Reliability and Maintenance Excellence (RME)

Understand how asset performance management links capital and operating expenditures to long-term value by optimizing reliability, lifecycle planning, and continuous performance monitoring through IoT, analytics, and disciplined maintenance.

Apply root cause failure analysis to shift from reactive to proactive maintenance, using five whys and fishbone diagrams to identify causes, document evidence and impact, and implement preventive actions.

Explore fracas, a closed-loop failure reporting, analysis and corrective action system that uses a database to capture failures, identify root causes, and implement corrective actions to improve reliability.

Explore reliability design principles, definitions, and metrics such as availability, maintainability, MTBF, and failure rate, plus bathtub curve, reliability block diagrams, and life-cycle cost considerations.

Explore maintenance work management essentials, including work IDs, prioritization, planning and scheduling, backlog and materials management, data accuracy, and KPIs, and learn the benefits of a best-in-class planning window.

Leverage planning and scheduling to reduce downtime and operating expenses, boosting revenue growth and profitability in the connected enterprise through predictive and on-condition maintenance.

Identify work with aggressive defect identification and correct equipment identification to prevent reactive maintenance, empower operators as the first line of defense, and validate work requests promptly for proactive maintenance.

Set up a work prioritization system that classifies tasks as emergency, urgent, or normal. Document an agreement among production, maintenance, and planning to reduce conflicts and guide prioritization.

Coordinate production and maintenance through a six-week cooperative scheduling process, refining the final schedule from six weeks to execution, emphasizing planned, backlog-backed work and resource leveling.

Treat backlog as a reservoir to balance workload with capacity and maximize resource utilization, keeping five to seven weeks of work on hand across ready, planned, and identified backlog.

Learn how managing materials and spare parts drives effective maintenance and corrective action, and why involving the material management team and warehouse is essential to prevent production-maintenance friction.

Assign work to responsible personnel, document deviations, collect feedback, and close the work order to ensure schedule compliance; prioritize internal craftspeople and confirm scope, parts, permits, and tools before execution.

Close the loop on work orders by ensuring data accuracy and quality to avoid garbage in, garbage out, and share this information across engineering, reliability, warehouse, and procurement.

Identify key performance indicators to measure maintenance and operations, align them with corporate goals, and use leading and lagging indicators to drive reliability, schedule compliance, and reduce emergency work orders.

Identify long-range work within the planning window, align seasonal requirements for winter and summer, and translate into a six-week maintenance cycle guiding backlog-driven weekly scheduling.

Review the work management loop from prioritization to closure, emphasizing documentation, feedback, and KPI-driven improvements. Leverage teamwork, data integrity, and clear roles to boost efficiency.

Explore workforce management in maintenance and reliability, covering planning, employee lifecycle, change and culture, benchmarking, data driven efficiency, and centralized organization structures to align vision and performance.

Explore workforce management within maintenance and reliability, covering planning, organizational change, alignment, employee lifecycle, generation gap, benchmarking, and organization structures centralized, decentralized, or hybrid for reliability success.