PCA Uses Performance Plus™ to Build Sustainable Reliability and Business Value
Performance Plus

For many manufacturing plants and other production-centered organizations, keeping up with the ongoing challenges of operations consumes most, if not all, of management’s focus. A complete transformation initiative designed to grow the bottom line sustainably may seem out of reach. Many will resort to a short-term solution or digital transformation quick fix but building and executing a sustainable program is within the reach of every organization. And in today’s competitive marketplace, not implementing one is destructive to value.

That’s where Performance Consulting Associates (PCA) comes in. We bring decades of experience and expertise through the structure of the Performance Plus Methodology to transform asset management and reliability. By balancing improvements across maintenance, spares parts management and reliability —disciplines that are often treated separately— companies working with PCA can more rapidly achieve dramatic gains in throughput and worker productivity while extending asset life and increasing return on invested capital.

Performance Plus helps companies achieve dramatic gains in throughput and worker productivity while extending asset life and increasing returns on invested capital.

The Thread of Excellence that Runs Through Everything We do

One of the main reasons why asset management programs fail is that the implementing consultants lacked a functional mechanism for delivering positive, measurable change and transferring the knowledge to achieve it over the long haul. This affects all of the typical industrial maintenance challenges:

• Frequent downtime
• Deferred maintenance
• Lackluster spare parts management
• Costly equipment repairs
• Poor visibility into inventory KPIs

At Performance Consulting Associates, we are not content to reorganize our client’s processes. Our focus is to radically improve the related outcomes, permanently. To accomplish this goal, we have developed the Performance Plus Methodology, an end-to-end framework for building, executing and maintaining a functional, effective Asset Management Strategy―and sustaining it through continuous improvement.

Post implementation, our clients enjoy more effective preventive maintenance, expedited equipment repair and the insights of accurate failure analysis. As a result, they can transition from reactive maintenance to true preventative maintenance, thereby maximizing equipment longevity and optimizing productivity.

PCA’s Playbooks Drive Performance Plus

• PCA’s team adapts our Playbooks to the unique needs of each client and designs an implementation plan to ensure that improvements stick
• PCA Playbooks provide industry- and CMMS-specific descriptions of all roles, responsibilities and expectations across all asset management functions
• Our experts help build strong, relevant, cross-functional client teams and then engage with them in a highly participatory manner to spark enthusiasm and ownership
• Our seasoned leaders work directly with client executives to develop effective and deeply knowledgeable leaders at the plant and corporate level
• Our efforts outline, in detail, all the steps organizations must follow to build upon their successes and continue the journey of excellence. We reinforce these efforts with operational templates and best practices documents that participants can apply in practice

Performance Plus focuses not only on teaching new procedures and processes―it also places emphasis on training approaches that enable knowledge transfer, skill development and mindset realignment among plant personnel. Most importantly, these “soft skill” improvements aren’t merely passed on to the current generation of learners. Rather, Performance Plus engenders in participants the desire and ability to continually evaluate their performance and seek improvements through better processes, tools and skills.

PCA’s Performance Plus Methodology engages your people in designing and implementing across three asset management domains: Maintenance, Spares and Reliability.

Assessment & Design

Just as an architect wouldn’t begin a blueprint without first surveying the site, no successful work management engagement should begin without an extensive assessment. With a PCA Assessment, our highly trained, experienced consultants lead clients through a series of self-exploration activities, on-premise evaluations, simulations, data gathering, and comparative analyses to measure and identify where they are now, and help them build a blueprint for change. Our clients actively participate in the design of the new operating model, which is embodied in a playbook. Client participation is at the core of Performance Plus!

Core Competency Development

When the organization has the information it needs to begin moving from “asset management as a necessity of business” to “asset management as an investment and value builder” the team moves from design to implementation. Core competency development is the first implementation step and involves the implementation team training and mentoring all stakeholders in the playbook. Performance Plus is a people-centric approach to achieving excellence and sustainable ROI and our clients own the process throughout.

Our holistic approach addresses key processes and workflows, including spare parts management, maintenance work management, planning and scheduling, condition monitoring and inventory optimization. By mastering the basics, our clients succeed at expediting equipment upkeep and repair processes.

Optimization

Once all stakeholders have a clear vision of their potential for improvement and a solid grasp on the new operating model, the implementation team gathers feedback on how the new model can be improved. As new skills and responsibilities are defined, they are added to the playbook. PCA consultants are very experienced in managing the optimization process, which is critical to keeping the new model on track. Optimization also includes the tracking of selected performance indicators which help gauge stakeholder adoption of the new operating model and guide the application of measures to overcome any sticking points.

Continuous Improvement & Sustainability

The Continuous Improvement and Sustainability phases are characterized by increasing ownership by the client organization. PCA’s consultants progressively hand over responsibility while continuing to provide expert guidance, coaching and mentoring.