Improvement Consultants, Operational Excellence Consultants
Hello and welcome,
What brings reliability, maintenance and operational excellence success? What are the answers that guarantee great production performance and high operating profit results? More importantly, how do you make your company become that good?
The single greatest business insight from the quality system revolution initiated by Japan in the 1950's and 60's is that success is a designed outcome—if you want to be successful you first build success into how your business works. You'll make Operational Excellence success a pre-ordained result when you design your company processes for sure operational excellence.
To be successful you need a business system designed for creating sure success. If you want the utmost uptime, throughput and productivity at least costs, your business processes must be designed and run to give you the utmost uptime, throughput and productivity at least costs. Having a successful industrial operation with world class performance is a purposely designed intent; the result is not a matter of chance and luck.
We also know from the quality system revolution that the problems which destroy your operating profits are all preventable. But first you'll need to design and build your operation into a 'system-of-reliability'.
Gold Miner lifts Availability 8% with Plant Wellness Way solutions and gains 29 production days a year
"In June 2011 Lifetime Reliability Solutions introduced the Plant Wellness Way concepts to the Barrrick Darlot gold mine here in Western Australia. In the following months we used the new solutions to lift processing plant Uptime from 87% to 95%."
Darlot Maintenance Planner
What is a 'system-of-reliability'?
Reliability is most simply defined as 'the chance of success'. When your business is a 'system-of-reliability' it uses the best methods and practices guaranteed to maximize your operating performance. When your company is a 'system-of-reliability' you select the optimal ways to make the most operating profit and engineer them into your business processes—you literally will build a 'business-system-designed-for-utmost-success'. But you must build a system. It cannot be done in any other way.
It's why we advise not to adopt Lean or Six Sigma unless they are first proven to be the right answers to your problems. If you use them as point solutions Lean and Six Sigma initiatives always fail to bring lasting success. Point solutions are totally ineffective for creating operational excellence that lasts forevermore.
As a 'system-of-reliability' there is no limitation on your company reaching world class maintenance, reliability and operational performance. Your day-to-day struggles disappear in just a few months because you turn your company into a set of processes that creates a world class operation producing world class performance. It is the natural outcome of being a 'system-of-reliability'.
Your Operational Excellence success is a realistic goal that can be surely achieved by building a business-wide, proactive, life-cycle long, 'system-of-reliability'.
How to get Your Company to Operational Excellence
Start your climb to operational excellence by analysing the cause of your current performance. Very often it takes the simplest changes to make you highly successful. Once you get the right focus the right things to do become very clear. Again, that is why we do not promote Lean or Six Sigma—most of the time there are far simpler things that you can do to create operational excellence in your company.
Below is an example of a starting analysis we would do to identify your problems using historic KPI's. The downtime outage run chart and uptime frequency distribution curve cover ten years of operation in a real company (we've disguised the dates and company). They indicate serious production losses. The business is underperforming and losing a lot of operating profits—easily several million dollars a year for this company. The shape of the uptime frequency distribution curve tells you so.
The early failure peak screams of lack of work quality control and work quality assurance. The negative slope of the curve confirms their current processes can never get them to the world class production performance they want, which is 60 days uninterrupted production Uptime between outages. That's happened only 5 times in ten years. Those 5 successes were all down to random luck. You know that because they were unrepeatable. The only sure thing in this business is that its Uptime has far more chance of being terrible than of being what the company actually wants.
The business and operational processes they use can only deliver the current uptime results you see in the plots. Remember, this is ten years of real production data—this performance is what they actually get from their business. Until they change to processes that guarantee the success they want, their future operating performance and losses must remain the same as their past.
If this was your company we would do our proprietary Plant Wellness Way analysis and recommend the most effective changes to make to your business processes so you get far more operating profits, and lasting new competitive success. You would receive an astounding return on investment.
