Maintenance and Reliability Networking Conference

theeventful group

Silver Partners: Produced by:

14 - 16 May 2012Esplanade Hotel Fremantle, Perth

Maintenance and Reliability Networking Conference

www.mainstreamconference.com Mainstream™ 2012 | 3

ContentsHot TopicsMaintenance and Reliability Professionals from more than 100 companies have collaborated to create the program around these specifi c hot topics

Meet the Keynote & International SpeakersLed by Drew Troyer, CRE, MBA & CMRP, Visy Pulp & Paper Pty Ltd (USA), this year’s line-up includes Joseph Park (Novelis Inc., USA), Tom Lenahan (Tom Lenahan Limited, UK), Mark Haarman (Mainnovation, Netherlands), Gavin Campbell (RailCorp New South Wales) and Silvia Damiano (Leadership Consultant and Author)

Meet the SpeakersPresentations from 31 local and international speakers providing insights into what companies are achieving here and overseas

Three-Day Program OverviewYour double-page guide to 36 presentations, workshops and sessions in six tracks over three days

Special Interest SessionsIn addition to the plethora of conference presentations, sessions and workshops, there are three special interest sessions: “Big Picture Thinking” - three in-depth interactive 2 hour sessions delivered by industry thought leaders; the inaugural Mainstream 2012 Award; and a panel session of industry leaders sharing their viewpoints on the decisions that affect you!!

View All Abstracts Every abstract from every company - their tips & tricks, challenges & solutions - all vetted by the Mainstream Conference Advisory Team representing large, medium and small organisations across many industry sectors

WorkshopsChoice of two interactive workshops:Workshop 1: Optimising Value From Your Maintenance Planning

Workshop 2: Creating a Winning Reliability Strategy

Compelling Reasons to Attend MainstreamGet information you won’t get anywhere else, develop professionally and personally and tap into the collective wisdom of community and connectedness. Someone in this community has the answer to your most pressing business or technical challenge!

Solutions ShowcaseThe exhibition features selected partners who understand the business of maintenance, reliability and asset management organisations and are serious about helping you make the smartest IT and business investments

RegistrationRegister online, via email or fax, or over the phone. Take note of the special early birdand group booking rates

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Thoughtfully designed to encourage you to look outside of your

company and industry, Mainstream is a gathering place where

maintenance and reliability people engage in brave and important

conversations, fi nd answers to common challenges and inspire one

another to explore future opportunities. Mainstream 2012 marks our 17th year

of serving and supporting the Australian Maintenance and Reliability Community.

Hot TopicsThe depth and breadth of the Mainstream Conference content is a result of 6 months of careful research and development. Maintenance and Reliability Professionals from more than 100 organisations across Australia have collaborated with the Mainstream Advisory Team in a series of Round Table Discussions to create this program around 12 Hot Topics.


Improving the Productivity of Your Workforce

• Achieving greater output from less resources

• Case studies from successful organisations on how to demonstrate ROI without compromising on quality

• Learn strategies and frameworks to achieve your KPIs and business goals, including Lean Maintenance and Six Sigma

• Building skilled teams and arming them with the right tools to meet your business requirements

• Connecting and communicating with your teams to understand the systems in place

• Boost productivity with advanced knowledge gathering techniques to avoid the information drain

• Mobilising your staff to achieve, simplifying processes and implementing effective change management techniques

• Improving your reliability and output from improved contamination control

Successfully Managing Aging Assets & Being Ready For Expansion

• Managing maintenance from the plant inception and planning for obsolescence through the whole asset life cycle

• Building effective assets with structural integrity

• Implementing tasks in the systems and plan for obsolescence

• Analysing material management for spare parts to minimise obsolescence

• Navigate away from the “it’s too late the equipment isn’t even supplied anymore” scenario

Implementing Overall Strategic Asset Management Strategies

• Understanding the journey of introducing asset management systems to ensure you reach your potential

• Meeting your future business requirements with a focus on reliability processes, systems, training and metrics

• Utilising your ERP/CMMS tools to capture information and provide real-time data, enabling clearer and more accurate decision making on asset life-cycles

• Sleep calmly knowing your operational risks are under control - evaluating risks in terms of cost and future spend

• Convincing and infl uencing your business managers and senior management of the worthwhile investment from the outset

• Insights into the models for measuring and extending the life of their assets

• Assessing the merits and impact of standards, OHSA projects and their potential impact to you

• Ensuring your plan is fl exible to cope with changing market conditions

Instill a Reliability Culture Throughout Your Business • Understanding your assets and maximising the information from

your RCM (Reliability Centred Maintenance)

• Building relationships with identical critical assets and knowing why output is variable

• Implementing effective practices with TPM, 5S and lean manufacturing

• Drive reliability improvement with correct data from your CMMS/ERP systems

• Sustaining discussions with your team to measure for continuous improvement

• Setting the skill sets needed for your new reliability engineers

• Instilling ownership within your teams

• Measuring your reliability improvement process and its intrinsic link to successfully communicate the reasons for change

Creating Benefi t From Your ERP/CMMS Maintenance Programs• Instilling a communication strategy to engage your team

• Technologies to ensure the quality of the data

• Practical examples of how to survive a corporate sponsored software project

• Setting-up and utilising your system to manage the whole life-cycle of your assets

• Getting people engaged and motivated

• Ensuring your system complies and communicates with existing systems

Getting Maintenance & Production Teams Working Together• Managing the roles of responsibility between operators and

maintenance

• Deriving benefi ts from maintenance and operations assisting in project teams

• Collecting and relaying clear and accurate data right across the organisation

• Effective methods of communicating with both teams, exposing the benefi cial synergies

Keep Your Intellectual Property Within a Changing Workforce• Developing your own library of critical knowledge to reduce

corporate memory loss

• You’re only as good as your best information, evaluating the risks and rewards if knowledge resides with only a few select people

• Take-away tools to enable you to identify the key learning styles for each individual - managing those individuals with different learning styles

• Introducing new technologies available to you and who to employ in the process

• Ensuring the right data (accurate and realistic) and information is collected and benchmarked

Negotiating the Skills Journey

• Train them and they leave, or don’t train them and they stay?

• Building in initiatives to develop leaders at all levels of your team, boost performance and champion the ideas of your staff

• The strategies you can employ to identify the key motivations of your team, their learning styles and how to defi ne their individual competency requirements

• Understanding the meaning of true collaboration as a way to build trust and inspire high performance

• New ways of thinking, creating the equation “available effective man-hours = man-hours required to complete maintenance”

• How you motivate your team to feel part of the decision making and improvement processes

• The benefi ts of developing a reliability engineering training curriculum

• Adequately providing your workforce with the necessary skills and framework to meet your goals

Communicating the Value of Maintenance to Management

• Effectively negotiating with a management team afraid of innovation and risk

• Case studies from organisations that have developed a business case which justifi es maintenance dollars

• Reporting tools to display real-time performance improvements

• Optimising relationships with operations to provide solid evidence for investment

You Are Only as Good as Your People

• The strategies to help make engineers the best managers they can be

• Building effective people managers - moving them from the shop fl oor to management

• Infl uencing management to provide greater clarity to achieve the desired result for the business

• Motivating your team through the demonstration of clear career routes for future management stars

• Ensuring your people do not get left behind with their skills knowledge

Build the Best Relationship with Your Contractors & Alliances

• Building suffi cient fl exibility in the contract and KPIs

• Organisations with primary evidence of an experienced and skilled reliability team

• Determining the skill sets of your personnel - are they the right skills for the job?

• Establishing “Service Level Agreements” to benefi t both you and your contractor

• Keeping project knowledge onsite and available to you in the future

Adapting & Managing Economic & Environmental Change

• How companies have employed technology to enable accurate decision making

• Preparing for the eventuality of standards, OHSA harmonisations and future government initiatives

• Ensuring your people are prepared for changing paradigms, roles and responsibilities


Value Driven Maintenance - Discover the Hidden Treasure in Your Maintenance Organisation

VITALE - a Best Practice Reference Model for Asset Lifetime Extension

Mark holds a Masters Degree in Mechanical Engineering (specialisation maintenance management) from the Delft University of Technology and an MBA degree from the Erasmus University of Rotterdam. He went on to work for the Rotterdam public transport company RET as an internal maintenance consultant. He subsequently headed the evaluation department at Rijkswerf (the maintenance and repair yard of the Royal Dutch Navy). In 1995, he moved to Ernst & Young Consulting, where he set up and led the global Maintenance & Service Consulting Practice. In 2000 Mark established Mainnovation, one of the leading maintenance consultancies in Europe and the inventor of Value Driven Maintenance®. Value Driven Maintenance® is a methodology for developing maintenance organisations so as to create demonstrable value for a company. Mark has become a maintenance expert with a wide array of expertise. He has acquired considerable knowledge and experience of various maintenance methods (including RCM and TPM), benchmarking and optimising maintenance organisations and selecting and implementing Enterprise Asset Management (EAM) systems.

