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Achieving World Class Reliability @ ARC's 2011 Industry Forum

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Achieving World Class Reliability @ ARC's 2011 Industry Forum by Paula Hollywood. …

Achieving World Class Reliability @ ARC's 2011 Industry Forum by Paula Hollywood.
Process and Manufacturing Industries Utilize and Extensive Asset Base
Majority of process company’s assets are in manufacturing
•Manufacturing assets account for 75% of total assets
•Raw material, energy, and conversion costs account for 65% of total expenditures
•Business Performance ~ Asset Performance
•Small improvements can have big impact
Process and Mfg Industries are All About Assets
Asset Reliability is Vital to Business Performance

Published in: Technology, Business
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  • 1. Achieving World Class Reliability Paula Hollywood Sr. Analyst ARC Advisory Group phollywood@arcweb.com
  • 2. 2 © ARC Advisory Group Priorities in Manufacturing What is Reliability?
  • 3. 3 © ARC Advisory Group  Process and Manufacturing Industries Utilize and Extensive Asset Base  Majority of process company’s assets are in manufacturing • Manufacturing assets account for 75% of total assets • Raw material, energy, and conversion costs account for 65% of total expenditures • Business Performance ~ Asset Performance • Small improvements can have big impact Process and Mfg Industries are All About Assets Asset Reliability is Vital to Business Performance
  • 4. 4 © ARC Advisory Group Rate the importance of the following risks to your organization
  • 5. 5 © ARC Advisory Group The Maintenance Spend Industry Maintenance Costs as % of Total Costs Oil & Gas Extraction 27 – 49 % Power Generation 9 – 67 % Mining 25 – 40 % Food Production 25 – 40 % Wood & Paper Products 1 – 34 % Chemical & Petrochemical 0 – 53 % Source: Plant Maintenance Resource Center
  • 6. 6 © ARC Advisory Group What are the drivers behind your reliability initiative? (Check all that apply)
  • 7. 7 © ARC Advisory Group What Is Reliability?  Ability of an system/asset to perform a required function under a stated set of conditions for a specific time period The Belief that an Asset Will Operate as it Should When Required
  • 8. 8 © ARC Advisory Group What is World Class Reliability? Objectives Communicated & Understood Defined Roles & Responsibilities Work Planned & Scheduled Strategic Maintenance Continuous Improvement LCC Analysis Effective Asset Management Balance Workload & Resources Education/Training Empowered Workers Overall Equipment Effectiveness Asset Information Management Best Practice Implementation Risk Management Meaningful Metrics Change Management Work is Prioritized It is a Culture Based on Organization’s Objectives C-Level Commitment Cross-functional Teams Reliability Based Maintenance Environmental, Health & Safety Management Sustainability
  • 9. 9 © ARC Advisory Group What do you consider to be the most important factors contributing to the success of your reliability initiative? (Select top 3)
  • 10. 10 © ARC Advisory Group What is the single greatest area of overall improvement your reliability program has achieved for your facility? (Select one)
  • 11. 11 © ARC Advisory Group Thank You. For more information, contact the author at phollywood@arcweb.com or visit our web pages at www.arcweb.com

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