Root cause failure analysis are an essential tool to asset management and reliability. If you lack the resources to identify, solve and implement process-based solutions to your complex and difficult failures you’re missing an opportunity to improve your overall equipment effectiveness. RCFAs can be a time consuming and often plant personnel are too busy to perform this analysis as they are on to the next task or priority of the day. ARPE Engineering can perform Root Cause Failure Analysis at your site and will deliver a detail report documenting the process with recommendations for corrective actions with potential cost savings.

Scope:

1. Define the problem.

2. Analyze past similar failures

3. Review available reports, drawings, work order history.

4. Perform Root Cause Failure Analysis (RCFA).

5. Develop recommendations for corrective actions.

6. Develop process implementation for cost effective actions .

Deliverables:

1. Report documentation of RCFA and recommendations.

An experienced and focused Reliability Engineer can pay dividends year after year with cost savings and increased production if your site has one. ARPE Engineering can supply one to work on your cost saving initiatives that your current personnel are too busy to handle. The benefit to the site is the focused uninterrupted stream of completed task such as creation and updates to procedures, BOMs, maintenance plans, checklist, drawings and mechanical integrity programs that not just anyone can do. These efforts will be completed effectively and timely without the interruption of day-to-day plant activities.

Project engineers are very focused and detail oriented when it comes time to front end load their project. The plant trusts these project management professionals to hand over a well running asset that delivers on the project’s original goals and potential cost savings. Often plants are happy with the asset for the first year of production only to find that they are ill prepared to maintain the asset due to lack of proper reliability design. Each asset’s reliability is fixed once the design stage is completed. Project managers and plant personnel are often too busy to carry out the reliability engineering necessary during the design phase to ensure an asset successfully reaches its predicted life. ARPE Engineering can perform a Failure Mode and Effects Analysis on your project and define engineering controls, maintenance plans, parts, checklist, training, and an annual cost estimate that is necessary to care for the new asset.

Scope:

1. Define the function of the asset.

2. Define an agreeable hierarchy of ranking for analysis.

3. Define the functional failures of the assets Specify failure modes of the asset on a component level.

4. Determine corrective actions for failures.

5. Engineering Economic Analysis of asset total ownership cost.

Deliverables:

1. Report of analysis and activity.

2. Presentation of findings and recommendations.

3. Cost estimation and recommendations for proceeding.

ARPE Engineering will assess your site’s current leadership and management structure for the necessary pillars of a successful Maintenance Department. People are the most valuable assets at a site and company’s need to retain and maintain them better than their equipment. Sometimes these assets just don’t fit or need a tune up like other machinery to produce results. Benefit from ARPE Engineering’s experience and perform a Leadership and Management Strategy review to ensure your site’s long-term success.

Scope:

1. Meet with site leadership to define goals and needs.

2. Interview site personnel.

3. Perform assessment of current policies, site planning and strategy.

4. Design improvement plan for management of assets and people.

Deliverables:

1. Documentation of assessment and findings with recommendations.

Preventive maintenance is the first line of defense in reliability centered maintenance from random failures. Often sites employ PMs as a reaction to a failure and the failure never occurs again making every one happy. Rarely does a site return to their PMs and question whether the PMs are still necessary. PM Optimization is the process of analyzing current PM plans and eliminating waste. ARPE Engineering can help your site and optimize your PM program for your needs today. This process frees up manpower and plant resources to complete other meaningful work increasing efficiency and ultimately saving or making the site more money.

Scope:

1. Collect PM plans, execution and cost data from site.

2. Perform analysis of PM program and labor hours.

3. Modify PMs to increase efficiency and effectiveness.

Deliverables:

1. Documentation of PM Optimization process and findings.

2. Recommendations for sustainable changes and future PM implementation.

Predictive maintenance execution is the sign of a mature maintenance program. Sites often feel they don’t have the expertise or resources to manage a predictive maintenance program and they turn away from huge savings due to the threat of the sophistication. Engineering can help by designing and managing your predictive maintenance program with the current personnel you have, no additional resources required. Condition based monitoring techniques do not have to be complicated and will save your site from unexpected failures. ARPE Engineering will work with your site to develop and lift your program to your expectation through education, ownership and accountability.

People are the greatest asset at a plant and they need attention/maintenance as well. ARPE Engineering has the below options for your training needs and will tailor its programs to your needs to increase effectiveness. Your site personnel will return enthusiastic about their role and you will see the difference in their approach to work. Struggling managers can benefit from the one-on-one coaching and third-party point of view from our Reliability Professionals and Professional ARPE Engineers. ARPE Engineering has experience starting new maintenance program initiatives and understands the challenge in active and passive resistance, contact us to discuss your traditional training workshops.

We offer:

• Tailored Reliability Retreats

• Boot Camp Training for Maintenance Leaders

• Professional 1 on 1 Coaching

• Educational Webinars