Mark Haarman - Managing Partner, Mainnovation (Netherlands)

Instilling a Reliability Culture Among Practitioners

Is Skill Shortage a Problem? Really?

Optimising Value From Your Maintenance Planning

Tom has been involved in maintenance for over forty years and during this time has built up a comprehensive knowledge of all aspects of these events and their impact on the wider maintenance system. Tom is also the author of the textbook “Turnaround Shutdown and Outage Management” which was the first ever book published on the subject. Tom has worked with, trained and facilitated major companies in over twenty countries around the world in the Oil, Gas, Aluminum, Chemical, Agrochemical, Cement, Paper and Manufacturing Industries.

Tom Lenahan - Director, Tom Lenahan Limited (UK)

Making Reliability a Strategic Corporate Initiative

Maintenance Embrace Lean - Are You Kidding?

Joe is responsible for training, coaching, auditing and the development of reliability programs within Novelis manufacturing facilities worldwide. As a Certified Lean Six Sigma Master Black Belt, he has led major projects in multiple manufacturing sites and was responsible for training and coaching of Novelis Black Belts and Green Belts. Prior to this he spent 9 years as the Engineering Reliability Leader for the finishing department at Logan Aluminum. He received his BSEE from Tennessee State University in 1988. Joe is an ASQ Certified Reliability Engineer and CMRP.

Joseph Park - NNA Reliability Manager, Novelis Inc. (USA)

We Lead the Way: Empower Frontline Leaders to Meet the Challenges of a Changed Environment

Panel Discussion: The View From Above - Influencing Change

As GGM Asset Operations, Gavin leads a team of approximately 4,000 people who work behind the scenes to maintain RailCorp’s assets, including rolling stock, track, signals, overhead wiring, communications and station buildings. Careful planning goes into the Major Periodic Maintenance (MPM) program to ensure that the assets perform at their best and meet the needs of train and station service delivery customers. Gavin spent much of his earlier career at Qantas where most recently he headed its Defence Services, delivering improved customer service, a new safety performance program and restructuring the business to position it for future growth. A Six Sigma Black Belt, Gavin oversaw the implementation of Qantas’ successful Lean Six Sigma business improvement program. Gavin has a Masters in Business Administration from the University of Wollongong and a Mechanical Engineering degree from the University of Technology Sydney. When not at work, Gavin likes to spend time with his family. He is keen to involve his two sons in his favourite sport which is surfing on the beautiful NSW south coast. He has also recently turned his hand to cooking and his family is enjoying many new recipes.

Gavin Campbell - Group General Manager, Asset Operations, RailCorp New South Wales

The Science of Engagement and Motivation

Silvia is a charismatic and thought provoking speaker and facilitator on the topics of emotional intelligence, neuroleadership and engagement. An expert in the design and implementation of organisational learning strategies, Silvia received in 2006 the learning and development Excellence Award for the best project by the AITD (Australian Institute of Training and Development). Silvia is a well sought after speaker and facilitator working with clients from a variety of industries, which include finance, pharmaceutical, health, manufacturing and professional organisations.

Silvia Damiano - Leadership Consultant and Author

Special Guest Speaker: Dynamic Leadership in a Crisis

Peter Baines is one of Australia’s leadership experts having road tested leadership the hard way. Peter spent 22 years with the NSW Police leading teams in response to acts of terrorism and natural disasters on a scale not previously seen. Peter was part of the leadership team that responded to Bali after the bombings in 2002 and was called upon in 2005 to lead national and international teams in response to the Boxing Day Tsunami, heading up multiple rotations into Thailand leading teams in the identification process of those who died. All the time his leadership theories were tested in this trying environment. This is an incredible story about a man who has worked in some of the most difficult situations. Hear how his experiences have inspired him to change people’s lives.

Peter Baines

Keynote & International Speakers

Building Plant Reliability - From the Middle Out

Lean Cell Concept for Equipment Inspections

Creating a Winning Reliability Strategy

President and Founder of Sigma Reliability Solutions, LLC and adjunct member of the National Reliability Management team for Visy Paper, Drew is a globally recognised expert on maintenance and reliability engineering and management, award winning author, trusted advisor to Fortune 500 companies around the world and a popular keynote speaker. Drew holds the Certified Reliability Engineer (CRE), Certified Maintenance and Reliability Professional (CMRP) and MBA qualifications to go along with 20 years in the trenches. Drew has figured out how to put you on the fast track and ready to execute a reliability strategy that produces results.

Drew Troyer - CRE, MBA & CMRP & Member of the National Reliability Management Team, Visy Pulp & Paper Pty Ltd (USA)


Speakers

Surviving the Knowledge Drought - How to Harvest Your Plant’s Critical Maintenance ‘Know-How’ Ian Renall - Ironmaking Maintenance Superintendent, New Zealand Steel Limited (New Zealand)

The Journey Starts - Introducing an Enterprise Asset Management SystemRory MacManus - Asset Performance Manager SEQ, Queensland Rail

Beyond Efficiency - Breaking the Work Management MindsetGary West - Chief Advisor - Asset Management, Technology and Innovation, Rio Tinto Limited

Design for Operations, an Oxymoron?Hugh Beveridge - Engineering Manager Tropicana Joint Venture, AngloGold Ashanti Australia Limited

Operator Essential Care - the Frontline Driving ReliabilityCraig Goldfinch - Senior Adviser Operations Improvement - Down Stream Gas, Santos Ltd

Effectively Deliver a Work Management ProgramPeter Durrant - Programme Manager Education and Change Management, Covaris Pty Ltd

Asset Integrity Management - a Key Solution for Asset Life-Cycle MaximisationPaul Sugis - CSG Lead Asset Integrity Engineer, Origin Energy Limited

Let’s Talk About the Elephant in the Room! Maximising Successful Implementations by Managing ChangeGreg Taylor - Head of Business Integration, Shared Services, UGL Limited

Breaking the Despair of Reactive Maintenance - Implementing Successful Proactive Approaches

Panel Discussion: The View From Above - Influencing ChangeEd Beattie - GM Property and Network Operations, Chorus (New Zealand)

Building Contractor Relationships to Keep Your Team FlyingDarren Shaw - Engineering Services Manager, Melbourne Airport

Maintenance - No More, No Less!Dr Phillip Tirabosco - Maintenance Services Manager, Woodside Energy Limited

RCM Ain’t RCM - the True Value in Improving Your PM Program

JumpStart: Making the Most Out of “Mainstream” and its CommunitySandy Dunn - Director, Assetivity Pty Ltd

Profiting From Contamination (Control)Mark Barnes - Vice President Reliability Services, Des-Case Corporation (USA)

Panel Discussion: The View From Above - Influencing ChangeJim Henneberry - Chief Executive Officer, Australian Paper

Eliminating Bolted Joint FailuresTrevor Robinson - Technical Director, Boltstress Ultrasonics

Panel Discussion: The View From Above - Influencing ChangeBarry Grant - Global Practice Leader - Asset Management, Technology and Innovation, Rio Tinto Limited

Breakfast Session: Energy Management and Equipment Efficiency in Mineral ProcessingGenghis Erkan - Installation & Commissioning Manager, Metso Minerals (Australia) Limited

The Implementation Void - Getting You, Your Planners and Your CMMS Aligned and on the Same PageJason Apps - Technical Director, ARMS Reliability

Building a Winning Maintenance Strategy: Using Technology to Improve Responsiveness, Reduce Cost and Improve VisibilityRob Attard - Principal Consultant, Mincom

ERP/EAM Software - How to Survive the Implementation, Create Benefits and Keep Corporate Happy?Kahn Ellis - Senior Partner, COO, Vesta Partners, LLC (USA)

