Corporate Operational Reliability Reliability Center, Inc. © Reliability Center, Inc. 1985-2002

Corporate Operational ReliabilityCorporate Operational Reliability

Reliability Center, Inc.

www.Reliability.com

© Reliability Center, Inc. 1985-2002

Who is Reliability Center, Inc.?Who is Reliability Center, Inc.?

Began in 1972 as Allied Chemical’s Corporate R & D Reliability Center

Split off as an independent organization in 1985

Pioneered the industry standard, “Reliability Approach to Quality and Productivity”

Developers of the award winning PROACT® Software Suite including the New LEAP™ Opportunity Analysis Software

Providing flexibilty through common Reliability assistance, processes and training platforms worldwide


A Glimpse at Our Customer BaseA Glimpse at Our Customer Base

Air Liquide

AK Steel

BP/AMOCO

Chevron/Phillips

Coors Brewing

Dominion Virginia Power

Dupont

Eastman Chemicals

Ecopetrol

Eli Lilly

International Paper

Lafarge

Lyondell-Citgo

M&M Mars

PECOM (Perez Companc)

PDVSA

PEMEX

PREMCOR

Shell Canada

Syncrude Canada

Chevron - Texaco

Whirlpool


Reliability Program InitiativesReliability Program Initiatives

Program Identifies Action Result

RCM Critical Facility Equipment

Develop Preventive/Predictive Maintenance Program

Minimizes Consequences of Events to Critical Equipment

Six Sigma Cost of Poor Quality Determine Confidence Intervals and Hypothesis Testing Requirements

Project Statistical Model

Re-engineering Critical Job Positions and Key Personnel

Elimination of Non-Critical Positions and Personnel

Streamlines Organization to Fit Business Environment

Total Quality Process Variations and Critical Variables

Implementation of a Statistical Process Control Program

Reduction of Defects in Final Product

Root Cause Analysis Opportunities for Improvement

Focus on Priority Issues Using GAP and Opportunity Analysis

Eliminates Risk of Problem/Event Recurrence


Eliminating the risk of recurrence of undesirable outcomes

Here’s how you start...

PROACT® SystemPROACT® System


Calculate the "Gap” using FMEACalculate the "Gap” using FMEA

PRECISION

Status QuoStatus Quo

Continuous Improvement

Human RootsAddressed

(Disciplinary Action)

Physical RootsAddressed

Untrusting workforce

Latent Roots Addressed

Problems


Your targets are now highlighted…This is your money leak!Your targets are now highlighted…This is your money leak!

0%

10%

20%

30%

40%

50%

60%

% of Loss

Failure Events80% of loss

PSM - Problem Solving Methods

RCA - Root Cause Analysis

20% of loss


From your “Significant Few” findings split the eventsto be eliminated by the relevant RCI programFrom your “Significant Few” findings split the eventsto be eliminated by the relevant RCI program

Events

Principal Analyst Required Involves All Levels Part Time/Full Time

Root Cause Analysis Extremely Disciplined/

High Attention to Detail

Significant Few - 80% of Losses

Hourly/Supervisory Level Part Time

Problem Solving SkillsLess Attention to Detail

Random Many - 20% of Losses100% Coverage

RCA Methods

PSM

Advanced For Facilitators - Major Events

Problem Solving Methods - Minor Events


The RCI Two-Track ApproachThe RCI Two-Track Approach

Root Cause Analysis Methods© (RCA) Advanced Facilitation Methods for Major chronic event elimination

Problem Solving Methods© (PSM)Chronic event elimination at the supervisory and front line level

The Reliability Performance Process© (TRPP)Managing Reliability Systems for Executives


The Supporting Software forRCI’s Reliability SystemsThe Supporting Software forRCI’s Reliability Systems

LEAP™ SoftwareOpportunity Analysis

(OA) Process

+PROACT® Software

Root CauseAnalysis (RCA)

=Best Practices and

Lessons Learned Database

1 2 3 4 5 6 7 8 9 10

Priority Work Identified

20%


PROACT® Enterprise VersionPROACT® Enterprise Version

Produces Quick and Quantum ROI’s

Establishes Knowledge Management System forCorporation to Share Successful Logic Trees

Used to Eliminate Failures

Develops World Class Analytical Skills

Results in Drastic Cost Savings and Improved Performance

Ensures Regulatory Compliance

Significantly Reduces Cycle Times to Conduct Root Cause Analyses

Benefits:


The Basis for your Knowledge Management & Best Practices Transfer NetworkTie-in to your existing CMMS, ERP, EAM systemsThe Basis for your Knowledge Management & Best Practices Transfer NetworkTie-in to your existing CMMS, ERP, EAM systems

Desktop Version

Single-User

VS Enterprise Version

Network (SQL/ORACLE)

Brazil

Argentina

Mexico

Server

Venezuela

Enterprise Version

Enterprise Version

Enterprise Version


Unfortunately, most companies do not allow the results they achieve to be published…but these did!Unfortunately, most companies do not allow the results they achieve to be published…but these did!

“Root Cause Analysis: Improving Performance for Bottom-Line Results” Latino & Latino, 2002, CRC Press, Boca Raton, FL, ISBN 0-8493-1318-x(See Case Studies in Chapter 11)

Eastman Chemical (World Hqtr.)50% Reduction in Customer Complaints

Weyerhaeuser25% Increase in Prod. Capacity

LYONDELL-CITGO17,900% ROI

(ISPAT) Inland Steel4,000% ROI

Eastman Chemical (TED)3,200% ROI

Alabama Power3,125% ROI © Reliability Center, Inc. 1985-2002

http://www.reliability.com/products/rcabook_2ndedition.htm

http://www.reliability.com/products/rcabook_2ndedition.htm

Maintain

Conduct RCA on High Return Event With Trained Team

Demonstrate ROI’s To Fund RCA Effort

Correlate RCA Objectives with Corporate Key Performance Indicators

Establish Performance Target

Set Up Management Support Structure

Train & Roll Out To Analysts

Prove Effectiveness

Keep It Up

How to start and fund your PROACT®Corporate Reliability ProcessHow to start and fund your PROACT®Corporate Reliability Process

Pilot

RCA

Provide

ROI

Establish

KPI’s

Develop

GAP

Set Up

Support

Roll Out

Track/

Measure


Calculate your company’s savingsCalculate your company’s savings

ROI

Now for the fun part!Click the ROI button below and put in your numbers (not ours.) You will be surprised at the reachable savings still to be had within your company.

(Click Here)


http://www.reliability.com/demo/ROI_Calculator.xls

http://www.reliability.com/demo/ROI_Calculator.xls

SummarySummary

The average analysis from start to implementation using the PROACT® System is 5 weeks - 5 months.

RCI offers quick results generated from within your company, not by outside consultants. No massive capital investments or major man hour allocations are required.

In our experience, the elimination of one major failure utilizing RCI’s PROACT ® process will fund ALL of your Reliability Programs.

WARNING! The worst case scenario we see day after day is training of a few individuals and expecting corporate to move from Reactive to Precision Based Reliability.

We invite you to visit our web site at www.reliability.com. There is a gold mine of information for you. If you are serious about a corporate change in your organization regarding improvements to your bottom-line we look forward to hearing from you. Contact Norman Haggie at804-458-0645 x311 or [email protected].


Thank you for your attention!Thank you for your attention!

Reliability Center, Inc.www.Reliability.com

804-458-0645

804-452-2119 [fax]

[email protected]

501 Westover Ave.

Hopewell, Virginia 23860


Documents

Corporate Operational Reliability Reliability Center, Inc. © Reliability Center, Inc. 1985-2002