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GPAllied Capabilities Document

GPAllied Capabilities Document



GPAllied is the most diverse reliability and operations consulting and services company in the world. ...

GPAllied is the most diverse reliability and operations consulting and services company in the world.

Combined, our unrivaled
technical expertise, solutions portfolio and global reach help you achieve rapid bottom-line improvement and sustained
cultural change.

GPAllied’s diversity and expertise result from joining together firms with experts in Maintenance and Reliability, Operational Excellence, and Workforce Development.

This winning team allows us to offer you expertise in the fields of Lean, Reliability Engineering, Six Sigma, Condition Monitoring, Change Management, Maintenance Planning and Scheduling, Workforce Development and Maintenance Craft Skills training.

However, only GPAllied can offer you solutions that fully integrate these specialties.



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    GPAllied Capabilities Document GPAllied Capabilities Document Document Transcript

    • GPAllied www.gpallied.com www.gpallied.com 26
    • GPAllied Tale of Contents Executive Summary ..................................... 1 Business Case for Change .............................. 3 Sustained Reliable Operations ......................... 5 Reliable Capital Delivery ............................... 9 Design/Build Services ................................ 10 Engineering Services ................................ 11 Installation, Commissioning, and Operational Support Services ................ 12 Workforce Selection and Development Support Services .................... 13 Reliable Maintenance Execution ..................... 15 Personnel Qualifications and Work Execution Standards ......................... 23 Training Classes ......................................... 25 www.gpallied.com i 28
    • GPAllied Executive Summary GPAllied is the most diverse reliability and operations consulting and services company in the world. Combined, our unrivaled technical expertise, solutions portfolio and global reach help you achieve rapid bottom-line improvement and sustained cultural change. GPAllied’s diversity and expertise result from joining together firms with experts in Maintenance and Reliability, Operational Excellence, and Workforce Development. This winning team allows us to offer you expertise in the fields of Lean, Reliability Engineering, Six Sigma, Condition Monitoring, Change Management, Maintenance Planning and Scheduling, Workforce Development and Maintenance Craft Skills training. However, only GPAllied can offer you solutions that fully integrate these specialties. To ensure that GPAllied provides you with latest thinking and proven best practices, we have attracted recognized experts to our team, benchmarked best-in-class operations and connected with thought leaders throughout the industry. Furthermore, we ensure that our project team members have technical expertise, as well as expertise as trainers and mentors through a rigorous qualification process and the establishment of work execution standards. GPAllied has modeled their deliverables based on the following core beliefs: 1. The reason our clients are in business is to make money 2. The first step to ensuring profitability is to have reliable “systems” 3. The term “system” speaks to the combination of the people who operate the equipment, the processes they follow to operate the equipment and the equipment itself 4. The definition of reliable is: the ability to perform a given task, at a stated rate, for a given period of time, under a given set of circumstances 5. The organization must be motivated and prepared for any change to be sustainable 6. Having successfully attained reliability, sustaining the improvements is paramount to on-going success 7. Optimization is achieved through the use of a culture of continuous improvement 8. Clients require a rapid return on investments To that end, GPAllied offers you a complete suite of solutions in the following categories: KPIs/Benefits Tracking Driven by: Category: Governed by: Sustained Reliable Operations Business Case Certification for Change Reliable Capital Delivery and Standards Reliable Maintenance Execution Optimization GPAllied prides itself on two (2) things: our passion for helping the client and the flexibility of delivery methods. Our passion is driven by the satisfaction of seeing our company help our customers build, utilize and realize the power of the Return on Asset Reliability (ROAR™). www.gpallied.com 1
    • GPAllied Our flexibility in delivery methods comes in any one of four (4) different ways. Each way specifically customized to meet the unique needs of the client. Those four (4) ways are: Training GPAllied offers all of our deliverables as classes for the client who prefers to implement using their own people. Coaching For the client who wants more than a training solution, but still prefers to implement using their own personnel, GPAllied offers a combination training/coaching package. The training class is augmented by a regimen of coaching and mentoring by our experienced consultants. Services Some clients prefer to contract out certain functions. GPAllied can deliver our services to the client in one of two forms: • Project Based – GPAllied personnel are on-site for the duration of the project • Full Time Equivalent (FTE) – GPAllied personnel are on-site, full time as contracted employees Consulting Whether you are starting a major change initiative or looking for the best way to improve performance, GPAllied’s consultants guide you as you set your direction, design and deploy your approach, and realize results. The GPAllied vision is to be the premier global provider of sustainable transformation driving improved customer operational and reliability excellence. To that end, we believe the best way to make our vision a reality is to optimize customer business performance through customized solutions utilizing our experienced people, innovative processes, and proven technologies. Thus achieving operational and reliability excellence sustained through the use of cultural change management with the relentless pursuit to deliver the highest return on investment. GPAllied’s expert team provides unparalleled solutions. You can count on us to provide the following: • A strong foundation to ensure that your organization’s systems reliably meet customer needs with lower cost • A roadmap to build upon that foundation to streamline your processes and help you achieve a culture of sustained continuous improvement • Consultants and trainers with technical expertise, interpersonal skills, and drive to work effectively with your team • Effective training to develop your people • Solutions customized to fit your needs, drawing from a diverse range of methods and services • A rapid return on your investment This Capability Document outlines the key deliverables our team can provide. www.gpallied.com 2
    • GPAllied Business Case for Change Establishing a business case for change is a necessary first step in most implementations. Understanding that the effectiveness and efficiency of the assets employed are what drive the financial performance of a company, a new metric called Return on Asset Reliability (ROAR™) shows the financial impact of uncovering the hidden potential in the currently installed asset base. With ROAR™, a higher return can be realized with little to no capital investment. ROAR™ is the primary driver behind building your business case for change. Recognizing that business needs vary, GPAllied offers several alternatives for developing your business case: • Maturity Analysis (Levels of Achievement) • Transformational Analytics • Theory of Constraint (TOC) Analysis • Process Simulation Modeling • Value Stream Mapping and Planning· • Key Performance Indicator Development • Lean Opportunity Analysis • Process Waste Analysis • Change Readiness Survey • Day in the Life Of (DILO) • Benchmarking Understanding the financial impact of system failures and inefficiencies are only part of the story, a complete analysis of the costs associated with conducting an improvement initiative also involves items like: • Internal Labor Costs (including Overtime) • # of Machines • Contractor Costs • Bill of Materials Accuracy • Downtime Costs • Repair Costs • Energy Costs • # of Planners • Scrap/Rejects/Return Costs • # of Engineers dedicated to Maintenance • Staffing Changes • # of PdM Personnel • Power Consumption • Amount of PdM Hardware and Software • Current PM Program Evaluation • Future PdM Design Changes • Evaluation of the Plant Culture • Length of Project • First Time Through Quality • Process Cycle Time • Rolled Throughput Yield • Product or Part Variety • Dock-to-Dock Flow Time • Lead Time • Inventory Turns • Total Production and Maintenance Space • Customer Demand Maturity Analysis (Levels of Achievement) GPAllied’s maturity matrix provides an innocence-to-excellence rating for each element of excellent maintenance and production systems. It provides a baseline view and identifies gaps to the desired state for elements such as workplace organization, operator- led equipment care, maintenance work cycle, problem solving, continuous flow, inventory management, leadership, metrics, management systems, business results and many other elements. GPAllied provides this service separately or in concert with other more-analytical analyses; and can provide it in a form that’s biased toward maintenance systems, or production systems, or both. Theory of Constraint (TOC) Analysis TOC analysis focuses on those problems which most directly affect the P&L statement, not simply where increased performance is possible. When looking at the system as a whole, increasing individual performance may not increase the performance of the system. TOC analysis can be applied to the manufacturing and processing environment and to the sales, marketing and accounting environments as well. GPAllied provides this service to help you identify the constraints of your critical systems and focus your improvements efforts there first. www.gpallied.com 3