Lean Processes to Improve Daily Breakdown Performance and Shutdown Maintenance OutcomesDuncan Anderson - Director, KM&T Pty Ltd

Is Understanding the Life-Cycle of Your Assets Really Worthwhile?Richard Johnson - Technical Director, Rylson Group

Surviving the Knowledge Drought - How to Harvest Your Plant’s Critical Maintenance ‘Know-How’ Mark Foster - 3D Visualisation Specialist, New Zealand Steel Limited (New Zealand)

Building Plant Reliability - From the Middle OutGrant Crosley - General Manager Reliability and Manufacturing Systems, Visy Pulp & Paper Pty Ltd



Panel Members: Jim Henneberry - Chief Executive Officer, Australian Paper

Barry Grant - Global Practice Leader - Asset Management, Technology and Innovation, Rio Tinto Limited


Ed Beattie - GM Property and Network Operations, Chorus (New Zealand)

09.00

Conference OverviewTuesday Conference Day Two

Tea & Coffee/Exhibition Viewing08.00

08.00 Breakfast Session: Energy Management and Equipment Efficiency in Mineral Processing

Genghis Erkan - Installation & Commissioning Manager, Metso Minerals (Australia) Limited

Wednesday Workshops

Workshop 1: Optimising Value From Your Maintenance PlanningLed by: Tom Lenahan - Director, Tom Lenahan Limited (UK)

Workshop 2: Creating a Winning Reliability StrategyLed by: Drew Troyer - CRE, MBA, CMRP & Member of the National Reliability Management Team, Visy Pulp & Paper Pty Ltd (USA)

Registration/Arrival Tea & Coffee

Mainstream Workshops Close

09.00

08.30

15.00

Beyond Efficiency - Breaking the Work Management Mindset

Gary West - Chief Advisor - Asset Management, Technology and Innovation, Rio Tinto Limited



10.40

Morning Tea & Coffee/Exhibition Viewing



10.00

11.35 Operator Essential Care - the Frontline Driving Reliability

Craig Goldfinch - Senior Adviser Operations Improvement - Down Stream Gas, Santos Ltd

The Journey Starts - Introducing an Enterprise Asset Management System Rory MacManus - Asset Performance Manager SEQ, Queensland Rail

Mainstream Conference Close

Eliminating Bolted Joint Failures

Trevor Robinson - Technical Director, Boltstress Ultrasonics

Closing Keynote Presentation: Is Skill Shortage a Problem? Really?Tom Lenahan - Director, Tom Lenahan Limited (UK)

14.20

15.40

17.45

13.25

16.35

Is Understanding the Life-Cycle of Your Assets Really Worthwhile?

Richard Johnson - Technical Director, Rylson Group

The Implementation Void - Getting You, Your Planners and Your CMMS Aligned and on the Same Page

Jason Apps - Technical Director, ARMS Reliability

Lunch/Exhibition Viewing12.25

Afternoon Tea & Coffee/Exhibition Viewing15.10

TRACK A TRACK B TRACK C

Lean Cell Concept for Equipment Inspections


Let’s Talk About the Elephant in the Room! Maximising Successful Implementations by Managing Change

Greg Taylor - Head of Business Integration, Shared Services, UGL Limited

Asset Integrity Management - a Key Solution for Asset Life-Cycle Maximisation

Paul Sugis - CSG Lead Asset Integrity Engineer, Origin Energy Limited

Mainstream 2011 - Innovating for Business Effectiveness

Presented by the Mainstream Innovation Award Winners

ERP/EAM Software - How to Survive the Implementation, Create Benefits and Keep Corporate Happy?

Kahn Ellis - Senior Partner, COO, Vesta Partners, LLC (USA)

Building a Winning Maintenance Strategy: Using Technology to Improve Responsiveness, Reduce Cost and Improve Visibility

Rob Attard - Principal Consultant, Mincom

Lean Processes to Improve Daily Breakdown Performance and Shutdown Maintenance Outcomes

Duncan Anderson - Director, KM&T Pty Ltd

Sunday JumpStart

Pre-Conference JumpStart Session: Making the Most Out of “Mainstream” and its Community

Led by: Sandy Dunn - Director, Assetivity Pty Ltd

Pre-Conference Networking Drinks

18.30

19.30

10.00

11.00

11.40

Monday Conference Day One

Registration/Arrival Tea & Coffee/Exhibition Viewing

Conference Opening and Chairperson’s Welcome

08.00

08.30

09.00 Opening Keynote Presentation: Value Driven Maintenance - Discover the Hidden Treasure in Your Maintenance Organisation


Keynote Presentation: We Lead the Way: Empower Frontline Leaders to Meet the Challenges of a Changed Environment



Big Picture Thinking Presentations

Maintenance - No More, No Less!

Dr Phillip Tirabosco - Maintenance Services Manager, Woodside Energy Limited



15.35

14.40

Building Contractor Relationships to Keep Your Team Flying

Darren Shaw - Engineering Services Manager, Melbourne Airport

Surviving the Knowledge Drought - How to Harvest Your Plant’s Critical Maintenance ‘Know-How’

Ian Renall - Ironmaking Maintenance Superintendent & Mark Foster - 3D Visualisation Specialist, New Zealand Steel Limited (New Zealand)


Design for Operations, an Oxymoron?

Hugh Beveridge - Engineering Manager Tropicana Joint Venture, AngloGold Ashanti Australia Limited






Drew Troyer - CRE, MBA & CMRP (USA) & Grant Crosley - General Manager Reliability and Manufacturing Systems, Visy Pulp & Paper Pty Ltd




Sandy Dunn - Director, Assetivity Pty Ltd

17.05 Effectively Deliver a Work Management Program

Peter Durrant - Programme Manager Education and Change Management, Covaris Pty Ltd

Profiting From Contamination (Control)

Mark Barnes - Vice President Reliability Services, Des-Case Corporation (USA)

Special Guest Speaker: Dynamic Leadership in a Crisis - Peter Baines

Mainstream Community Networking Drinks Sponsored by

18.00

19.00

Afternoon Tea & Coffee/Exhibition Viewing16.25

Lunch/Exhibition Viewing13.40


Monday 14 May 2012

Sunday 13 May 2012

Registration/Arrival Tea & Coffee/Exhibition Viewing


Conference Opening and Chairperson’s Welcome

08.00

11.00

08.30

09.00

18.30

19.30

10.00

Opening Keynote Presentation: Value Driven Maintenance - Discover the Hidden Treasure in Your Maintenance Organisation

“What actually is the added value of maintenance?” is a frequently heard question in boardrooms across the world. Even though maintenance is often critically important, few Maintenance Managers are able to answer the question convincingly, with the result being that maintenance is predominantly treated as a cost item. Especially in times of economic downturn.

• The four economic value drivers of a maintenance organisation

• How you can measure the economic value potential within your own department

• How you can design your most valuable maintenance organisation and why it is different for each individual company

• Does Value Driven Maintenance (VDM) replace best practices like TPM, RCM, PdM and RBI?

• How you can steer value to lead to continuous improvement

• Learn from leading VDM organisations from around the world

Key take-away points:

1. A template for a maintenance business case that convinces corporate management

2. Guidelines for building your most valuable maintenance organisation

3. Tools that monitor your value performance


Pre-Conference JumpStart Session: Making the Most Out of “Mainstream” and its Community

Mainstream is not just a conference. It provides a portal into a vibrant and knowledgeable community of maintenance and reliability experts.

This session is designed for companies and individuals new to Mainstream. It will provide you with guidelines, tips and tricks about how best to utilise your three days so as to get the best possible return on your conference investment. It will give you an overview of the event and then point you towards specifics in the program so that you can:

• Leave with real solutions to business and technical problems

• Hear what to do (and what not to do!) from customers

• Identify implementation tips and tricks

• Review and select solutions and services

• Become part of a long lasting network for ongoing advice and knowledge

Led by: Sandy Dunn - Director, Assetivity Pty Ltd

Pre-Conference Networking Drinks

Keynote Presentation: We Lead The Way: Empower Frontline Leaders to Meet the Challenges of a Changed Environment

RailCorp’s Asset Operations Group faces four major challenges: increasing government expectations for safety, service quality and efficiency; a growing asset base; pressure to reduce maintenance costs; and tough competition for skilled workers.

Though the group has worked hard to develop the right skills, it has not traditionally focused on developing leadership ability. Yet without capable leaders at all levels of the organisation, a disconnect forms between the strategy and the execution.

