Boost productivity, equipment life and the bottom line
Asset Reliability Optimization
In an increasingly competitive global market with shrinking margins and even tighter profits, owners of asset-intensive operations can no longer ignore the value of asset maintenance management. Yet, the rush to pursue improvements in other areas―or simply to remain afloat―often relegates this important function to the back burner.
This unfortunate decision costs plants and other industrial facilities hundreds of millions of dollars per year in equipment downtime and failure, reducing productivity, fueling premature replacement cycles and potentially damaging customer goodwill. Performance Consulting Associates’ (PCA’s) Asset Reliability Optimization helps reverse this downward spiral by leading organizations to take charge of their asset life cycles.
Companies using our program have achieved significant improvements, including 30% increase in workforce productivity, 50% reduction in overtime, 25-50% reduction in equipment failures and outages and 100% timely completion of plant turnarounds.
Drawing on best practices of reliability-centered maintenance, our consultants and engineers develop solutions that foster excellence, implement the processes and practices and provide tools and training that help you optimize asset reliability. Our proactive workflows make deferred maintenance a thing of the past, instead condition monitoring, preventative maintenance and efficient equipment repair to increase overall equipment effectiveness.
Reliability Focused Maintenance™ (RFM)
Through modeling, planning, team-building and other activities, PCA and the project team create a reliability-centered framework for maintenance. The program includes two pilot efforts to improve the reliability of specific equipment and reduce maintenance costs. It also includes delivery of the Performance Plus RFM model of best practices, policies and procedures for ongoing maintenance excellence and expedited equipment repair.
Asset Reliability Optimization is just one component of PCA’s end-to-end asset analysis, planning, management, optimization and information delivery solution. To ensure superior asset longevity and availability and achieve the highest ROI possible, we recommend enterprises engage in all of them.
Field Engineering Services
As Performance Plus™ engagements progress, PCA often finds that clients need to improve their fundamental asset data to continue optimization of their processes. PCA can supply the manpower and expertise needed to build these data assets. Learn more about Field Engineering Services >.
Preventive Maintenance (PM) Optimization
PCA analyzes and assesses the enterprise’s core competencies and its operator, maintenance, and engineering functions and then works with the organization to identify the “sweet spot” of optimal asset care through PM. Learn more about PM optimization >.
Predictive Maintenance (PdM) Adoption
PCA helps organizations explore and develop processes that move maintenance from reactive to proactive. Preventative maintenance that leverages PdM helps prevent unplanned downtime through condition monitoring and proactive repair of any damaged components. PCA consultants work directly with facility technicians to ensure hands-on application of predictive maintenance principles and develop appropriate asset monitoring and care techniques, data-based work schedules and more.
Bills-of-Material (BOM) Development
Bills-of-material greatly accelerate the maintenance planning process by bringing together the parts catalog and the asset, thereby simplifying spare parts management. Planners save many hours that would otherwise be spent reviewing OEM drawings and searching the parts catalog and storeroom. BOMs also help keep the MRO catalog current: when assets are retired obsolete parts are easily identified and removed. Learn more about BOM development >.