The Plant Wellness Way is the Operational Excellence creation model and tool kit we use to redesign your company and let you build the simplest, least-cost 'system-of-reliability' that gets world class maintenance, reliability and operational excellence.
Unlike other methodologies, the Plant Wellness Way uses lifecycle and system-wide solutions to fix the causes of your problems; not point solutions that just address the symptoms. Plant Wellness gives you simple, quick to implement, and lastingly effective system-wide answers.
You can secure the Plant Wellness Way methodology for your operation right now. Details of how to get a site license is at: Getting Your Site a Plant Wellness License to Operational Success.
By turning your business into a holistic, life-cycle long, integrated financial, operational, engineering and marketing system you'll create Operational Excellence. Plant Wellness takes 'luck' out of reaching Operational Excellence.
The exceptional Return on Investment (ROI) from the Plant Wellness Way comes from its ability to:
- Measure the important factors that really drive successful reliability, maintenance and operational performance
- Make work error-free and defect-free so only right-first-time quality is achieved
- Eliminate 9 out of 10 of your equipment breakdowns
- Keep your plant and equipment always operating at 100% capacity during scheduled production
- Deliver record high Plant Availability and Uptime never seen before in your operation
- Get your production plant processes totally in statistical control and 100% capable all the time
- Improve your workplace safety results to world class safety performance
- Drive maintenance costs down rapidly to world class ratios
- Eradicate your production waste, quality losses and scrapped work
- Produce the lowest unit cost of production possible from your operation
- Take companies like yours to lasting Operational Excellence success
You now have a powerful way to most quickly, effective and for least cost get Operational Excellence performance that lasts forevermore. Quite literally, you'll design and remake your company into a system-of-reliability, i.e. a sure system-for-success.
LRS Consultants is a global network of professional Plant Wellness consultants who are dedicated to help you get to Operational Excellence fast. Their job is to focus client companies and businesses on developing a ‘system-of-reliability’ so they most quickly, effectively, and for least cost, get Operational Excellence performance. With their help you'll design and create successful and simple maintenance, reliability, operational and business processes that get world class results and productivity. You can expect large and lasting improvement in operating profit, product quality and plant and equipment availability in record time.
To answer all your questions please contact your local licensed LRS Consultant. Just click on the world map to find their contact details.
Learn more about the Plant Wellness Way from the free information available throughout the website and listed below. You can get reliability, maintenance and operational process improvement solutions that work from the online store.
All the very best to you and your company's future,
Lifetime Reliability Solutions Global
5 ways to get Operational Excellence Success in Your Company
1) DOWNLOAD A FREE PDF BOOKLET FOR EXECUTIVES AND SENIOR MANAGERS on key physical asset management and reliability concepts you need to know about to improve your business processes by clicking the link in the blue panel below. You get new insights, simple answers and easy to use methods for small, medium and large industrial businesses who want Operations and Maintenance Excellence results.
Download the most Successful Industrial Operations, Maintenance and Reliability Success Strategies to Use
See how industrial company CEO's, Executives and Managers can improve their company's maintenance and operating processes and get world class asset management performance.
Read Enterprise Asset Management Success for CEO's, Executives and Managers and learn of the reliability improvement strategies that create a business system for maximum success. (2.5 MB PDF document)
2) GET THE FREE PLANT WELLNESS WAY PDF BOOK introducing the simple 6-step IONICS methodology you use to get outstanding reliability and production success in industrial operations. Click this link and request a free PDF Plant and Equipment Wellness book. This book has the foundation knowledge to use in any industrial operation and business for identifying correct strategy and developing a properly targeted business design to create world class reliability and get Operational Excellence results.
3) SEE THE FREE ONLINE PLANT WELLNESS WAY TRAINING VIDEOS and discover how we design and build your enterprise so it is destined for reliability, maintenance and operational excellence success. You get full access to all the vital concepts and methods of the Plant Wellness Way (PWW) system-of-reliability—just click the link in the orange panel below.
