Consulting
Elimination of Costly Equipment and Processing Problems
Typical Characteristics of Major Problems
- Have multiple root causes
- Some cause and effect relationships are far apart in time or space
- Some root causes require innovative solutions
Problem Solving
Our approach is based on analyzing the Problem using a cross-functional team of 5 - 7 people; the team is led by a Principal Analyst who is charged with the responsibility of Solving the Problem, under the guidance of one of our consultants. The team works full-time on the project during one or two weeks to:
- Learn the PROACT RCA methodology
- Define the problem and set objectives for its resolution
- Collect data and develop the RCA tree
- Document and present the findings
- Prepare an action plan to resolve the problem
The team continues working on the project, part-time, until the objectives are met (problem solved). This may take considerable time depending on the nature of the problem, the process and the equipment. Follow-up visits by our consultant every two or three months may be beneficial.
Benefits of Our Approach
- During the initial visit the trivial root causes related to maintenance and operations are eliminated. This generally pays for the effort
- While some of the trivial causes are eliminated we continue learning about the more complex ones
- Analysis is carried out down to the physical, human and latent to the root causes
- Decisions are team based, so, the course of action is generally sound.
- The learning is 100% related to the company; best training possible!
- Enthusiasm is generated to solve this problem and opens the minds to additional opportunities
Maintenance Management Improvement
Diagnostic:
Our approach includes doing a short diagnostic to identify the main deficiencies and prepare a plan for improvement. The main areas covered are:
- Maintenance Management Strategy
- Human Resources
- Routine Work Management Processes
- Parts and Materials Inventory
- Continuous Improvement Program
The outcome of the diagnostic is an Action Plan that is presented to the key stakeholders.
Implementation:
The client generally looks after the implementation of the Action Plan with periodic visits by one of our consultants
Tools used include:
PROACT Root Cause Analysis (RCA), Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM), Uptime maintenance assessment methodology