    • GPAllied Value Stream Mapping and Planning GPAllied facilitates a comprehensive analysis and planning process that results in a detailed transformation master plan and business case for improvement. This process, also known as shikumi, includes initial data gathering, current state value stream mapping analysis, summary of the current state in terms of waste and key characteristics, targeted training, future state vision development, and transformation planning. GPAllied provides this service in several ways: performing the value stream current state analysis only either facilitating your cross-functional team, or via a series of interviews and observations, or facilitating completion of the current and future states and transformation plan. Lean Opportunity Analysis GPAllied provides an in-depth, analytical process to rigorously define the baseline of the current situation, assess the company’s current competitive needs, and to use Lean, Six Sigma, and Reliability principles to design a new set of processes that achieve quantum-leap improvement in order-fulfillment (typical duration of 2 weeks). This process fully integrates the views of Lean, Six Sigma, and Reliability. This results in a comprehensive redesign of operations, maintenance, quality support for production, inventory management, and may include the value chain beyond your facility. For example, this analysis may result in recommended changes to facility layout, location and reporting relationships of quality and maintenance staff, actions for improving equipment uptime, and other specific recommendations. Change Readiness Survey Successful change is a function of elements such as leadership, vision, metrics, means, resources, and others. GPAllied surveys employees and managers to determine the current perceived state for each of these elements. The analysis highlights differences in perception between different organizational levels and work groups and provides direction on changes needed to ensure success of the change effort. Benchmarking Benchmarking is a powerful way to see the potential for performance improvement first hand. GPAllied provides training in a structured benchmarking process and arranges and facilitates benchmarking study missions. Transformational Analytics™ The GPAllied team has quantified hundreds of millions in savings potential for clients using Process Reliability analyses to deliver measurable results focused to increase first-pass product yield, improve variable margin, capital effectiveness and customer satisfaction. Strategically, the results have helped businesses optimize capital planning through realization of the hidden capacity potential in their existing assets. Tactically, a single client site utilizing this approach helped identify specific improvements that are currently delivering $1M/year recurrent revenue in combined energy savings and capacity rate improvements. A one-time investment of $10K realized these savings. We have applied these analyses to a wide range of operations, from small plants to the larger corporations in the manufacturing sector. It has been our experience that when leadership is proactive and aggressively focusing to eliminate wastes and improve effectiveness of work management and decision making processes, a company will realize their biggest return on investment. Our approach will help you to find un-tapped potential in your existing assets (hidden capacity) and drive such results as: • Enhanced Safety Management • Improved Production and Capacity Planning • Effective Prioritization and Resource Allocation • Setting realistic stretch goals for improvements • Challenging the “status quo” • Improving the effectiveness of Capital Planning www.gpallied.com 4
    • GPAllied Process Simulation Modeling Alternatively, when a client has invested to compile more detailed production failure data, they may also decide to aggressively pursue a more in-depth analysis to define where to immediately focus improvement opportunities. The GPAllied team has developed a non-invasive approach that involves employing client failure data in conjunction with Monte-Carlo simulations to develop priority setting and driving work on the RIGHT-THINGS-FIRST! We will compile the results from the simulation and will assist the client to focus and strive to achieve sustainable improvements. Our integrated improvement approach utilizes proven methods such as: • Lean Manufacturing • Six Sigma • Organizational Development • Reliability Engineering Principles These improvement technologies will to help guide a company to drive effective implementation and reap the benefits of improved profitability. Key Performance Indicator (KPI) Development For any change that has been implemented, ensuring compliance is a critical part of understanding what changes were successful and what changes still need to be made. GPAllied can help implement meaningful KPIs that show the progress of the change initiative and educate client personnel about the analysis and relevant use of the metric(s). Process Waste Analysis GPAllied works with you to “walk” your maintenance work cycle processes to identify common waste and opportunities including rework, unclear instructions, searching for information or parts, and other hidden wastes. The analysis results in a prioritized list of improvements. Day In the Life Of (DILO) Study The DILO study focuses on individuals in their daily work and determines the amount of time spent performing work (“wrench time”), attending meetings, searching for parts or information, etc. It provides a different view than the waste analysis which follows the flow of a process; however, it also results in a prioritized list of improvements required to affect a person’s daily effectiveness and efficiency. Sustained Reliable Operations GPAllied provides on-site operations management and process-improvement training, coaching, and facilitation for your specific needs, timing, and budget. GPAllied supports implementation of a tool like 5S or a large-scale transformation. When doing so, GPAllied provides critical support during implementation of your operations solution, including the following: • Building a business case for change • Selecting Key Performance Indicators and Developing Benefits Tracking Systems • Ensuring correct application of tools • Driving the transformation project forward • Developing your Implementation Team through Learn Do, or training and coaching your Green Belts and Black Belts • Teaching and coaching managers throughout your implementation to help them understand the process changes and their changing roles www.gpallied.com 5
    • GPAllied GPAllied provides the following tools and methods separately or integrated within a transformation project: Leadership and Change Management Performance Improvement • 5S and Visual Management • Deploying an Initiative Workshop • Standardized Work • Leadership Alignment Workshop • Problem Solving: FFA, A3, and STP • Leadership Boot Camp • Quick Changeover • Improvement Office Development • Production Cells • Implementer Methods Immersion • Pull Systems • Leadership Team Coaching • Leveled Production • Teaming for Success • Continuous Flow Processing Management Systems • Error/Mistake-proofing • Measuring What Matters • Job Methods and Job Instructions • Guiding Principles • Routine Equipment Care • Production System • TPM • Daily Management System • Supply Chain Improvement • Goal Deployment System If your organization needs to transform operations, then GPAllied provides a transformation roadmap that applies the right mix of methods and tools to meet your organization’s needs: • Select a value stream/pilot area and perform value stream mapping and transition planning • Implement improvements on the value stream/pilot area, and develop implementers and managers • Design and deploy the best practices for your operating and management systems • Establish and implement a plan for refinement, replication, and deployment Leadership and Change Management Successful change requires committed leadership. GPAllied has woven change management methods into our solutions, and the solutions listed here focus on engaging and aligning your leadership team. These solutions are included in the following: • Fit for Purpose: Deploying an Initiative for Your Organization. This workshop helps you make key decisions about the design and deployment of your Operational and Reliability Excellence initiative. Customized for your needs, the Workshop covers Lean, Six Sigma, Maintenance and Reliability / TPM, plus the key management systems of Daily Management and Goal Deployment required to sustain your initiative and map the way to achieving sustained optimized operations. • Leadership Alignment. The Alignment Workshop focuses your management team or work group in a planned, common direction. Your organization will benefit when setting direction, initiating and deploying a major program, or developing implementation plans. • Leadership Boot Camp. This “immersion conversion experience” jump starts your company’s culture change and provides practice with key leadership tools like teamwork, listening, and decision making. It is always organized around a major theme, which is specific for your company. • Improvement Office Development and Deployment. An Improvement Office provides critical horsepower to speed your transformation. During this Development and Deployment workshop, your management team learns about the purpose, types, and personnel expectations of Improvement Offices and develops the design of your improvement office. • Implementer Development—Methods Immersion. This intensive development experience prepares people selected to act as Implementers or Internal Consultants to actively engage the transformation process. The Implementers can learn Lean, TPM, Equipment Reliability Systems, Reliability methods, Six Sigma, or a combination of these methods based on the needs of your company. The Methods Immersion is designed to enable the Implementers to actively participate during implementation of a transformation plan, under guidance of a sensei/coach as they put their learning into practice using Learn Do. www.gpallied.com 6
