Reliable Process Solutions offers training and consulting services in the area of equipment reliability. These training programs can increase your equipment life cycle which improves uptime and operating efficiencies. The programs are designed to stop using maintenance as a resource to fix things when they are broken, but to keep equipment operating at its peak performance. Reducing downtime, lost rate, quality issues, and reduce redundant equipment. All the training programs can be customized for your business and timeline.
Consulting and Training Services:
Preventive Maintenance Strategies
The function of performing Preventive Maintenance is used in all industrial process plants. The important function of this training course is teaching how to determine which tasks add value and extend equipment life. Many processes are covered to help plants develop PM tasks that add life cycles to the equipment. Process such as RCM, PM optimization, MTBF, and Asset Criticality are covered along with charts, and software to help make the right decisions. In many cases a 30% reduction is seen in PM tasks and other tasks become more effective.
Benefit: Stop wasting valuable man hours on tasks that do not add value. Increase equipment life cycles and add dollars to the bottom line.
Time: This is an 8 hours course, can be completed in a 4 hour short course
Lubrication Excellence Training
This training is performed to teach methods to improve the lubrication program at a facility. Most companies think that by having a written PM program for lubrication that they are in good shape. A Lubrication Excellence defines cleanliness methods for new and existing lubricants and processes. The training covers the 100 major failure modes of the lubricants and lube programs. Learn how small amounts of moisture can shorten component life by 50%. Learn how the temperature of the lube determines its effective life. This program knowledge can add 3-8 times to the life of the equipment components.
Benefit: The training process will help your people fully understand lubricants how with proper handling and techniques equipment will last 3-8 times longer.
Time: 8 hour course, can be 4 hours based on plant needs
The 20 step lubrication assessment is designed to locate deficiencies in your lubrication programs that may be shortening your equipment life. 50% of all bearing and rotating equipment failures result from lubrication related issues. The audit will identify deficiencies in your current program and provide a report to guide the improvement process. The Lubrication assessment alone can help identify problems and get you on the path to longer equipment life.
All assessments come with a written audit report that will identify deficiencies and design a path to improvement. Lubrication Excellence training after the audit is the next logical step for the improvement process.
Benefit: By understanding your lubrication program weaknesses a plan can be develop to correct them. From this audit training programs from the lubrication excellence training can be customized for your plant.
Time: 4 hours to 8 hours based on plant size for audit. Full written report within 24 hours.
Equipment Failure Modes Training
This is an excellent training program designed to look at individual equipment components and how to make them last forever. Motors, Bearings, Belts, Chains, Pump seals, are just a few components covered in the Failure Modes Training. If it is important to your business to have your equipment run longer cycles with less breakdowns than this is a great addition to your training program. Learn the 50+ failure modes of electric motors, the 15 failure modes of pump seals, and many more for bearings and other components.
Benefit: This training program teaches RCM fundamentals and how to look at all equipment at the component level and determine how these components can fail. By understanding this process the PM program changes to do PM’s that are effective and not just a routine.
Time: 8 hour course depending on plant needs, can be 4 hours
RCM Process Training
RCM (Reliability Centered Maintenance) is a process that defines the most complete and efficient maintenance strategy to perform on each component in our equipment based on Failure Modes of the component. The RCM process training is a process that teaches the most efficient method of RCM analysis. This training includes the RCM access database which belongs to your company after the training. The process was developed by the airline industry and is now used by Nuclear power plants, the military, and many petrol-chemical plants. This process gets maintenance, operations, and engineering working as a team to improve your process. RCM not only addresses uptime but rate, quality, and HSE issues.
Benefit: Understanding how RCM can reduce failures and improve preventive maintenance. To actually perform your own RCM analysis on your equipment or common industry equipment..
Time: This is a 2-3 day session actually using RCM software
Predictive Technologies Training
This training program is designed to teach companies about all the predictive technologies that are available to predict equipment failures months before they occur.
Technologies are available today to predict 90% of all bearing failures, 90% of all motor failures, and many others. Why wait for equipment to fail and catch you in crucial operation times when you can know months before and plan the repair. Learn how to know what technology to use on specific equipment. Learn how to determine which vendors to use and how to understand the readings.
Learn the fundamentals of the 7 major predictive technologies.
Benefit: Learn how and where to apply each technology to find the component that can fail. No individual predictive technology can detect all failure modes effectively.
Time: 8 hour course can be combined with Proactive course or reduced to 4 hours
Proactive Maintenance Techniques Training
The most efficient time to perform maintenance is when the equipment is new or when it is running well. This program teaches the top 13 proactive methods that will keep your equipment running for many more years. Using these practices will reduce reactive maintenance to less than 10%. Learn how to move from reactive to proactive maintenance and eliminate unexpected failures. Using these methods correctly can move your maintenance efficiency to 70-100%. Typical reactive maintenance methods only can get to 20% efficiency. Training on precision alignment, precision balance, RCM, Planning, and proper use of CMMS are just a few of the topics covered.
Benefit: Learn how to set a 3 year goal to reduce reactive maintenance to less than 10% and reduce maintenance costs by 30-50%
Time: 8 hour course, can be combined with Predictive course for 8 hours
Maintenance Excellence Audit
The maintenance excellence audit looks at 25 areas of maintenance and rates your plant or process in each of the areas. The audit looks at every component of a best of class maintenance process including leadership, CMMS, predictive, proactive, and 20 more items. You will receive a report on each area of weakness and suggested steps for improvement. Every operation should receive a yearly audit to know where to concentrate there efforts in the coming year.
The audit reviews every aspect from management and leadership, predictive, proactive, preventive, and even CMMS functionality.
Benefit: Understand the weaknesses of your maintenance program and where to concentrate the training and financial resources.
Time: 4 hours to 8 hours based on plant size. Full written report in 24 hours.
Asset Criticality Software and Training
Use software to determine the criticality of each piece of equipment in your operation. This is the only way to know where and how to apply your maintenance resources. The training comes with a Reliable Process Solutions Equipment Criticality database that you can use at your plant. The software looks at not only maintenance issues, but safety, food safety, environmental, quality, and customer’s issues.
Benefit: Understanding which equipment is important and critical to the process is more than just what maintenance thinks is critical. It’s not making a decision based on the fact that it breaks down more often, or has expensive parts. Helps the entire plant understand and rate critical assets. The software package comes free with the one day training. Great team building exercise!
Time: 4-8 hours depending on training or actual start of criticality assessment
Environmental, Health & Safety Software and Training
Use the software and training to determine the ranking of all the equipment and processes in a plant. This software determines a ranking that will allow the proper resources to be allocated to reduce the risk of exposure of in these areas. Much faster and more efficient than PSM, Hazop, HSA, or other time consuming processes. The software package comes free with the one day training program.
Benefit: Helps everyone understand that failures in equipment or processes can cause E,H,&S incidents. Great team building exercise.
Time: 4-8 hours depending on training or actual start of analysis.
All training programs can be combined and customized for your plant size and operation. Mix and match the programs to fit the needs of the organization and budget. The training can be spread over months and years to develop a continuous improvement process and greater retention of the learning tools.
Performing plant audits of current practices and issues is the best method to set up training and train on issues to improve work practices.