To tackle these issues head-on, the organisation implemented an incredible program which has derived massive benefits.

• Three major leadership development programs for senior managers, women and frontline supervisors

• An experiential learning process to build self-awareness and capacity among leaders - so they understand their role and the tools available to them

• The right support for leaders, so they can boost performance and champion the ideas and concerns of their staff

• Empower the front line to develop solutions for their area of responsibility: solutions that are informed by direct experience, have credibility with the workforce and give the front line a sense of ownership

• Build a robust, flexible organisation by connecting every level with high-quality, two-way communication


1. How to implement a leadership program that goes beyond your standard management training

2. How frontline leaders can apply new skills and techniques to solve real-world problems

3. How a focus on leadership can enhance safety, efficiency and customer experience


Monday 14 May 2012Big Picture Thinking Presentations11.40 - 13.40Three in-depth, interactive two hour sessions delivered by industry thought leaders.

Big Picture Thinking: it’s what every organisation pursues for strategic advantage and business performance improvement. It’s what is expected from all of us if we are to succeed. The ability to read the signs and the trends, to formulate strategy, to determine the way forward and drive towards our goal achievement.

It’s what you have asked for. We are thrilled to offer you, in response to all the invaluable feedback from our research, these intensive, thought provoking sessions. You will hear from three industry gurus on three critical issues currently impacting your teams and businesses. Each will take you outside of the box and arm you with Big Picture Thinking to cut through the hype, to deliver insights and high value to your teams and to give you thoughtful fuel for progress in your organisation.

Big Picture Thinking Presentations… your leading presenters:

1. Human motivation - with world renowned author and practitioner Silvia Damiano Experience a fascinating exploration of human motivation. Through hands on activities, access the secrets of leading and inspiring a successful team and practical tools you can apply back in the workplace.

2. World-class equipment asset reliability management with Drew Troyer and Grant Crosley of Visy Join Drew and Grant as they take you on a journey towards world-class equipment asset reliability management, highlight the obstacles you need to avoid and shed light on the routes you need to take on the roadmap to future success.

3. Reliability culture with legendary Tom Lenahan Tom will demonstrate how you can develop a high performance reliability culture within your teams and build a toolset for a reliable plant!

Tuesday 15 May 2012Panel Discussion - The View From Above - Influencing Change 09.00 - 10.00Battling against a smaller skilled labour base? Tasked with more systems and processes to manage? Weighed down by budgetary requirements and viewed by operations and management as a cost centre? Does this scenario sound familiar to you?

This expertly moderated panel discussion gives you the perfect platform to get answers to all the difficult questions you’ve ever wanted to ask. This 60 minute session will pose both prepared and live audience questions to the expert panel from Rio Tinto, Schweppes, RailCorp, Australian Paper and Chorus New Zealand. Hear the views of these senior industry leaders from Australian and international organisations. Understand their concerns, indicators and guidelines which shape the decisions they make. Look through the window into their worlds. Take away tips and tricks to help you manage upwards and communicate more effectively the benefits of your department and the initiatives it delivers - and win the favour of your own management teams.

Case Studies From the Winners of the Inaugural Mainstream Award for Innovation in Maintenance and Reliability14.20 - 15.10To elevate and recognise the innovation in maintenance and reliability that is at the heart of Mainstream, the 2012 event will feature the winners of the very first prestigious Mainstream Award. The two winners, to be judged by industry luminaries from across the country, will present their winning concepts at this year’s conference, adding more spice to the huge value you derive from this, our flagship community event.

Attend these two real-life 20 minute case studies to see and understand how an idea was conceived, grown into an initiative and brought to fruition - and how it made a positive impact on people, processes and performance.

Get in the running for the Award!

Did you attend Mainstream 2011 and from your conversations there take-away an idea and put it into practice in your organisation? If you did then you are eligible to enter and be crowned a winner of the inaugural Mainstream Award for Innovation in Maintenance and Reliability. For more details on how to enter with a short submission, please contact Ian Collier at [email protected]

In twelve months time this award could belong to you, your team and your organisation! That’s what can happen from the brave conversations you have with us - delivering terrific benefits to you and your organisation in 2012-13!!

Special Interest Sessions


18.00 Special Guest Speaker: Dynamic Leadership in a Crisis - Peter Baines

Mainstream™ Community Networking Drinks Sponsored by 19.00


Have you ever wondered what engages people at work? Explored and shared with your boss what engages you? Curious to know what has changed in terms of how engagement is viewed from the perspective of neuroscience?

If you answered yes to any of these questions then this presentation is the right choice for you.

Knowing how to engage others firstly requires an understanding of what engages “you”. Engagement is an active process and starts within yourself. Join Silvia in the fascinating exploration of human motivation while learning the secrets of how to lead and inspire a successful team. This presentation is a combination of the latest theories, hands-on activities, providing you with a myriad of practical tools that you can apply back in the workplace.

• How to identify key people motivations from a brain perspective

• Exploring ideas to create a favorable working environment based on the wisdom of our biology

• Communicating and connecting to drive inspiration and commitment - even with a technical background

• Understanding the meaning of true collaboration as a way to build trust and high performance


1. Learn the 3 E’s of engagement

2. People’s thinking as the greatest asset

3. Discover the latest findings of brain research


Big Picture Thinking Presentations Three in-depth, interactive two hour sessions delivered by industry thought leaders.

11.40


On the surface, improving the reliability of an equipment asset dependent company seems simple. It’s not. Sure, it’s easy enough to identify the root causes that lead to failures - poor design/manufacture/installation/commissioning and suboptimal and/or poorly executed maintenance. Likewise, the technical aspects of correcting the root causes are just as simple. It’s culture and cultural change that always throws a spanner in the works.

The characteristics of world-class equipment asset reliability management are pretty well-defined. This said, achieving success requires orchestration and implementation of a cross-functional team of individuals - from the “walnut offices” of the CEO to the operators and maintainers on the plant floor.

The pathway to success is an onerous one. Many organisations fail. In this presentation we’ll share the story so far of our quest for world-class equipment asset reliability management - and our plans for seeing the plan all the way to fruition.

• The gap analysis to define your strengths and weaknesses

• The implementation plan - first things first

• The importance of a realistic timeline

• Solving the implementation labor dilemma

• Overcoming “psychological inertia” and achieving critical mass


1. Understanding the importance of the quantifying the value proposition

2. Mapping your losses - knowing where the money goes

3. Gaining senior leadership support and creating the EARM policy to frame and hang on the wall

Drew Troyer - CRE, MBA & CMRP (USA) & Grant Crosley - General Manager Reliability and Manufacturing Systems, Visy Pulp & Paper Pty Ltd


We all want a reliable plant - that’s the whole point of maintenance! But “reliable plant” is the ultimate OUTPUT of the maintenance system and we can’t control outputs - we get what we get. What you can control are the INPUTS and in maintenance these fall into three broad categories:

• Practices (that’s “what” we do)

• Processes (that’s “how” we do what we do”)

• People (that’s “who” does it)

This interactive session will define reliability in a particular way and then seek to clarify the issue of what is the best action to take, how to ensure our inputs into the maintenance system are reliable, because that’s how we will greatly increase the chances of achieving the output we all want - a reliable plant.


1. A more powerful definition of reliability

2. In depth understanding of practices, processes and people

3. A set of actions so you can start to improve


Maintenance - No More, No Less!

This presentation will outline a methodology on how to engage a business to support a sustainable level of maintenance that is both effective and efficient in delivering safe, reliable production.

There is great difficulty in using the capitalist principle of supply and demand to determine the appropriate balance for annual maintenance expenditure. These attempts usually end up reducing maintenance budgets year after year. Many companies have unfortunately gone down this path until reality strikes, in some cases with a big bang! So when should maintenance budgets increase or decrease?

A more sustainable approach towards maintenance requires the typical “maintenance orphan” to be collectively adopted and parented by engineering, operations and maintenance groups within an organisation. This cooperative approach could be considered similar to a three legged stool that is underpinned by SAP PM at Woodside Energy. What are some of the tools and techniques that can be used to ensure that your three legged stool is solid, sturdy and balanced to support your maintenance requirements?