    • GPAllied • Leadership and Team Coaching. Whether supporting your problem solving method, changing your planning and scheduling process or changing your company’s culture, your people need to acknowledge habits that need changing. Change requires a clear vision of what to change to, motivation, and repetition. GPAllied provides consultants with senior-level industrial experience plus training and experience in coaching techniques to work side by side with key individuals in your company to help them successfully change. • Teaming for Success. The foundation for progress lies in teamwork; however, teaming effectively requires tools, common understanding and goals, and commitment. This two-day course provides opportunities to learn and practice teaming skills such as chartering a team, recognizing the stages of development, identifying roles, writing an agenda, tracking action plans, and communicating effectively. Business Management Systems A business management system defines how production and maintenance are performed, drives change and improvement, and directs how goals for processes are set, deployed and managed day to day. It weaves the way of doing work into the very fabric of the company’s culture. For each of the systems listed below, GPAllied provides a four-step process design system with a management team to customize and deploy training with integrated coaching to ensure continued application—to guide and speed implementation: • Measuring What Matters. A Performance Measurement System defines KPIs, establishes three views—strategic, operational, and improvement—and links to goal deployment and daily management. • Guiding Principles. Guiding Principles augment a company’s vision and includes concepts like using visual management to surface problems. GPAllied provides education and facilitates a leadership team in the definition of these principles. • Production System. The Production System defines the key methods to ensure production reliability and includes processes like in-station process control, and continuous flow. • Maintenance System. The Maintenance System defines the key methods for maintenance execution and reliability engineering and includes processes like the maintenance work cycle, routine equipment care, and others. • Daily Management System. Daily Management ensures that output of a production or maintenance process meets daily requirements for quality, quantity, and safety; and includes processes like Job Instruction, Multi-Level Audits, Fast Failure Analysis, and Visual Management. • Goal Deployment System. Goal Deployment, often called hoshin or policy deployment, links strategic goals to specific action plans and includes goal setting catchball, annual action planning, and monthly plan reviews. Performance Improvement Lean Six Sigma Implementation Implementing Lean Six Sigma might mean applying a particular tool like 5S or Operator Equipment Care, or it might mean an implementation of many tools in a Learning Line. In either situation, GPAllied can help your organization realize gains faster. GPAllied provides training and coaching during your implementation in the following tools: • 5S and Visual Management • Leveled Production • Problem Solving • Materials Management • Quick Changeover • Daily Management • Production Cells • Continuous Flow Processing • Pull Systems • Error/Mistake-proofing • Standardized Work • Job Methods and Instruction • Routine Equipment Care www.gpallied.com 7
    • GPAllied Rapid Improvementâ (Kaizen) A Rapid Improvementâ Workshop (RIW), also known as a Kaizen Event, is a method to achieve dramatic change in a specific process in only one week or less. Our method, carefully designed and refined for more than 15 years, includes four phases: Assessment, Planning, Workshop, and Follow-Up. A RIW can be used to streamline, standardize or redesign a process; or even to design and create a new process. GPAllied provides two versions, one for manufacturing operations and one for transactional or service processes that include the following elements: • Rapid Improvementâ Leaders Kit - Includes Leader’s guide, forms, and slides • Rapid Improvementâ Leaders Seminar - An intensive, interactive three-day learning and skill-building experience that is the first step in certifying the Rapid Improvementâ leaders • Rapid Improvementâ Implementation - During Rapid Improvementâ Implementation, our consultant and your Rapid Improvementâ leaders conduct the four phases of Rapid Improvement for your organization 5S and Visual Management 5S and Visual Management are simple, visually-oriented systems of workplace cleanliness, organization, and communication designed to facilitate greater productivity, safety, and quality. GPAllied offers media and consulting services for your manufacturing or service organization’s 5S and Visual Management implementation through: • Five S: Creating the Productive Workplace books and instructional DVD • 5S and Visual Management Deployment Workshop - A one-day interactive workshop that helps you initiate your customized 5S and Visual Management program • Rapid Improvementâ Workshop—5S and Visual Management. GPAllied provides detailed planning for and implementation of a two-day 5S and Visual Management Rapid Improvementâ Workshop • Customized Programs Problem Solving Management Problem solving is a fundamental process-improvement skill for operations, maintenance, and management. Problem solving applies to both failures that occur and opportunities to improve. GPAllied offers the following services to help you increase your rate of process improvement problem solving through: • Problem Solving Management. One of the benefits of working with GPAllied is our emphasis on the system or infrastructure, and the standards and actions that managers and supervisors need to perform in order for problem solving to be sustained for the long-term. GPAllied provides consultation, typically in a one-day workshop, to help you make and deploy decisions on your problem solving system. • Problem Solving Methods. Just like there are different types of problems, there are different types of methods for problem solving. GPAllied provides courses, coaching, distance coaching, and distance learning on these methods: - Fast Failure Analysis (FFA). FFA is effective for many typical failures and can be completed quickly. The core of this method is to engage front-line workers in solving day-to-day anomalies with the 5-Why method. - A3.The A3 method, sometimes called the Quality Improvement Story (QIS), provides a more-robust approach to solve more complex failures or develop solutions to opportunities for improvement. It can apply to chronic problems and applies analytical tools in addition to 5-Why. - RCFA. Root Cause Failure Analysis (RCFA) is thought of in two ways: a failure of a process (the way people interact with each other and the machinery they operate), or an equipment failure. GPAllied’s RCFA method addresses both and draws from Reliability Engineering with rigorous development of root causes backed by substantial evidence. - Situation—Target—Proposal (STP). STP is a direct and straightforward problem solving and decision making methodology that is especially useful for transactional environments and management decision making. Using STP, an individual or team factually describes the situation, states the desired future-state target, and proposes a solution based on analysis. - Six Sigma. When problems are complex, then more advanced problem-solving tools might be needed. GPAllied provides training and coaching on these advanced tools as part of Six Sigma Green Belt and Black Belt certification programs, or as targeted training (for example, training on Measurement System Analysis). • Teaming and Problem Solving Skills. Even if your organization has established its problem solving system and provided training in one or more of the problem solving methods, your people might still need fundamental skills building in how to team effectively and how to use problem solving tools. www.gpallied.com 8
    • GPAllied GPAllied offers services to build these skills such as: Standard Work Process Standard work is fundamental to reliable operations and maintenance performance, and provides the basis for further improvement. Unfortunately, if your company is like many, you will find that different work groups, individuals, or shifts actually perform work differently; workers are indifferent toward following standards and using a disciplined process to improve standard work; and most importantly, supervisors lack the skills needed to lead standard work execution and improvement. The Standard Work Process might well be the most important method for institutionalizing needed skill development and culture change. It engages front-line workers, front-line supervisors, and higher-level managers in ensuring that process performance reliably meets customer requirements. When followed, it leads to continuous process improvement. GPAllied provides solutions to help you gain the benefits of the Standard Work Process: • Standard Work Process Management. GPAllied helps your organization make and deploy decisions on your Standard Work Process, including how standard methods are set, job instruction is taught, work performance is measured and audited, and how performance anomalies are solved. • Training and Coaching. GPAllied provides courses and hands-on coaching for each element of the standard work process. Reliable Capital Delivery The difference between effective and ineffective launching of a new facility or installing a new asset is costly in terms of time, money, and customer satisfaction. People, processes, and technology—these are the essential elements of your industry. When it’s time to bring your business to a higher level, all three (3) must be ready. GPAllied provides a suite of services designed to make your capital project launch successful. We categorize these services as follows: Design/Build Services Installation, Commissioning, and • Design Verification/Optimization Operational Services • Life Cycle Cost Analysis • Commissioning, Acceptance Testing and • Construction Operational Support • Construction Management • QA/QC, Witnessing, Inspection and Test Plans • Warranty Claim Management • Procurement • Spares Optimization • Facility Layout for Lean Manufacturing • Quality System Implementation • Design for Condition Monitoring • Workflow Processes Development • Procedure Development Engineering Services • Project Management • Civil • Mechanical Workforce Selection and Development Services • Electrical • Employee Screening and Selection • Chemical • Operator and Maintenance Training • Fire Protection • Leadership Development and Culture Establishment • Environmental • Safety • Custom Certification Programs • Training Center Construction • OEM Training and Documentation Coordination • Knowledge Management Systems www.gpallied.com 9
