Decoding plant reliability in manufacturing and a process to reach there

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Decoding plant reliability in manufacturing and a
process to reach there

• Process manufacturers typically operate in
  data-rich environments and know their plants
  inside out. While they know their assets and how
  their resources are deployed, they are often
  unaware of factors contributing to optimal asset
  performance. Even if this information exists
  within the manufacturing ecosystem, the plant
  maintenance and operational heads dont really
  know how to use it to achieve optimum plant
  productivity.
• Studies reveal that frequent downtimes at process
  manufacturing plants can result in nearly
• 15000 per hour of lost revenue. Digitalization
  of the maintenance process and proactive asset
  performance management directly contribute to
  saving this cost. Prioritizing plant reliability
  becomes the only way to improve overall
  operations and mitigate unplanned downtimes.
• But what is plant reliability, and what processes
  need to be institutionalized to achieve it? In
  this article, we will discuss what reliability
  means for manufacturing and lay out a six-step
  process to devise a plant reliability strategy
  for a manufacturing plant effectively.

What is Plant Reliability, and how can you
measure it? Any reliable system accounts for its
safety and trustworthiness while ensuring minimal
maintenance costs. For plant assets, reliability
can depend on performance, condition, maintenance
needs, and availability. An asset reliability
check can be done based on factors like frequency
of maintenance or repair costs, number of
malfunctions, unexpected downtimes, and
more. Keeping plants maintenance up to the
mark ensures that assets run 24/7 with fewer
interruptions or unexpected delays due to
frequent maintenance incidents. This leads to
faster
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go-to-market, better output quality, employee
productivity, and significantly lower operational
costs or costs per unit. Plant reliability in
production can be quantitatively measured using
the Overall Equipment Effectiveness (OEE). A
popular metric for measuring manufacturing
productivity, OEE factors in a product of
availability (number of downtimes/uptime),
performance (speed or run time of your
processes), and quality (number of defects). An
OEE score of 100 indicates a completely
reliable, dependable, and high-quality plant with
maximum productivity. Therefore, calculating OEE
and securing a top score should be part of your
asset managements best practices. Six steps to
creating an effective reliability plan at your
plant. Every successful plan consists of a set of
clear and executable steps. And the same
principle applies to achieving top-notch plant
reliability as well. Without a clear, planned
route, it can be hard for you to envision your
end goal optimum plant and asset reliability
management. Here are the six actionable steps
that are essential to executing your plan
successfully 1. Building the right team The
right team can make or break reliability goals-
from top to bottom. Effective leadership,
skilled personnel, and onsite-plant operations
team must be aligned with accomplishing plant
reliability goals. Achieving reliability is a
team effort and a continuous improvement process.
Designated team champions have to be distributed
within Operations, Maintenance, and Engineering
along with sufficient alignment around their
common goals individual targets. This way,
every individual is well aware of their role in
constantly improving the plant and understands
their dependencies on the other teams. There has
to be also a Reliability Leader who helps drive
this initiative
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2. Creating the right mindset for reliability For
a successful plan, having the right mindset for
asset reliability is as important as relevant
skills, processes technical understanding. Sin
ce achieving reliability requires continuous
effort, you can try to define your target
numerically align every departments target
accordingly. This target its deadline needs to
be agreed upon by each department-operations,
maintenance, engineering, and the subsequent KPIs
that befall them individually. It is critical
that all teams uphold this goal as their guiding
principle and implement it through individual
responsibilities every day.
3. Adapting Predictive Maintenance (PdM)
approach Plant reliability is also heavily
dependent on asset health reliability. The
approach towards asset reliability is centered
around the plant maintenance methodology
chosen. An advanced framework like predictive
maintenance alongside numerous assets and
operations can speed up the process of obtaining
plant reliability. By proactively anticipating
flaws or anomalies within the plant and
addressing them, reliability objectives can be
progressively achieved. And when you
proactively work towards fixing them, you can see
your maintenance costs and the dreaded plant
downtimes plummet instantly. Also, by
understanding what caused these failures, your
teams can work towards optimizing their
maintenance strategy in the future.
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