Free Plant Wellness Way 'Change the Game' for high Reliability and Operational Excellence training videos
Learn to 'Change the Game' of enterprise asset management, maintenance and operational excellence with 14 hours of free training in the Plant Wellness Way methodology.
Click the link to complete the form at request to see the Plant Wellness Way videos.
4) DOWNLOAD A FREE SPREAD SHEET WITH ISO 55001 MAPPED TO PLANT WELLNESS WAY showing you the appropriate slides and concepts from our 3-day Plant Wellness Way training course presentation to use in satisfying the clauses of the ISO 55001 asset management standard.
Simply click the link below and you go to the webpage where you download a free copy of the mapping spread sheet and free PDF versions of the Plant Wellness Way training course slides.
Free spread sheet of ISO 55001 mapped to Plant Wellness Way training course slides
5) ADOPT THE PLANT WELLNESS WAY TO RELIABILITY AND OPERATIONAL EXCELLENCE and make world class production performance, high productivity and outstanding operating profits each month a normal result in your company.
You gain four great advantages when you adopt the Plant Wellness Way to Maintenance, Reliability, and Operational Excellence.
- Your company gets to Reliability and Maintenance Excellence performance much faster—the PWW methodology is designed to get you there in months, not years. Starting from where you are today, you redesign your processes in weeks and install world class solutions in months.
- It focuses your efforts into planning and installing the simplest and most successful maintenance and operational excellence solutions for your company. You use specially developed operating risk abatement tools to create a business built for maximum success, productivity and operating profits, using the resources you have today, without putting the business in danger.
- The PWW process improvement methodology lets you model and prove that your solutions work before you use them. You apply probabilistic stresses to test what causes a process to fail and how best to make it robust and anti-fragile.
- You work through a holistic strategy that insures operational, reliability and maintenance excellence is the only way that your business can operate. Your company only uses business-wide and life-cycle long solutions built to prevent operational losses and deliver maximum operational success.
Endless Operational Excellence the Plant Wellness Way
The Plant Wellness Way combines the right enterprise asset management and business process optimization into either a ISO 9001 or ACE 3T quality system. We work with you and your people to redesign your operational and business processes and put Operational Excellence into every department. Every task and practise in your company becomes world class so you can produce world class operational performance.
When your company uses the Plant Wellness Way system-of-reliability you break the cycle of operational troubles, problems and failures and replace them with lifecycle business processes built to get lasting reliability, maintenance and operational excellence results. Your company is designed and rebuilt to successfully drive your unit cost of production down to levels that give you massive competitive advantage.
When you ask us to help you become a world class operation, instead of wasting your time and money trying to get you to become Lean, we start by identifying what needs to be done to your business processes so you get maximium success with what you already have. You are taught to use the reliability strategies that get you the best plant uptime and equipment utilization. You are shown how to immediately add powerful work quality assurance techniques to reduce human error rates by up to 10,000%. You learn how to intentionally make your company processes so robust and anti-fragile that you create a business-wide, lifecycle-long, system-of-reliability for sure Operational Excellence success.
The Plant Wellness Way powers companies to world class maintenance, maximum productivity and least operating costs with a system-of-reliability that:
- Gets your plant and equipment operating trouble-free and highly reliable.
- Stops machines failing so they keep running and producing at best performance.
- Turns your business into a lifecycle system built for Operational Excellence success.
- Lets you run your operation systematically, with right-first-time production ticking over like clockwork.
- Measures operational risk and probability of success so you pick your best business options.
- Applies the science-of-failure so your equipment works within the limits of its material physics.
- Removes the tens-of-thousands of lifecycle failure causes waiting to be triggered in your business.
- Turns your operating losses into operating profits by preventing failures, wastes and excesses.
With the Plant Wellness Way system-of-reliability you use powerful business risk abatement tools in a simple methodology that gets you all the right answers to Operational Excellence success.