    • GPAllied Design/Build Services Design Verification Every new facility is justified based on specific requirements for business performance. GPAllied uses powerful Monte Carlo- based simulation software to verify that facilities will produce the required safety, environmental, and operational performance based on the impact of its proposed equipment’s reliability and maintainability. Changes can be easily implemented if this process is initiated early enough in the design process. Design Optimization Minor changes in the design of a facility may yield high returns, but it is often hard to tell what that return will be in a complex system. GPAllied can model the complex relationships and help develop designs optimized to produce the highest business performance and the lowest cost of installed capital. Life Cycle Cost Analysis Deciding between business alternatives requires an understanding of the through-life cost of the alternatives being considered. GPAllied can show you the cradle to grave costs of ownership and through the use of Life Cycle Cost Analysis methods help ensure that your company picks the investment that best meets the business goals. Construction From fuel station and alternative fuels construction to aerospace and water treatment plants, GPAllied has the industry insight and experience needed to meet stringent quality and safety requirements. When you hire us to construct your small to mid-sized specialized systems facility, you can rest easy knowing we offer: • In-house, turnkey services for responsiveness and reliability • Proven, long-term experience to ensure deadlines and budgets are met • Multi-disciplinary capabilities in design and engineering, procurement, quality assurance, compliance, construction management, and more for added peace of mind • Unmatched service, backed by a company known for superior quality work Construction Management From individual task management and field office support to third-party oversight and comprehensive project management, you can count on GPAllied to get the job done. Our multi-disciplinary experience in design and engineering, procurement, construction, inspection, maintenance, and repair gives us unique insight into construction management to help build specialized facilities. Add to that our certifications, skills, standards, accountability, and proven track record for on-time and on-budget delivery, and you’ll see why we deserve our reputation for superior performance and quality. GPAllied specializes in construction management for heavy industry, process and chemical, utility, university, and government facilities worldwide. Our Owner’s Representative and Guaranteed Maximum Price services include: • Project and contracts management • Quality assurance support • Inspections, examinations, and tests • Certified welding consultation and procedure development • Project and contracts control • Procedure development • Third-party oversight • System validation www.gpallied.com 10
    • GPAllied Procurement Procurement is one of the key areas that can make or break your budgets, timelines, and construction quality. GPAllied’s procurement and purchasing services are backed by our end-to-end knowledge of design and engineering, construction, and construction management. We understand the issues that keep you up at night, and we know how to procure building materials and supplies along proven strategies that maximize value and: • Optimize materials and processes • Utilize well-honed negotiation skills to minimize costs • Maximize tax benefits • Help maintain productivity and efficiency throughout the job site Facility Layout for Lean Manufacturing Layout of a facility—the location of equipment, work-in-process inventory, supplies and parts, tooling, support groups like maintenance and quality—all determine the ability to meet customer needs with minimum cost. GPAllied’s 15-Step Plant Layout Process starts with agreeing to the manufacturing strategy, includes definition of performance metrics, designs equipment and support process locations to enable Lean processing, and develops an implementation plan. Design for Condition Monitoring GPAllied can help ensure that your new plant design is optimized to take full advantage of all condition monitoring technologies. Whether it’s detailing the permanent installation of accelerometers for ease of routine vibration data collection or the use of infrared line scanners on rotating vessels, GPAllied can help. Available continuous on-line monitoring systems available are: • Vibration Analysis • Torque and Torsion • Infrared Thermography • Ultrasound • Motor Circuit Analysis • Oil Analysis • Process Parameters Engineering Services The more complex your plants and systems, the more you need an experienced and specialized design engineering company like GPAllied. With complete in-house capabilities and proven expertise, GPAllied is uniquely qualified to serve the engineering and design needs of small to medium-sized plants and systems. From design, to construction, to improving the efficiency and reliability of your existing facilities, we offer registered engineers in the following disciplines: • Civil • Mechanical • Electrical • Chemical • Fire Protection • Environmental Engineering • Safety www.gpallied.com 11
    • GPAllied Installation, Commissioning, and Operational Support Services Commissioning, Acceptance Testing and Operational Support GPAllied engineers can offer a number of services to assist with machine assembly and commissioning, as well as baseline condition monitoring services. Some of the services include: • Alignment • Balancing • Thermal Growth Analysis • Leak Detection Survey • Resonance Testing • General Machinery Acceptance Testing • Failure Investigation • NDT Inspections • Installation and Commissioning Quality Assurance and Quality Control (QA/QC) and inspections - Personnel are available with extensive experience in QA/QC of process machinery assembly and overhaul - Assistance can be given with the development of commissioning procedures and collection and analysis of commissioning data • Overhaul Quality Assurance and Quality Control (QA/QC) - GPAllied has personnel experience in QA/QC Control of Equipment Overhauls - This work would involve developing overhaul QA/QC specifications - Developing overhaul procedures - Developing inspection and test plans - Witnessing inspection and test plans - Shutdown project management and supervision - Commissioning - Overhaul report writing GPAllied senior engineers have extensive QA/QC experience with boilers, fans, gearboxes, pumps, HV motors, standard AC motors and compressors. QA/QC, Witnessing, Inspection and Test Plans Plant equipment modifications often are performed with little or no QA/QC during the modification, installation and commissioning stages of implementing a solution. GPAllied can assist by providing experienced specialists in all areas of solution implementation to develop inspection and test plans, for which expert witnessing and sign-off can be achieved, ensuring the solution design and implementation is performed to specification. Similarly, this service offering can be performed on plant equipment that is undergoing planned maintenance and overhaul to ensure the asset is returned to the original design specification, or if up rating, the plant equipment is modified to the modified specification. Warranty Claim Management This service is provided to manage RCA investigations and warrantee claims on behalf of the customer inclusive of provision of expert witness services. The purpose of this service is to ensure that all reported findings are presented by the expert witness as a representative for the customers to maximize on any loss claims. Spares Optimization The base load of spares for new capital equipment depends on the failure modes present, the lead time for spares, and the equipment maintenance plan developed to battle the failure modes. GPAllied can help you minimize the investment in capital spares required to operate the facility and achieve the best business results. www.gpallied.com 12