1. A simple but robust model will be displayed, that can be used to model alternative scenarios for analysis and comparative purposes

2. Empower “maintainers” and “non-maintainers” to jointly view the predicted outcomes of their proposed actions

3. Empowering all parts of the three legged stool to influence their maintenance destiny

Dr Phillip Tirabosco - Maintenance Services Manager, Woodside Energy Limited

14.40 Design for Operations, an Oxymoron?

Where and when should maintenance and operational personnel be involved in facility design? Inevitably there are conflicts between the three key groups involved in any project, these groups being executive management, project management and operations management.

Executive management expects maximum productivity and minimum capital and operating costs in order to maximise profits. The Project Manager is driven to meet agreed cost and schedule budgets.

Operations management want a facility that is built to last, is reliable, maintainable and operable, within the parameters of the agreed operations budget that is often set prior to design or construction commencing.

While these three desires are not in themselves contradictory there are elements in all three that are in conflict. These conflicts inevitably lead to one or all of the three key stakeholders being less than satisfied and usually leads to expensive post commissioning reworks or and/or modifications.

This presentation will give you an insight into how some of these expectations are formed, can be influenced and importantly how some of these conflicts may be resolved, avoiding expensive mistakes.


1. An understanding of the relationships between a projects key stakeholders

2. When and how maintenance and operations can influence a project to get the best result

3. How operations can assist a project team avoid expensive mistakes

Hugh Beveridge - Engineering Manager Tropicana Joint Venture, AngloGold Ashanti Australia Limited


13.40 Lunch/Exhibition Viewing


Hear how Chorus travelled from a maintenance culture where the main focus was reactive service restoration, right through to a philosophy which delivered improved reliability from proactive and preventive maintenance programs. Key to all of this was a program of instilling a culture of guardianship across the whole organisation. The improved reliability has delivered some key features including the driving of customer preference, utilisation of the network and reduction of costs.

• The reactive world that Chorus experienced

• Navigating the journey and the change program to proactive maintenance

• Adopting the multiple approaches and work programs required

• Benefits that we have seen with the new culture

• Future plans to continue further step change


1. Culture change is slow to achieve and there will be speed bumps on the path

2. You too can have the benefits of proactive maintenance which make the changes worth while

3. There is no single silver bullet, a range of simultaneous approaches are required for success



Novelis has recently embarked on an effort to develop a comprehensive approach to reliability across thirty plants on four continents. It is being led from a corporate level by a team of reliability practitioners whose primary focus is on assessment, training, sharing best practices and education of the workforce.

The focus is on reliability as a network made up of multiple disciplines such as maintenance, engineering, procurement, operations and human resources.

• Success can and has been achieved - here’s how they did it!!

• Leadership training and engagement to form internal development and implementation of a “facilitated self-assessment” for developing baselines for each plant

• Development of a reliability engineering training curriculum

• Integration with Six Sigma, lean manufacturing, quality, EHS, energy and reliability

• Forming a successful global model across four continents

• On site plant support approaches to win


1. Development of an internal assessment and the assessment methodology and the metrics for success

2. Illustrating the advantages of an internal vs. an external consultant model

3. Build an army of reliability professionals within your organisation


15.35 Building Contractor Relationships to Keep Your Team Flying

Melbourne Airport is one of Australia’s busiest Airports, catering for more than 28 million passengers. This iconic Victorian site is a 24/7 low cost high service facility that needs to be operational for all its stakeholders to operate effectively and efficiently. Partnering and working with great contractors to facilitate reactive, preventative and regulatory maintenance with minimal or no operational restrictions, is where choosing the right contractors and building great relationships can make or break a great operation.

• Forging effective selection criteria for contractors

• Establishing “Service Level Agreements” for both parties

• Getting contractors to be part of the team not just the hired help

• Establishing a working relationship beyond the contract terms

• Successfully integrating contractors with your own teams


1. Use service providers who can deliver what you need when you need it

2. Standard terms & conditions with clear KPIs for all contracts with service providers

3. Incorporate service providers as part of your team not just the hired help

Darren Shaw - Engineering Services Manager, Melbourne Airport


Surviving the Knowledge Drought - How to Harvest Your Plant’s Critical Maintenance ‘Know-How’

We all know the story… beware the great ‘brain drain’ is upon us due to the dwindling supply of skilled workers. Enter the age of the retiring baby boomers… to be replaced by a generation of computer savvy ‘Gameboy’ kids. How competing enterprises deal with this key business issue over the coming years will separate the wheat from the chaff.

Already facing this certain reality head on, the ironmaking unit at New Zealand Steel adopted a pioneering strategy to cultivate a ‘living’ library of plant maintenance knowledge for mission-critical equipment by leveraging the visual power of interactive 3D modelling and animation.

The results are superior knowledge management, job planning and work execution - helping frontline staff to improve the company’s safety performance and profitability, while mitigating business risk related to the looming skills shortage drought.

• Boost productivity and depth of understanding for frontline maintenance staff

• Help to eliminate complexity and reduce hazards

• Achieve better utilisation of contract maintenance personnel during shutdowns


1. You’re only as good as your best information!

2. Develop your own living 3D library of critical knowledge and help reduce corporate memory loss!!

3. The game is changing and so are the players! Engage the new tech savvy generation

Ian Renall - Ironmaking Maintenance Superintendent & Mark Foster - 3D Visualisation Specialist, New Zealand Steel Limited (New Zealand)


In the words of Sol from the old Castrol ad “oils ain’t oils” and the same is true of Reliability Centred Maintenance (RCM). Many consultants and contractors are offering services and/or training in RCM and it is becoming one of the standard tools that can be applied to improve equipment reliability and reduce costs. Yet many organisations are not yet achieving full value for money from their RCM programs.

This presentation will summarise the main approaches to PM program development that are currently available, discuss the key factors for success, and suggest a framework for deciding which approach is best for you.

• RCM - some core underpinning principles

• Alternative approaches to the development and/or review of PM programs

• Factors to consider for a successful PM development program

• A framework for cost-effective implementation of RCM


1. RCM doesn’t need to stand for “Resource Consuming Monster”

2. Streamlined approaches - what works and what doesn’t

3. How to make RCM work for you

Sandy Dunn - Director, Assetivity Pty Ltd

17.05 Effectively Deliver a Work Management Program

Experienced maintenance personnel have attended workshops and training and by and large know what good practice maintenance looks like. What they need is:

• Specific actions to be undertaken in the future that use people’s knowledge and understanding of what is expected of them

• Guidance to work towards performance goals and specify self-measurement processes - “how will I know that what I am doing is a better way to do it?”

• Leadership for people to commit and be accountable for their own improvement and contribution to the team’s improvement

• Coaching as a means to encourage and inspire people, to provide support when it is hard to improve and appreciate that every individual has different needs

This presentation will introduce a proven and repeatable program which is focused on ensuring that people are skilled, empowered and accountable to implement the work management processes established as the intended best practice to be adopted at your site.


1. Setting very clear objectives

2. Plan and manage change in minute detail for optimum benefits

3. A training course is not enough… coaching and mentoring is an art form to be respected

Peter Durrant - Programme Manager Education and Change Management, Covaris Pty Ltd


Profiting From Contamination (Control)

With 60-70% of all lubrication related problems directly or indirectly attributed by experts to contaminants, getting them under control can add quickly to a company’s bottom line. Hear about the reasons why contamination related failures are so prevalent and through a series of case-study based examples, discover how to build an executable action plan and business case analysis to close the gaps on contamination control.

• What really causes machines to fail?

• Case studies in contamination control

• Building the case for your facility and what should be your next steps


1. Improve your reliability through contamination control

2. Build a case for higher profits in your facility

3. Where you can start and what is the most cost effective solution for you

Mark Barnes - Vice President Reliability Services, Des-Case Corporation (USA)

16.25 Afternoon Tea & Coffee/Exhibition Viewing


Tuesday 15 May 2012Tea & Coffee/Exhibition Viewing08.00

09.00

08.00

10.00



Beyond Efficiency - Breaking the Work Management Mindset

Rio Tinto has been implementing a global asset management improvement program since 2005. This program has delivered in excess of $US1B in tangible bottom line value so far, yet metrics tell them that while they have made significant in-roads in work management, they are only just scratching the surface as a high reliability organisation.

Find out how technology is starting to change the game for Rio Tinto and how they are preparing to meet the future with a renewed focus on reliability business processes, systems, training and metrics.