The Plant and Equipment Wellness system-of-reliability can be used to power all other operational excellence, enterprise asset management and quality system frameworks. If you use PAS 55 Asset Management, ISO 55000 Asset Management, ISO 20815 Production assurance and reliability management, an ISO 9001 quality system, or any other quality system framework, the Plant and Equipment Wellness Way works with all of them. It becomes the powerhouse that drives the system-of-reliability improvements you need to reach world class Operational Excellence performance.
Your operation generates more operating profits, higher productivity, and hundreds (even thousands) of percent ROI with the Plant Wellness Way. It is because your new, best-practise reliability and maintenance solutions quickly stop your production, maintenance and reliability problems.
Talk to us about exactly how to get new, lasting Operational Excellence success and high operating profit margins for your company. Find your nearest LRS Global Operational Excellence and Maintenance Consultant and phone them or send an email. Ask them how to build a system-of-reliability in your operation that successfully stops maintenance problems and rapidly improves reliability and production results.
Discover how the Plant Wellness Way lets you design and create world class reliability at Plant and Equipment Wellness Way: a life cycle system-of-reliability .
Find out how working with LRS Global Operations and Maintenance Consulting gets industrial operations to Operational and Maintenance Excellence.
For maximum operating profits read how you get Maximum Profit Production.
A full range of Industry Consultants, Operations Consulting and Maintenance Consulting Services for Reliability Success
Get more information on world class operations consulting, maintenance consultant and process reliability solutions by following the individual industrial reliability and maintenance consultant services listed below.
Industrial Asset Management and Maintenance Consultants for outstanding reliability
- Industry Maintenance Consultant Services to help you set-up best practice maintenance processes, install precision maintenance skills and build a truly useful CMMS in your operation. Our years of practical, hands-on expertise and insights will save you a great amount of time and money.
- Enterprise Asset Management Consultant Services integrates operational, maintenance and asset management strategies and methods into a business-wide, life cycle solution.
- Maintenance Management and Maintenance Audits shows you where to make changes in your maintenance strategy and maintenance practices to surely lift your maintenance performance and maintenance results.
- Better than Reliability Centered Maintenance RCM. Read this PDF document about a far less expensive method than RCM. A Physics of Failure Analysis quickly arrives at the ideal asset maintenance management strategy, process improvements and best practices for your business.
- Machinery Precision Maintenance Consultant for equipment failure prevention and defect elimination using precision maintenance work skills that produce outstandingly reliable machinery and mechanical equipment.
- Petroleum and Petrochemical Refinery Consultants who maximize petrochemical and petroleum refinery reliability with materials assurance surveys that stop your process plant materials and equipment failures.
Process Improvement Consultant and Operations Consultants for production success
- Operational Excellence Consultants who change your company into a world class operational and production performer so you can release the FORTUNE long hidden in your business.
- Lean Manufacturing Consultants that increase production throughput and lower operational costs by using Lean tools and methodologies that gets the most value from your manufacturing processes.
- Lean Consultant Services for industrial operations who want a simple, quick, lasting transition to effective and efficient Lean methods, practices and tools.
- Business Process Improvement Consultants with the Enterprise Wellness Way to identify the business process improvement opportunities you have to create new and sustained competitive advantage.
- Wind Energy Development Consultants who make sure your wind energy development review and wind energy project risk abatement goes from market identification to wind turbine reliability and maintenance.
ISO 9001 Consultants of quality systems used for world class industrial operations
- ISO 9001 Consultant Services to build you a best practice ISO 9001 compliant quality management system ready for ISO 9001 2008 certification. We are quick, smart, and make sure you have a streamlined system just right for your needs and nothing more.
- ISO 9001 Audit Service shows you how to improve your quality system performance to gain or retain ISO 9001 accreditation.
- ISO 9001 Consultants who build your business documentation into a powerful and successful business improvement system that drives high productivity.