    • GPAllied Procedure Development Well-written procedures provide a consistent and safe method for performing job tasks and establishing a foundation on which to improve process and safety performance. GPAllied provides the specialists you need for timely development of process safety, operating, maintenance, mechanical integrity, inspection and test, quality assurance, start-up, and shut-down procedures. GPAllied prepares, in addition to documented standards, supporting materials such as system descriptions, alarm response guides, job aids, and on-the-job training guides. Quality System Implementation Quality systems assure that customers receive the right shipment at the right time with the right quality. GPAllied provides quality systems design including product requirements, design and process FMEAs, standardized work, control plans, audit plans, quality records, and supplier quality improvement and assurance plans. Workflow Processes Development Understanding how information flows around an organization is a key metric in determining its maturity. Non-value added steps, like unnecessary reviews, edits and approvals, drag down the efficiency of an organization to the point of being ineffective. Additionally, when people don’t know their role in the group and how their role affects others, further inefficiencies are created. GPAllied can help. Our engineers and consultants have the right experience to help you re-engineer your processes and eliminate the non-value added steps and clearly define everyone’s responsibility with respect to different topics. Project Management GPAllied develops complete project plans that provide our clients the insight needed to ensure a smooth project progression. We have saved our customers millions of dollars through effective Outage planning and facilitation. GPAllied implements facility outages using our qualified staff, knowledgeable and certified in the work required, or by providing project management and facilitation to your staff. If training your people is your goal, we offer best-in-class Project Management for Engineers and Project Bottom Line Success courses. Workforce Selection and Development Support Services Employee Screening and Selection Properly selecting and developing your employees is one of the most important considerations for ensuring reliable capital delivery. GPAllied specialists can employ a structured job and task analysis process based on your anticipated staffing requirements and your facility specific equipment to identify the skills and knowledge your employees will need to reliably operate and maintain your plant. Using this information, we create job descriptions and legally valid skill and knowledge assessments for use in screening qualified job applicants. Our specialists can conduct the screening or prepare your personnel to do so. Operator Training Based on the information developed through the job and task analysis, GPAllied training specialists can develop and deliver customized operator training programs specific to your facility. Depending on your specific needs, GPAllied can deliver this training through instructor-led sessions, self-study guides, computer/web-based training, or structured on-the-job training (OJT). GPAllied can deliver the training or can provide train-the-trainer sessions to prepare your subject matter experts to deliver the training. Maintenance Training GPAllied can design, develop, and deliver complete maintenance training programs that cover everything from basic core competencies through high-level equipment specific training. Our maintenance training programs are described in more detail in the Reliable Maintenance Execution section of this document. www.gpallied.com 13
    • GPAllied Leadership Development and Culture Establishment Installation of new capital is also a time to ensure that the equipment is run right and maintained right. Whether the equipment is incrementally improved (like at Toyota), or deteriorates due to lack of maintenance depends on management culture and processes. GPAllied’s solutions start by providing managers with the motivation to manage differently through education, benchmarking, and coaching. That is coupled with establishing an agreed-to Daily Management System that shows managers how to manage well. Custom Certification Programs If you are looking for a way to recognize and reward your employees’ technical expertise and capabilities, but have not been able to find an industry standard certification program that meets your needs, GPAllied can help. Our training specialists have guided many customers through the process of creating legally-valid custom certification programs to support initiatives such as pay-for-skills or multi-skilling. We employ a structured process to identify the critical skills and knowledge your workforce requires to successfully perform their jobs. We then work with a team of your subject matter experts to rank these skills and knowledge requirements to create career progression paths for your defined job roles. Finally, we create legally valid skill and knowledge assessments that are used to verify your employees’ mastery of the skills and knowledge required for each step of the career progression. Training Center Construction GPAllied firmly believes that for operations and maintenance training to be effective, it must be delivered in a hands-on training environment. In some cases, the most economical means to achieve this is through the construction and provisioning of an on- site training center. GPAllied is experienced in all phases of training center construction including design, construction management, outfitting of training labs, preparation of instructors and delivery and monitoring of training classes. Our turn-key solution begins with the identification of the skill and knowledge requirements of your workforce. We then use that information to design the training labs, prepare budget estimates, and identify and select building contractors/training equipment providers. GPAllied specialists then manage the construction of the training center, procurement of the training equipment, and outfitting of the training labs, providing you with a completely functional training center ready to support your personnel. OEM Training and Documentation Coordination Coordinating and ensuring the quality and consistency of the training and documentation provided by your equipment vendors can be a huge challenge during a capital project. Fortunately, GPAllied has developed a proven process to overcome this challenge. It begins with the development of a detailed training and documentation bid specification that is included with the equipment bid packages sent to the vendors. The training and documentation bid specification clearly outlines your expectations of the training and documentation to be provided. As the capital project progresses, GPAllied specialists will work with your vendors to ensure compliance with the bid specification and coordinate and monitor vendor training sessions and documentation submittals to ensure your employees gain the knowledge and skills they need to effectively operate your plant. Knowledge Management Systems GPAllied empowers your organization with the insight and knowledge you need to enhance or introduce enterprise e-learning initiatives. Our experience and knowledge helps you evaluate your unique opportunities effectively and identify the optimal solutions to meet those opportunities. Our recommendations take your e-learning requirements into consideration, as well as future growth, emerging possibilities, process refinement, implementation, support, and growth strategies. The result is the right solution for your people and processes—an infrastructure that delivers strong returns now and in the future. GPAllied’s areas of expertise include learning management systems (LMS), portal development, learning content management systems (LCMS), content management systems (CMS), performance management systems, reporting, and talent management. We provide end-to-end services, including selection consulting, installation, and configuration, paying special attention to system integration, content integration, web interface design development, and data migration. Because GPAllied is not in the business of selling our own, proprietary software solutions, we approach your recommendations and implementations from the perspective of someone who uses these systems daily in our business—from the same perspective you would have. While we have significant knowledge of each system out there, we remain software agnostic, working diligently with all leading suppliers and product developers to identify the best-in-class solution for you. www.gpallied.com 14
    • GPAllied Reliable Maintenance Execution GPAllied provides on-site maintenance management and process-improvement training, coaching, and facilitation for your specific needs, timing, and budget. We work side-by-side with your management and crew to improve the entire maintenance work cycle and the processes that support it. GPAllied helps your organization clearly understand and improve maintenance performance; and streamline, agree to, document, and institutionalize your company’s best practices resulting in bottom-line cost reduction and higher equipment utilization. GPAllied provides critical support during implementation of your maintenance solution, including the following: • Building a business case for change • Selecting Key Performance Indicators and Developing Benefits Tracking Systems • Ensuring correct application of tools • Driving the transformation project forward • Developing the Implementation Team through Learn Do, or coach Reliability Green Belts and Black Belts • Teaching and coaching managers throughout the implementation to help them understand the process changes and their changing roles Reliable Maintenance Execution requires the creation/improvement of the following elements: • Strategy Development: The analysis of predominant failure modes and their effects leads to the development/ assignment of Proactive Inspections like Preventive Maintenance (PM) and Predictive Maintenance (PdM) tasks as countermeasures. • The Maintenance Work Cycle: The identification, prioritization, planning, scheduling, preparation, execution, and reporting of maintenance tasks; and the assessment of maintenance task performance and equipment history. • Work Measurement and Execution: The cost-efficient and effective performance of maintenance tasks with people having the right skills and following maintenance standard work. • MRO and Lubrication Management: The determination of quantities of spares, storeroom management, vendor management, and repair specifications; and the consolidation, labeling, and storage of lubricants. GPAllied offers the following solutions: • Shutdown, Turnaround, and Outage (STO) • Historical Failure Analysis • MRO and Lubrication Management • Reliability Centered Lubrication • Phase I Assessment • Asset Health Management • Phase II Development - Condition Monitoring Work-Scope Generation • Hierarchy and Master Equipment - Analyst and Technology Specifications List Development - Supplier/System Audit • Equipment Walk-Down - Skills and Competencies Development • Criticality Analysis and Assessment • Equipment Maintenance Plan (EMP) - Contract/System Implementation Development • Maintenance and Reliability Kaizen Event • Preventive Maintenance Evaluation (PME) • Solution Design (Defect Elimination) • Preventive Maintenance Optimization (PMO) • Solution Planning and Implementation • Advanced Machinery Diagnostics • Sourcing Strategy • Baseline Asset Health Audit • Maintenance Craft Skills Training www.gpallied.com 15
