Proactive Reliability

Proactive  Reliability

Transformational Performance Solutions, LLC are experts in maintenance and reliability management, using Proactive reliability strategies for preserving the reliability of machines or equipment. The reason for proactive reliability is to view machine failure and similar problems as something that can be foreseen and taken care of before they occur.

It is a universal truth that it costs 10% of the failures costs to be proactive and stop it from happening. Another way to look at this is to gauge the internal rate of return when comparing reducing your reliability costs over increasing sales. A 10% strategic reduction in reliability costs in a plant creates a bottom-line effect equal to a 40% increase in sales. Which is easier, increasing sales 40% or reducing reliability costs through proactive efforts by 10%?

Can you Count on Your Equipment?

Reliability Engineering at Its Best

Reliability Engineering at Its Best

Reliability Engineering is a sub-discipline of systems engineering that emphasizes dependability in the lifecycle management of a product. New parts fail in three phases along the bathtub curve (a widely used example in reliability engineering). The bathtub curve has three phases – the early failure, constant or random failures and wear-out failures, where the middle phase has the lowest failures. One of the goals of proactive maintenance and reliability is to ensure the parts reach the third and final phase known as "wear out." Any failure in the first two phases results in loss of component life and possibly unscheduled downtime (increased costs).

Transformational Performance Solutions, LLC

The three main reasons (forced deterioration) a part fails prematurely, in infant mortality, is:

  • Improper Lubrication
  • Contamination
  • Improper Installation

Our goal is to work alongside your team to reduce and eliminate these main reasons for infant mortality (first phase) through continuous and proactive improvement.

Lubrication Programs

Many organizations do not realize that there are significant differences in the various types of lubricants available in the market. If you are using a lubricant with a gas company's name on it, you are using an inferior product.

Another common mistake made in reliability is allowing your lubricant provider to manage your lubrication program. This is a fatal mistake, as their interest is in selling lubricants to you, specifically those lubricants that make them the most money.

Contamination Control

Contamination Control

Proactive reliability is all about keeping your equipment clean, cool, and dry. After years of research on this, we have come up with the following steps to help you eliminate contamination:

  • Set target fluid cleanliness levels for all equipment.
  • Select and install filtration equipment (or upgrade existing filter rating) and contamination prevention techniques to achieve the desired cleanliness levels.
  • Monitor cleanliness at pre-determined intervals to achieve the cleanliness levels.
  • Prevent storeroom contamination.
  • Specify your cleanliness standards to your vendors.
  • Store your spares properly.

Proper Installation

Proper Installation

Proper installation involves having the right person with the right part at the right time and in the right condition.

Proper installation requires:

  • Design for reliability.
  • Storeroom management.
  • Technicians and operators with the right skills.

We use very specific process flow diagrams and other techniques to help you in making the right decisions.

I am keynote speaking and exhibiting at the Reliable Plant Conference & Exposition July 25-28, 2022