Reliability Leadership for Manufacturing Excellence

The very best plants can accomplish reliability and manufacturing through the application of a reliability strategy, which supports lean manufacturing, supply chain principles, and excellence in operations and maintenance, and assures them of being the low-cost producer. This strategy ensures optimal production capability at a minimum sustainable cost. Costs are avoided by eliminating the “defects” which cause the costs being incurred in the first place, optimizing the work that adds value.

Typical Course Candidates

• Managers – Production/ Operations & Maintenance
• Engineers – Reliability, Maintenance, Process& Safety
• Anyone who leads or influences the direction and success of manufacturing plants

Course configuration:

Overview of Reliability Leadership for Manufacturing Excellence:

• Introduction
• Manufacturing Excellence Overview
• Asset Utilization / Overall Equipment Effectiveness
• Safety and Reliability – Mutually Dependent
• Benchmarks

The Reliability Process: Design, Buy, Store, Install, Operate, and Maintain for Reliability

• Designing for lowest life cycle cost vs. lowest installed cost
• Buying for supplier reliability and total cost of ownership
• Stores as a value adding asset and support function for reliability
• Installing/starting up with precision; avoiding infant mortality failures
• Operating with care, precision, consistency, and conformance

Maintaining with care and precision, and imputing reliability into the plant:

• Preventive, Predictive, and Proactive Methods

Reliability Related Methods and Tools:

• Reliability Centered Maintenance (RCM)
• Total Productive Maintenance (TPM)
• Case Studies – Combining RCM and TPM Principles – Business Level FMEA Leadership and Organizational Issues/ Strategies

Strategy for Implementation

• Leadership Principles
• Alignment and Teamwork
• Change Management

Success Stories

Summary