    • GPAllied Shutdown, Turnaround, and Outage (STO) Improving the efficiency and effectiveness of your STO events represents one of the largest opportunities for controlling your maintenance cost and improving equipment availability. GPAllied helps your organization implement or improve the execution of STO with the following solutions: • STO “Current State” process mapping and opportunity identification • Facilitation and documentation of a Standard STO Model including forms, tools, and key-event timing • Targeted training to enable implementation of best-practice improvements • Facilitation of STO Risk Analysis and definition of Risk Mitigation Actions • Hands-on, best-practice implementation, coaching, and guidance • Simple Excel Gantt Chart planning tools • STO Execution Daily Management coaching and Action/Countermeasure management • STO Visual Management techniques — Preparation Matrix and Plan-to-Actual Status Wall • Facilitation of Post-STO Review of “Things Gone Right” and “Opportunities for Improvement” including development and implementation of continuous-improvement Action Items • Specific training, simulations, improvement workshops, and custom solutions MRO and Lubrication Management Significant waste in maintenance execution occurs from inadequate management of spare parts and lubricants. GPAllied helps your organization implement or improve execution of STO with the following solutions: • MRO/Lubricant “Current State” process mapping and opportunity identification • Facilitation and documentation of a Standard STO Model including forms, tools, and key-event timing. • Stores strategy and efficient layout planning and implementation • Visual management • Vendor management strategies Phase I Assessment The audit is a structured evaluation of current maintenance and reliability practices as compared to best-in-class standards. The assessment is accomplished through several actions such as, current production analysis (to approximate the lost opportunities) and personnel interviews (to establish common practices). Once the current state is determined, it becomes a lot easier to talk about the efforts required to move forward and improve. Specific deliverables coming out of the Phase I Assessment are: • 1-day Reliability Overview Training Class • Process Analysis of Current Production Data • Assessment Report Ranking Current Maintenance and Reliability Practices versus Best Practices • Return On Asset Reliability (ROAR™) Model Detailing the Business Justification for Change The audit process confirms, conducts and evaluates the following: • Group Reliability Structure • Predictive Maintenance Strategy • Plant Hierarchy Structure • Equipment Attribute Library • Plant Criticality Analysis • Equipment Maintenance Plan • Reliability Management Structure • Maintenance System Levels of Achievement www.gpallied.com 16
    • GPAllied Hierarchy and Master Equipment List Development Having a functional equipment hierarchy is paramount to managing the information coming from the maintenance and reliability functions. Hierarchies have to be capable of rolling up both cost data and failure data to ensure meaningful analysis. GPAllied uses a systematic method of verifying the equipment at a facility and organizing the equipment into a hierarchy that is useful to both accounting and maintenance simultaneously. Equipment Walk-Down Few maintenance planners and engineers have a complete set of individual component data required to perform their job effectively and efficiently. Most of the time, when a critical piece of information is required for parts ordering or job plan development; someone is tasked with going into the field and finding that piece of equipment and documenting that information. GPAllied uses a custom designed software application to help organize the information as it is gathered. This database is then used for: • PM Program Design • PdM Program Design • Job Plan Development • BOM Development • Lubrication Program Design Examples of data that are collected and data-based are: • Bearing numbers • Geartooth count • # of Rotor Bars and Stator Slots • Coupling type • # of Blades/vanes • Lubricant type • Power factor • Materials of construction • Nominal thickness The data in the application can be easily loaded into the existing CMMS, making data management easy. Criticality Analysis The intent of the site criticality survey is to rank all site equipment based on the aggregated risk of environmental, safety, capital replacement cost, history and cost of failure and production impact. A rational equipment criticality coding system can greatly assist an organization in the setting of management, operational and maintenance priorities when dealing with assets and equipment. The Criticality review uses a simple qualitative analysis utilizing the knowledge of key site personnel with the data recorded in a software package. We use a ‘Risk-Based’ approach to equipment analysis and to the development of maintenance systems. Many equipment criticality analysis approaches are consequence-focused rather than risk-focused. Consequence-focused equipment criticalities tend to prioritize failures by consequence only, irrespective of probability of occurrence. Failure Risk for an item of equipment or process can be determined by the probability of failure occurring, multiplied by the likely consequence of the failure. The process used relies on key personnel to make qualitative judgments on a range of Criticality Factors for each piece of equipment. www.gpallied.com 17
    • GPAllied The Criticality Analysis uses five qualitative variables: • Safety Impact • Environmental Impact • Operational Impact • Customer and Quality Impact • Failure Frequency The output is a fully documented report of the Criticality Review and machine rankings. Criticality Analysis is a necessary precursor to the design/evaluation of any existing reliability program. Equipment Maintenance Plan (EMP) Development The PM and PdM tasks that are brought to bear on a given machine form the core of the Equipment Maintenance Plan (EMP). Typically, the balance between PM and PdM isn’t correct in the maintenance scheme. This imbalance creates a higher cost of maintenance and lower levels of reliability than what is possible, and certainly not what is expected of the system. GPAllied can develop an EMP that reflects the proper balance of PM and PdM for a select number of machines or the entire system. The final product is delivered in electronic form for easy import into a CMMS. Characteristics of an EMP include: • Failure Mode • PM/PdM Task Description • Craft/Operator Assignment • Task Frequency • Duration (Clock-Hours and Labor-Hours) Preventive Maintenance Evaluation (PME) All too often, too much emphasis has been placed on the PM procedure and what results it can bring. There is a belief that an organization can PM its way to reliability. Time and time again, this has proven incorrect for some of the following reasons: • Intrusive inspections can introduce infant failures if proper procedures aren’t followed • Certain failure modes don’t follow a set time pattern • Task frequencies are incorrect based on a belief that if we just opened it up more often, we would catch the problem • Non-value added tasks have been added to the PM, building a false sense of increased security • There are tasks in the system that are not failure mode based • Too much reliance on OEM recommendations that do not take into account the operating context A Preventive Maintenance Evaluation (PME) conducted at the task level of a PM program can identify tasks that need to be: • Deleted from the PM program and the labor re-assigned • Deleted from the PM program and the task assigned to Operations • Deleted from the PM program and the task assigned to a Lubrication Specialist • Deleted from the PM program and the task assigned to PdM Specialist • Remain in the PM program, but re-engineered to make the task more quantifiable, executable and repeatable • Remain in the PM program, as written Preventive Maintenance Optimization (PMO) Once PM tasks have been analyzed and determined that they are to remain in the PM program, but need to be re-engineered, the optimization process is ready to begin. The optimization process involves recreating the task in such a way as to guarantee consistency of execution. This guarantee is accomplished through the use of best practice techniques designed to make the task description clear, concise and free of ambiguity. www.gpallied.com 18