• Four critical business processes - operational readiness, operate for reliability, defect elimination and tactics development

• Underpinning systems - remote diagnostics and reliability engineering tools

• Competence development - bringing systems, people and processes together

• Metrics - some of the challenges in defining reliability metrics and the way forward


1. Work management improvement is largely about fine tuning existing business processes, skills and systems; reliability improvement is about changing the game with new processes, skills and systems

2. Getting the message to business leaders is critical

3. Overcoming the challenge in setting up business wide metrics

Gary West - Chief Advisor - Asset Management, Technology and Innovation, Rio Tinto Limited

10.40 Lean Cell Concept for Equipment Inspections

The purpose of equipment inspections is simple - ensure that the machines are working properly and identify items that require maintenance, preferably proactive work that avoids functional failure. The problem is that under the traditional model the inspect-to-work process frequently fails. Work requests often don’t get communicated, evaluated, discussed, approved and executed in time to avoid functional failure. In some cases, the work requests fall through the cracks of the system entirely.

The problem is the serial nature of the inspect-to-work process with all its handoffs and time-lags. Moreover, the traditional approach is often wasteful in that operators, mechanics and craftspeople are walking down the same equipment in the same day. Further, they view the equipment through the perceptual lens of their specialty not as a holistic system.

What’s the answer? The Lean Cell concept. The Lean Cell is about decentralising work to minimise hand-offs, time-lags and communication errors. This presentation will discuss the deployment of the Lean Cell inspection and provide specific case study details about its implementation at Visy Paper’s Tumut Mills.


1. Gain an understanding about why the traditional functionally focused, serial inspection process often fails

2. A method using probability for estimating the effectiveness of your inspection process

3. Facts about the hard benefits of the Lean Cell approach to inspections and the softer benefits of improved teamwork, communication and cross-functional learning


Asset Integrity Management - a Key Solution for Asset Life-Cycle Maximisation

With the operations and maintenance team constantly dealing with production requirements, preventive maintenance activities, unplanned maintenance, improvement projects, resources shortage, strong weather conditions and plant reliability issues; it becomes critical to manage our maintenance/integrity programs from a risk perspective in order to manage risk and minimise operational expenditure across our facilities.

• Asset Integrity Management - what it is, how it’s achieved and the benefits you can derive

• Asset Integrity Management System - understand your asset performance and problems

• Asset Criticality Assessments - legal, production, safety and environment

• Operational Integrity - are your operations/maintenance personnel trained? Do they understand the activity? Do they know the hazards involved? Do they know how to operate/maintain the equipment?

• Conditioning monitoring - inspections, operational data, fluid analysis, etc…

• Sleep calm knowing your operational risk is under control and manageable


1. Manage your facility from a risk perspective, or prioritise base on risk

2. Ensure your risk is visible

3. Know the remaining life of your equipment

Paul Sugis - CSG Lead Asset Integrity Engineer, Origin Energy Limited


• Battling against a smaller skilled labour base?

• Tasked with more systems and processes to manage?

• Weighed down by budgetary requirements and viewed by operations and management as a cost centre?

Does this scenario sound familiar to you?

This expertly moderated panel discussion gives you the perfect platform to get answers to the questions you’ve always wanted to ask. This 60 minute discussion will pose both prepared and live audience questions to the expert panel from Rio Tinto, Schweppes, RailCorp, Australian Paper and Chorus, New Zealand.

Hear the views of senior industry leaders from Australia and international organisations - their concerns, indicators and guidelines which form the decisions they make. Gain a window into their worlds and learn tips and tricks for you to manage upwards, communicate effectively the benefits of your department and its initiatives and win the favour of your own management teams.

Panel Members: Jim Henneberry - Chief Executive Officer, Australian Paper

Barry Grant - Global Practice Leader - Asset Management, Technology and Innovation, Rio Tinto Limited



Breakfast Session: Energy Management and Equipment Efficiency in Mineral Processing

Management of energy consumption has become very important for the mining and mineral processing industries. Most companies in process industries work hard to reduce their energy consumption, resulting in reduced emissions. In order to be effective in the long run, a comprehensive program is necessary to address energy in all aspects of the business and for each role within the organisation. A holistic, consistent approach will help manufacturing sites to minimise energy consumption, maximise production efficiency and move sustainability goals into tangible business solutions by:

• Reducing energy use

• Reducing emissions

• Ensuring profitability

• Improving efficiency

• Eliminating waste


1. Design the plant for efficiency

2. Control the process to reduce energy consumption

3. Operate intelligently to keep efficiency high

Genghis Erkan - Installation & Commissioning Manager, Metso Minerals (Australia) Limited


Research in the Netherlands showed that 55% of all technical assets (plants, rail, roads, fleets, etc.) reach their end of life within 10 years. Due to the current economic climate, companies are no longer able to replace these assets and are looking for ways to extend the lifetime. But they don’t know how. For this reason the Dutch Institute of World Class Maintenance has recently developed a reference model called VITALE (Value & Innovation Through Asset Lifetime Extension).

• Aging assets - facts and figures in the Netherlands

• Triggers that initiate the end-of-life of a technical asset

• Make or buy - how to determine the best option

• The 10 key processes of VITALE

• Importance of asset portfolio management, condition monitoring and degradation management

• Self assessment for measuring the VITALE maturity in your own organisation


1. Understanding the need for and impact of lifetime extension programs

2. Insights into a best practice reference model for asset lifetime extension

3. Learn from best practice lifetime extension programs from leading Dutch companies


11.35 Operator Essential Care - the Frontline Driving Reliability

Santos has embarked on a significant review and change management process to improve equipment reliability with the introduction of the Reliability & Maintenance Management System (RAMMS) which involves a shift from a reactive to a proactive focus.

It was quickly identified that one of the core ways to improve reliability was for better engagement and utilisation of the Process and Production Operator workforce. These operators look, touch and run the equipment daily - why not get their help?

Santos South Australia wanted to find a way to both engage the operators but also change the mindset from “reliability is someone else’s job” to making them feel part of reliability which has led to the Operator Essential Care Program.

• Assigning operator tasks with rationale and conviction

• Taking the data and making it useful information

• Engagement of different functions in the reliability challenge


1. Use the power of the frontline operator to improve your reliability

2. Tips on making this work - engaging the key movers and shakers

3. How to “grease the wheels” - simple and consistent communication is the key

Craig Goldfinch - Senior Adviser Operations Improvement - Down Stream Gas, Santos Ltd


The Journey Starts - Introducing an Enterprise Asset Management System

To introduce a best practice asset management system, overcome the 140 year old “Memory Wall” and reach their full potential - Queensland Rail required a major shift in their thinking.

Moving from their present “run to fail” culture to an integrated “whole of life” asset management approach, meant realising the purpose of a safe, customer focused and efficient railway.

• How Queensland Rail started off applying best practices

• How to get your maintenance team on board

• What makes a good planner?

• Managing your work-order backlog

• The network owner and operations partnership

• Managing large corridor closures with over 50 work groups and 125 work activities including 924 tasks

• Evidence of continuous improvement


1. Get your staff trained in best practice methodology

2. Get your communication sorted - be the one to change the attitude with your staff

3. Trend your achievements and enjoy and celebrate success

Rory MacManus - Asset Performance Manager SEQ, Queensland Rail

Eliminating Bolted Joint Failures

The humble bolted joint is a simple design but it is often the cause of both late and unplanned shutdowns. Both are extremely costly and harmful to a maintenance professional’s career.

With over 20 year’s experience in measuring bolt tension, Trevor has seen the good, the bad, the ugly and the just plain daft bolting practices. This presentation looks at proven solutions for heat exchangers, pressure vessels, grinding mills, valve body joints, fair ground equipment, bridge structures and diesel engines.

Learn short, sharp lessons on how to get reliability in:

• Grinding mill structural bolting

• Heat exchanger design anomalies

• Grinding mill liner bolting

• Managing the emergent work

• The Sydney Harbour Bridge - proving that trivial pursuit is wrong


1. How to identify poor design and engineer failures

2. Choose the best technology for each job and understand the reliability of any system

3. Focus maintenance activities on key areas

Trevor Robinson - Technical Director, Boltstress Ultrasonics

13.25 Is Understanding the Life-Cycle of Your Assets Really Worthwhile?

The concept of developing life-cycle plans for our assets has been around for well over 20 years and yet many, or most organisations are yet to develop them, which begs the question if it is worthwhile doing.