    • GPAllied The litmus test for whether or not the PM task has been optimized is this: Can the 2nd year craftsperson and the 19th year craftsperson complete the PM tasks with the same results? If the answer is yes, then the procedure is a good one. If no, then there is improvement left to be had. Advanced Machinery Diagnostics With the use of the latest technology in vibration analysis, thermographic imaging, lubricant analysis, motor circuit analysis and ultrasonic analysis, our team of industry recognized experts can assist clients with the identification and solving of their complex machinery defects on highly critical machines and machines that have exhibited chronic failures. All reports identify maintenance recommendations, which allows for the prioritization of maintenance activities. Typical mechanical and electrical anomalies would include: • Misalignment • Insulation integrity • Unbalance • Electrical phase unbalance • Soft Foot • Hot Bearings due to incorrect installation or lubrication • Gear Meshing practices • Journal Bearing Faults • Blockages and Dead Spots in circulation systems such as the cooling tubes of heat exchangers can be identified • Belt Drive Faults without the need to ‘crack’ lines • Mechanical Looseness • Vessel integrity checks on furnaces, autoclaves, • Switchgear and MCC faults mills, kilns, etc • Pump Faults – Blade/vane pass and cavitation • Gas Leaks • Critical speed analysis • Electrical Discharge • Beat Frequencies • STEAM Trap Auditing Baseline Asset Health Audit This is a snapshot of the health and condition of the assets as identified through the use of visual inspection and predictive maintenance technologies and involves: • Vibration surveys • Thermal Imaging surveys of electrical, mechanical and stationary equipment • Oil Analysis surveys of oil lubrication systems (basic tests only) • Ultrasonic Surveys of pressurized plant equipment The Audit is intended to: • Rapidly produce a broad overview of plant and equipment condition • Identify conditions of immediate concern • Validate the existing PdM program • Identify immediate Root Cause Analysis (RCA) opportunities for critical equipment • Set the workshop with key client personnel to develop solution activities for rapid return on investment through failure avoidance Historical Failure Analysis Understanding the nature of how the machines in a given system have failed paints a very clear picture about any future changes that may be needed. GPAllied engineers can help you find trends and patterns in your failure data to better understand the required action items. Using simple tools like Pareto analyses and distribution reports to complex simulation modeling, the nature of the failures can be identified and action plans developed. www.gpallied.com 19
    • GPAllied Reliability Centered Lubrication Development It has been found that poor lubrication can result in a loss of 10-15% of a plant’s maintenance budget. Much of this time can be attributed to poorly designed lubrication PM’s that have no engineering reasoning behind them. GPAllied provides an approach to lubrication that allows for equipment reliability and personnel optimization. The Reliability Centered Lubrication plan addresses the key components of a lubrication program such as: • Standards and Procurement • Re-lubrication Practices • Storage and Handling • Program Management • Sampling • Procedures • Contamination Control • Program Goals • Training • Continuous Improvement • Oil Analysis Asset Health Management Condition Monitoring (CM) Work-Scope Generation Establishes CM Standards and serves to provide the following: • Identification of machines that warrant monitoring • Identification of typical failure mechanisms • Failure Mode Symptoms Analysis (FMSA) for critical plant only • P-F interval (via interview with key client staff) for each of the machines identified • Most appropriate primary and correlation CM techniques • Defined monitoring frequency • Identification of in-line/on-line monitoring requirements • Consideration for safe access for PdM activities The process relies heavily on the interviews with key client staff and is conducted as per a “Greenfield” site with no reference to any existing program or capability. Analyst and Technology Specifications This process involves the development of the technical specification required for the implementation of a standardized program. This process is also known as OP-1/OP-2 development. The specification covers, but is not limited to, the following: • Safety and Site Access • Analyst Certification and Qualification • Data Collection, Analysis and Alarming specifications • Reporting Standards • Communication Protocols • Contract Performance Criteria Supplier/System Audit This process involves the auditing of the program against agreed-upon standards for each condition monitoring technique, the generated work scope and the technical contract conditions. This program identifies the deficiencies and areas of improvement for work scope, monitoring strategy, test regimes, databases, reporting, safety guidelines and management systems and structure. This process also serves to confirm staffing levels, skills, competencies and certification requirements for the service personnel. www.gpallied.com 20
    • GPAllied The final report identifies areas of risk, and deficiencies in: • Management • Technology • Reporting • Communication • Personnel Skills and Competencies • Safe Work Procedures Skills and Competencies Development and Assessment This task involves the development of the PdM Skills and Competencies system and career development plans, inclusive of the following elements: • Phase 1 – The introduction of the Skills and Competency Assessment Process and Tool and the initial completion of templates for further development by each team • Phase 2 – The completion of the Template Skills and Competency Assessment Tool for each team and modification of the Behavioral Competency profile component with customer requirements • Phase 3 – The development of a Skills and Competencies Management System that outlines the procedures and processes for using and maintaining the Skills and Competencies Assessment Process Contract/System Implementation This process involves verifying that the implementation of the Condition Monitoring (CM) Program is in compliance with ISO standards, the generated work scope and the technical contract conditions. This process also involves the verification of database structures and designs as well as data communication protocols. Similarly, it also serves to verify that appropriately qualified and certified service provider personnel have been assigned to the service provision. Program Management An ongoing function, the primary function of the Program Manager is to ensure the integration of the information coming from the PdM program with the daily management scheme of the facility. This is accomplished through a combination of tasks. Those tasks include: • Ensuring that reporting mechanisms, database structure, alarm level settings, collection specifications, included machines are all in accordance with agreed upon standards • Identifying and setting training programs for technical staff and prioritize same • Training/coaching on communication protocol and quantification of success of the program • Educating plant personnel about the effectiveness of the PdM technologies. Phase II Development Once a Phase I assessment has been completed, a plan to close the identified gaps must be developed. This detailed plan (including ROI calculations) encompasses the elements needed to not only close the gaps, but close them in such a way as to make the changes sustainable. Root Cause Analysis (RCA) Management RCA is the heart and soul of any improvement initiative. The desire and ability to sort through the static and identify what could have been done differently to avoid the failure is what separates the companies who see step changes in performance and those that see mediocre to no improvements. RCA is typically thought of in one of two different ways. Either a failure of a process (the way people interact with each other and the machinery they operate) or an equipment failure. While the philosophies of these two techniques are precisely the same, the methodologies are a little different. GPAllied has experts in both types. www.gpallied.com 21
    • GPAllied The majority of the time, the biggest problem with RCA is lack of follow-through on the action items that come out of such an analysis. GPAllied’s RCA courses have strong components for the management of those action items. The management of root cause analysis projects typically involves a two-tiered process. It consists of a response plan of managing the tasks immediately after a failure occurs, including but not limited to: • Resource management (mandate by senior management to use specific personnel and equipment for the project) • Time management (available time-frame to carry out RCA) The next steps involve the project management of the RCA including but not limited to: • Information and evidence gathering before and/or during restoration/overhaul of equipment • Systematic process of development of root cause statement(s) that is backed by substantiated evidence Maintenance and Reliability Kaizen Event The M&R Kaizen events are designed to deliver a high degree of value to the client in a very short period of time. Understanding that simply performing a series of analyses (like PdM/RCM/RCA) isn’t enough for most companies to see change/value. The M&R Kaizen event has but one intention…stabilize one or two bad actors to a point where reliable operation is actually possible. Activities performed during this one-week engagement include: • One-day Reliability Overview • Baseline Asset Health Audit • PM Program Evaluation and Improvement • Lubrication Procedure Review and Improvement • Operator Care Tasks Review and Improvement • Equipment Maintenance Plan Review and Re-Design • Design for Maintainability Study Solution Design (Defect Elimination) Failure mode elimination consists of a process of designing solutions around design, manufacturing, installation, operational, and maintenance (DMIOM) systems and processes to avoid recurring failures. The solutions can address one or a combination of these DMIOM areas to avoid recurring failures. The Solution Design process provides a method for: • Specifying what the solution(s) will accomplish • Specifying the minimum solution requirements • Evaluating solutions • Understanding the benefits and risks associated with each solution or a combination of thereof Solution Planning and Implementation Solution implementation is one of the final steps of the RCFA process that involves the facilitation and project management of the solution design implementation to eliminate identified failure modes. The outcomes of the solution implementation phase include: • Installation QA/QC • Commissioning QA/QC • Implement Monitoring Strategies and Systems • Baseline Readings www.gpallied.com 22
    • GPAllied Sourcing Strategy It can be difficult for an organization to decide how to staff an initiative. There are always three options, in-house, contracted or hybrid. Which is more advantageous? Which is more troublesome? What are the advantages and limitations? GPAllied has a facilitated session that walks an organization through a series of questions and scenarios designed to clarify an understanding of the culture of an organization and help decide which of the three sourcing options is the best choice. Maintenance Craft Skills Training The diverse needs of today’s maintenance workforce can’t be met with a single canned solution. Producing multi-skilled maintenance technicians demands a multi-tiered solution that addresses diverse skill gaps and training needs. GPAllied’s solution, based on years of maintenance training, allows us to deliver the best training solution to your maintenance technicians regardless of their level of need. It all begins with a needs or gap analysis, followed by a training strategy design and customized course development and delivery. Our depth of experience and qualified maintenance experts ensure a highly-targeted program that transcends the limitations of canned approaches, and is based on a progression through four competency levels: • Level 1: The Core Competencies level provides the basic essentials for new hires or entry-level employees, and focuses on core math, print reading, and technical skills to ensure that they can perform at the higher levels. • Level 2: The Fundamentals level introduces much of the theory, such as Kirchhoff’s Law and Pascal’s Law, associated with the maintenance processes and includes basic concepts of hydraulics, pneumatics, pumps, PLCs, motors, etc. • Level 3: The Advanced Fundamentals level transfers the theory and knowledge elements into practical applications. This level ensures that your maintenance professionals are trained to perform all of their required tasks and gives them the hands-on learning opportunities to practice these critical skills. • Level 4: The Equipment Specific Training level ensures that your maintenance team is fully capable and well trained on the use and maintenance practices specific to your equipment. GPAllied, your total solutions partner, provides the following services: • Assessment and Planning. GPAllied provides Program Evaluations, Training Needs Assessment, Delivery Mode Analysis, Curriculum Architecture, and Training Plan Development. • Training Development. GPAllied provides review of prior training, and the analysis, design, development, and evaluation of customized training. • Training. GPAllied provides structured OJT programs, Train-the-Trainer Programs, On-Site Instruction (classroom or hands-on), Computer/Web-Based Training, and a large number of maintenance skills and maintenance systems courses. • Training Center Management: Apprentice programs. GPAllied provides employee testing, screening and selection; establishment, staffing, and management of craft training centers; training administration and logistics; structured on-the-job training; and certification programs. Personnel Qualifications and Work Execution Standards Personnel Qualifications Before a GPAllied person is deemed Task Qualified on a particular deliverable, they must meet a specific set of criteria. The criterion are based on the knowledge and experience required to maintain the highest standard of execution. The detailed qualification standards contain the following: • Background • References/Body of Knowledge • Qualification Levels • Education, Training and Experience Requirements • Certification www.gpallied.com 23
    • GPAllied For each of GPAllied’s processes and accompanying tools, there exists a training and qualification process which must be followed to ensure the integrity of the overall concept and process deliverable. GPAllied has developed a four (4) tiered approach for the qualification of delivering and utilizing our processes and tools. • Level I (User): This level of qualification is accomplished through successful completion of the training class or workshop associated with the process/tool. During the training session, each participant will be taught the concepts behind each process and/or accompanying tool. After the session, field homework is assigned to reinforce the concepts covered in the classroom. Successful demonstration of the ability to use the process/tool will constitute qualification as a Level I User. • Level II (Coach): This level of qualification is accomplished through the successful completion of a one week, process and tool specific, targeted training session. Each process requires a combination of course training and on- the-job (OJT) training and one day of task observation. During the course training both the process and tool requirements will be explained in detail to ensure the trainee has the ability to perform each task appropriately. The OJT training is utilized as an evaluation method, specific training objectives and observation materials will be used. This training is structured to properly evaluate an individual’s knowledge, skills and abilities to perform the desired task. Upon demonstrating their ability to perform the given task(s), they will be qualified as a Level II User. The Level II training develops a more thorough understanding of the intricacies of both the tool and the process than Level I. • Level III (Instructor): This level of qualification has a pre-requisite requirement that the individual has been through either the Level I or Level II qualification process and is a GPAllied employee. The participant will be evaluated through their performance of carrying out the desired task unassisted. The evaluation process is used to determine not only the individual’s ability to perform the task unassisted and thus demonstrating their knowledge, skills and abilities, but also to determine their ability to respond to any abnormal conditions that might occur. Upon successful demonstration of the ability to perform the given tasks, without assistance, they will be qualified as a Level III User. • Level IV (Discipline Leader): This level of qualification has a pre-requisite requirement that the individual has successfully completed Level III of the qualification process. The Level IV User not only has mastered both the process concepts and tool applications, but the user also has the administrative authority to modify integral tool functionality. Each GPAllied process has a Level IV Discipline Leader which owns the Management of Change (MOC) process and understands how that process integrates with other GPAllied processes. Work Execution Standards The execution of all of GPAllied’s specific deliverables is guided by a specific work execution standard. This standard is in place to guarantee one thing…consistency of execution. Whether you are working with us in North America or Malaysia, the delivery of a class, a workshop or a specific consulting project, will be done to the same exacting standard. Contained within the Work Execution Standard for each of the key deliverables will be items like: • Scope and Purpose • Terms and Definitions • Key Concepts • Process Overview • Specific Procedures • Process Exceptions • Key Performance Indicators Stakeholders inside of GPAllied follow a common MOC procedure for getting modifications made to the standardized deliverable. This is not to say that flexibility of delivery isn’t possible. In fact, flexibility is required for your success. But fidelity to the core concepts of the deliverable is the cornerstone of attaining successful results. www.gpallied.com 24
    • GPAllied Training Classes At GPAllied, we understand that you are not interested in “training for training’s sake”. You need hard-hitting, impactful training that addresses the specific need of your employees, delivers value for your training dollars, and produces bottom-line results. That’s what we deliver. In today’s increasingly competitive business environment, your training investment only makes sense if it yields a tangible improvement in KPI’s like: • Production efficiency • Asset downtime • Employee retention • Labor costs • Quality control • Safety With over 200 courses that can be easily customized to your equipment and processes, we are the one-stop shop for all of your technical and change management training needs. We offer these classes on-site at your facilities, for your employees; or periodically around the world on an open-enrollment basis. Please contact us for more specific information on training in the following areas: • Asset Health Assurance • Reliability Engineering • Lean • 5S • Six Sigma • Change Management • Leadership and Management Systems • Operator Maintenance • Electrical Maintenance • Mechanical Maintenance • Instrumentation and Control Systems • Planning and Scheduling • Shutdown, Turnaround, and Outage Management • Project Management • Safety and Environmental www.gpallied.com 25
    • GPAllied www.gpallied.com GPAllied is the most diverse reliability and operations consulting and services company in the world. Our technical expertise, product portfolio and global reach are unmatched. This diversity is our considerable strength. It enables us to develop significant value propositions for you by delivering solutions across different industries, different geographies and, even more importantly, across different aspects of your operation. In our constant strive to deliver greater value to you, we have sourced recognized industry experts to join the GPAllied team. We have extensive experience across all industry sectors and in the specialty fields of Lean, Reliability Engineering, Six Sigma, Condition Monitoring, Change Management, Maintenance Planning and Scheduling, Workforce Development and Maintenance Craft Skills training. For more information: 1.888.335.8276 or email us at info@gpallied.com 4360 Corporate Rd. Suite #110 North Charleston, SC 29405 www.gpallied.com Visit our web site at www.gpallied.com 27