• Why do we constantly talk about life-cycle planning but never develop life-cycle plans?

• What benefit is delivered to the business of having these plans?

• How do you convince senior management that the money is a worthwhile investment?


1. Predict the future of your assets

2. Establish flexible plans to meet changing market conditions

3. Demonstrate the value in implementing strategic asset management plans

Richard Johnson - Technical Director, Rylson Group


The Implementation Void - Getting You, Your Planners and Your CMMS Aligned and on the Same Page

Typically RCM projects are conducted in isolation to planning and CMMS system representatives. This leads to RCM project teams designing maintenance tactics and forming them into packages when they are not aware of the appropriate standards and structure required to support implementation and execution in their CMMS system.

By drawing on a client case study this presentation identifies some key elements of an RCM project which will ensure that RCM project outputs support the implementation and execution of the resulting tactics in a CMMS system. This presentation will also cover the use of direct integration of RCM with a CMMS vs. the use of configured CMMS “load sheets”.


1. Standards and guidelines to support consistency of application

2. Setting the scope of equipment to cover is critical for a successful implementation

3. How to focus on the right competencies for Reliability Engineers

Jason Apps - Technical Director, ARMS Reliability

12.25 Lunch/Exhibition Viewing



Novelis has been deeply engaged in the concepts of lean manufacturing for a number of years, but has continued to struggle with how to capture the minds and hearts of the maintenance organisation. Too frequently, the role of maintenance is to be the recipients of “to do” lists of work identifi ed by a lean event team. The team wanted to fi nd a way to actively engage the maintenance workforce in an event that specifi cally targeted areas of interest for them. It proved very benefi cial to educating operators about how equipment operates and their role in caring for physical assets.

• Meaningful engagement of maintenance personnel in the lean manufacturing process

• Ensuring “as new” condition prior to implementing an asset care plan

• Use of visual management and lean manufacturing techniques

• Education on the operation and care of equipment

• Lean manufacturing isn’t just for production


1. Equipment should be in good condition prior to implementation of an asset care plan

2. Use of visual controls and other lean techniques in the care of equipment

3. Logistics of a TPM initialisation event


14.20 Let’s Talk About the Elephant in the Room! Maximising Successful Implementations by Managing Change

“We had a great technical solution, but we couldn’t get the users to let go of their old habits”.

Have you heard of this in your organisation?

Many project teams stumble at the fi nal hurdle when they hand their neatly crafted solution over to their users. Even for enhancements and changes to processes, it is important to have a strategy for helping people adopt change with confi dence.


1. Understand why people are challenged by change and learn how to overcome it

2. Appreciate how long it takes people to gain confi dence and what tools work best

3. Identify strategies that you can use to align your project team and get your users to “own” their processes long after the project team has left

Greg Taylor - Head of Business Integration, Shared Services, UGL Limited


Mainstream 2011 - Innovating for Business Effectiveness

To reward the enormous innovation in maintenance and reliability that Mainstream has become synonymous with, this session will showcase the two winners of the Mainstream Innovation Award.

Hear the two 20 minute winning presentations, judged by industry luminaries from across the country, which were simply ideas 12 months ago when the winners attended Mainstream 2011.

Hear how they have grown into an initiative, been brought to life and discover the business benefi ts their organisations derived from attending Mainstream 2011.

Presented by the Mainstream Innovation Award Winners

15.10 Afternoon Tea & Coffee/Exhibition Viewing

ERP/EAM Software - How to Survive the Implementation, Create Benefi ts and Keep Corporate Happy?

Many companies have implemented or are considering implementing Enterprise Software for managing maintenance and reliability. These projects often move from local plant level CMMS systems to larger “corporate infl uenced” enterprise packages. These projects are often part of the implementation of an ERP package or at least tightly integrated with corporate software. This presentation will address how to fi nd success in these projects.

• How to balance enterprise standards with plant or local needs

• Tips on how to support corporate initiatives and still fi nd plant level value

• Practical experience on how to survive a corporate sponsored software project

• Specifi c examples from SAP implementations but applicable to any multi-plant software implementation

• How to create value to maintenance and not just survive the project

• Setting up and utilising your system to manage the whole life-cycle of your assets

• Getting management to understand the value of the system to maintenance


1. Creating value to maintenance from EAM software

2. Practical experience in how to succeed with large multi-plant projects

3. Discussion on common standards vs. local fl exibility

Kahn Ellis - Senior Partner, COO, Vesta Partners, LLC (USA)

15.40 Building a Winning Maintenance Strategy: Using Technology to Improve Responsiveness, Reduce Cost and Improve Visibility

For asset-intensive organisations, the right asset management strategies and fl awless execution are critical to the success of the company. A successful execution transitions organisations from being reactive to proactive, improving overall effi ciency and cost-effectiveness. To achieve this, organisations need an asset-centric approach to managing their operations across the life-cycle from capital projects, through to effective operation, optimised maintenance work and the ability to business-case continued operation or replacement.

Using a leading utility in Australia as a case study, understand how they have successfully implemented their asset management program to deliver real benefi ts.


1. Identify critical success factors for achieving strategic asset management business discipline

2. Effective asset management requires a ‘cultural shift’ throughout the business - not just the maintenance team

3. Getting the right inputs for informed asset management - the role of mobility and technical control systems

Rob Attard - Principal Consultant, Mincom


Lean Processes to Improve Daily Breakdown Performance and Shutdown Maintenance Outcomes

Manufacturing engineering teams and maintenance service providers are staffed with experienced engineers (and some not so experienced) who know exactly what needs to be done to improve asset performance. The problem is you sometimes don’t get around to doing it all because you’re fi ghting fi res, covering for staff absences, waiting for parts and arguing with production about operators damaging the machinery and what the priorities are for repair.

KM&T’s lean maintenance tool box will provide focus and results. Born out of the KM&T’s deep experience of the Toyota Production System , their Toyota trained consultants have developed a set of simple processes, planning tools and communication approaches that bring discipline and accountability to planning and execution of maintenance activities.

Hear how these management disciplines have improved collaboration and teamwork between maintenance and engineering teams and their internal and external customers.

• Work sequence planning for long term shutdowns

• Problem and countermeasure processes for solving unplanned problems

• Supply chain planning and performance management of key suppliers

• Skills matrices and roster planning for best resource cover

• Cooperative maintenance - how operators can contribute to asset performance

• Quick changeover planning to reduce changeover downtime


1. How to make dynamic work sequence planning work for you

2. The importance of regular communication and rapid problem solving

3. Avoid delays by proactively managing suppliers

Duncan Anderson - Director, KM&T Pty Ltd

Mainstream is a uniquely curated conference focussing on the strategic areas of maintenance and reliability: on people, leadership and culture; overall reliability; continuous improvement; and aligning and integrating maintenance with your business

Mainstream Conference Close17.45

16.35 Closing Keynote Presentation: Is Skill Shortage a Problem? Really?

Some companies believe they face a “resource” problem and categorise the root cause as a “skill shortage”. This constrains perception to a single element of the problem when the real issue, not having suffi cient effective man-hours to complete maintenance work, is a more complex problem generated by a number of factors both internal to the maintenance function and external to the company.

We live in the real world - instead of bemoaning the fact that there are “not enough skilled people out there” we should ask “what will it take to create the equation?“

Available effective man-hours = man-hours required to complete maintenance.


1. A clear understanding of the “maintenance man-power” equation

2. A guide to evaluating external and internal factors

3. An outline strategy to resolve the “skill shortage” problem


www.mainstreamconference.com

WorkshopsWednesday 16 May 2012

The workshops are optional and separately bookable and will run from 9.00am to 3.00pm (places are limited, you may attend only one and preference will be given to conference attendees). Registration opens at 8.30am and morning tea and lunch are included.

Workshop 2: Creating a Winning Reliability Strategy Most initiatives to improve reliability fail to reach the finish line because most attempts never actually make it to the starting line. Achieving world-class equipment asset performance is a multi-dimensional and multi-functional proposition. To win, we must:

• Design and procure equipment that’s reliable, maintainable and operable

• Operate the equipment correctly and efficiently

• Inspect and monitor the condition of the equipment and proactively manage the root causes of machine failure

• Plan and schedule maintenance work to ensure efficient and effective repair of equipment

• Manage parts and materials inventory to ensure that we have the right parts that are in the right condition at the right place at the right time

• Effectively collect and analyse reliability data

• Manage procedures, skills, motivation and the human factors of failure

• Monitor our performance with a balance of leading and lagging metrics

To win, we require a strategy that’s comprehensive and long-term in its orientation. This requires an orchestrated effort that is vehemently supported by senior management and operational management across all the affecting functions of the organisation. Gaining this support requires a clear strategy and a clear value proposition. In this workshop, you’ll learn how to create and implement that strategy.

This workshop is not a seminar - it is a facilitated working session that’s intended to send you away with the must-have tools to get your organisation to the starting line in deploying world-class Equipment Asset Reliability Management (EARM):

• A draft EARM policy that is comprehensive and ready for your CEO’s signature, framed and hung on the wall in your plant’s foyer - next to your quality and HS&E policy - a clear proclamation of your commitment to EARM

• A baseline gap analysis of your strengths and weaknesses on the key dimensions of EARM and the tool to re-benchmark yourself every quarter to mark your progress. This is the S and W in a SWOT Analysis (Strengths, Weaknesses, Opportunities and Threats)

• An economic analysis of what a substandard EARM policy is costing the organisation and a clear definition of the economic impact associated with closing your gaps

• The basic format for developing your master plan so you can manage the execution of the EARM policy like a project

Led by: Drew Troyer - CRE, MBA, CMRP & Member of the National Reliability Management Team, Visy Pulp & Paper Pty Ltd (USA)

Workshop 1: Optimising Value From Your Maintenance PlanningWorking in competitive markets, companies are under sustained pressure to produce higher quality goods and services at lower production costs. A key component of production costs is maintenance and the key role of maintenance is to guarantee the reliability of the production plant.

In the maintenance department, the central element that ensures maintenance is cost effectively delivered is the planning and scheduling of maintenance tasks.

In this workshop, which has been successful worldwide, industry guru Tom Lenahan will explore the parameters of maintenance planning and provide a set of guidelines for:

• Planning and scheduling routine maintenance tasks generated by predictive and preventive maintenance programs

• Planning tasks to recover from malfunction or breakdown

• Approaches to coping with random failure

This fast paced workshop is a must attend if you are tasked with optimising and driving more value from your maintenance plans. Attend this workshop and you will take away:

• A thorough understanding of the total role and potential value of you as a Maintenance Planner

• Game changing process maps detailing various aspects of maintenance planning

• Clear and concise rules for agreeing plant availability with operations

Led by: Tom Lenahan - Director, Tom Lenahan Limited (UK)

Mainstream™ 2012 | 21

Solutions Showcase

Assetivity is a fast growing consultancy that specialises in improving maintenance and physical asset management performance for organisations in capital-intensive industries. We apply a unique combination of engineering, commercial and management expertise to make improvements to Engineering, Production, Maintenance and Supply Management processes and systems. Unlike most other similar consultancies we apply high level strategic thinking, combined with practical, hands-on assistance right down to shop-fl oor level. We offer our services throughout Australia, as well as overseas.

www.assetivity.com.au

Boltstress Ultrasonics Pty Ltd (based in Menora, West Australia) is a highly specialised company with 20 years’ experience providing increased uptime by ensuring bolted joints have reduced assembly and disassembly times by at least 50% and that they hold integrity from shutdown to shutdown. This is achieved by utilising state of the art technologies, Ultrasonic Bolt Tension Measurement, Intrinsi-TAG RFID fl ange tagging and Quickfl ange Weldless fl ange attachments. Save 50% of your bolting time using our Intrinsi-TAG system. To learn more about who we are and what we do please visit:

www.boltstress.com.au

Silver Partners

Partners


TM

Reasons to Attend Mainstream

Experience a Uniquely Curated 3-Day Program 1 Using a uniquely crafted research methodology and expertly guided by a

Conference Advisory Team, we curate a program that gives you answers to current challenges and inspiration to embrace future opportunities: 36 presentations and sessions in 6 tracks over 3 days.

Gather Information You Won’t Get Anywhere Else2

This is the only event of its kind in the region. Mainstream is not a technical conference and differentiates itself by focusing on the strategic areas of Maintenance and Enterprise Asset Management. It’s a place where Maintenance and Asset Management professionals come together in the same place at the same time for three days.

Immerse and Network Within a Thriving Community3 Someone in this community has the answer to your most pressing business

challenge. Tap into the collective wisdom of delegates, speakers, sponsors and experts during tea and lunch, in between sessions, at speakers’ corner, over a drink at the networking cocktail party…. and beyond.

Acquire Exclusive Access to Collaboration Tools and Resources4 Connect with other attendees before, during and after the conference

with our online tools and onsite forums. You will also receive a networking list with contact details for all participants and exclusive electronic access to all content after the conference.

Engage with Leading Maintenance and Reliability Vendors5

See all the best tools in one place. You’ll have ample opportunity to speak frankly with leading vendors and creative start-ups to fi nd the right tools and technologies for your business. The exhibition features selected partners who understand the business of maintenance, reliability and asset management organisations and are serious about helping you make the smartest IT and business investments.

Look Outside of Your Organisation and Your Industry6 As good as it is to invest in consulting and internal training, the conference

is a great platform to assess your strengths, weaknesses, costs and decision making against other organisations both inside and outside your industry.

Attain Professional Development and Improve Your Skills7 Return to the offi ce with new knowledge, enhanced skills and a renewed

sense of confi dence in your abilities and your organisation’s direction. You’ll hear essential tips and techniques from leading experts, designed to help sharpen your skills and accelerate your career growth.

Play Your Part in the Mainstream Community8 Gratifi cation is always greater in giving than in receiving. Open your

mind to new opportunities and be challenged to consider new ideas and theories. Open your heart to new friends and be inspired. Pinpoint new and different ways to improve both professionally and personally.

Hedge Your Attendance with a 100% Investment-Back Guarantee9 If for any reason you believe you did not get value from attending

Mainstream, we will refund your entire registration fee.

Payment Options:Special Note: Payment required prior to the event. Please include accommodation (if required).

Cheque made payable to: The Eventful Group Pty Ltd

Visa Mastercard AMEX Diners

Card Number

Card Expiry CCV

Name of Cardholder:

Signature:

Email of Cardholder:

01

02

Conference Registration Fees:Includes electronic access to all content, participant contact list, entry into conference and exhibition, lunches, refreshments and networking drinks. Team bookings are encouraged to accelerate the spread of knowledge across your organisation.

Workshop Registration Fees: The workshops are optional and separately bookable. You may attend only one and preference will be given to conference attendees.

$850 (+GST)/participant

Workshop 1: Optimising Value From Your Maintenance Planning

Workshop 2: Creating a Winning Reliability Strategy

Early Bird Registration:Register on/before 16th March



Standard Registration:Register after 16th March



1 - 4

5 or more

TOTAL 1 : AU $

TOTAL 2 : AU $

04

05

Accommodation:Conference Venue: Esplanade Hotel Fremantle Corner Marine Terrace & Essex Street, Fremantle, WA, Australia

Standard Room AU $210 (+GST/room/night)

Arrival date:

Departure date:

Mr/Mrs/Ms First Name

Surname

Position

Organisation

Address

Postcode

Phone

Mobile

Fax

Email

Twitter Handle - @

Which phone number would you prefer on the Networking List?

Phone Mobile

Special Dietary Requirements

Approving Manager

Position

Email

Please send the tax invoice to my approving manager

Please send the tax invoice to me

TOTAL 4 : AU $

TOTAL 1 + 2 + 4 : AU $

Contact The Eventful Group to Register

Mail: PO Box 3514 Perth Adelaide Terrace WA 6832

Phone: +61 8 6188 6100

Fax: +61 8 6188 6800

Web: www.mainstreamconference.com

Email: [email protected]

(Please photocopy for additional participants)

Cancellations

Cancellations must be advised in writing at least 21 days prior to the event. Where an alternate delegate is not possible, an administration fee of $550 (+ GST) per delegate will be incurred for cancellations. A refund will not be given if a delegate fails to attend or cancels within 21 days prior to the event.

*The Eventful Group reserves the right of admission.

How to Register

03 Please Also Register Me For the Complimentary Sessions:

Sunday JumpStart Session: Making the Most Out of “Mainstream” and its Community

Tuesday Breakfast Session: Energy Management and Equipment Efficiency in Mineral Processing

Documents

Maintenance and Reliability Networking Conference