End the Waste
Unless your plant has achieved the highest level of reliability you are wasting resources – wasting the raw material used to create your product, wasting manpower, wasting energy – and wasting money. Your maintenance and operations expenses will be too high. The output of your plant will be lower than it should be. Jeff Dudly*, ex Corporate Reliability and Maintenance Director at Dow Chemical states that “Organizations with poor reliability practices waste 10% of their revenue, waste 15% of their resources, disappoint customers, disengage customers, and constantly deal with new and repeated unplanned events”
If you improve reliability, improve work execution, and use condition monitoring you will reduce costs and increase availability and plant capacity. And these are the keys to asset management and responsible risk management.
iLearnReliability [Enterprise] enables you to achieve these goals because it helps you create the reliability culture throughout the organization and it provides the strategy and education to make the required changes.
* Jeff Dudly contributed to the development of iLearnReliability.
It is quite amazing what reliability improvement and condition monitoring can do for an industrial facility. Reduction in costs, improvements in availability, and reduction in safety and environment incidents all contribute to the financial viability of the organization and the wellbeing of employees and shareholders.
But achieving these goals has proven difficult for most organizations. Some hire consultants, only to find the plant returns to the “bad old days” soon after they leave. Some try training a select few to become expert in the subject, but that approach struggles because there is no plant-wide buy-in and people believe reliability improvement is the responsibility of the reliability group alone. That is the wrong approach; reliability is everyone’s approach. Some try a “home-grown” approach of external courses and internally developed e-learning. And there have been other attempts, from classical RCM to Lean, Six Sigma, TPM, and others. It is not to say that those approaches don’t make an improvement, but they often don’t result in a sustainable improvement in reliability.
iLearnReliability [Enterprise] takes a different approach. It provides training to everyone, from the most senior management to the plant-floor workforce. Everyone learns how they contribute to the reliability improvement initiative.
It is important to understand the strategy used by iLearnReliability [Enterprise].
If you follow the “Roadmap to Reliability” process defined within iLearnReliability you will have a condition monitoring program that provides early warning of electrical and mechanical faults and you have make a range of changes that will result in far fewer failures. You will monitor and improve the condition (and therefore the reliability) of your critical plant assets.
And most importantly you will have an engaged workforce that has adopted a “reliability culture” that ensures that the improvements made will be sustained for the long term.
And if you follow the strategy sequence that we have outlined, you will be sure to follow a sequence of steps that build on each other and continually provide a positive return on investment.
Training for Everyone
This is the key to iLearnReliability. And this is key to success.
You cannot improve reliability and enjoy the benefits unless you involve everyone in the initiative. Not just a few people in the reliability group. Not just a few condition monitoring specialists. Everyone has to contribute to the initiative because everyone currently plays their part in the poor reliability you are experiencing. Not deliberately of course, but the policies and practices from the board room to the plant floor, and from the design/construction/procurement phase all the way through operation/maintenance/disposal phase all contribute to the reliability of the plant.
So iLearnReliability [Enterprise] includes Manager Briefings for senior managers and Toolbox Talks for the “plant floor” staff that are designed to create awareness and buy-in. It is essential that these modules are used.
The Essential Elements provide a very useful overview, and the Program Management Training modules add a great deal of depth for the reliability engineer, maintenance and production staff, and supervisors of all kinds.
For example, while it is obvious that the planner needs to know about planning and scheduling, so do other people in the organization so that they really appreciate the decisions being made. But the planner also needs to understand his/her role in the reliability initiative, and he/she should understand scheduling and inventory management, and they should understand precision skills and condition monitoring – and the list goes on.
When everyone understands how they benefit AND how they can contribute AND they know not to fear the changes, you will develop a reliability culture in the organization. Without it you will never reap the full rewards of reliability improvement. You may achieve short term benefits but those benefits will not be sustained. Thousands of plants worldwide have experienced this for themselves.
iLearnReliability [Enterprise] covers the topics that your team will need to master in order to understand asset management, leadership, the strategy of plant reliability improvement and the individual building blocks required for a successful implementation. We have categorized them for simplicity:
STRATEGY, LEADERSHIP AND CULTURE CHANGE
Roadmap to Reliability | Leadership and executive sponsorship | Benchmarking and KPIs | Developing a reliability culture | Change management
Criticality Analysis | Defect elimination | RCM Reliability Centered Maintenance | FMEA Failure Mode Effect Analysis | PMO Preventive Maintenance Optimization | RCA Root Cause Analysis | ODR Operator Driven Reliability
Maintenance practices | Master Asset List | Preventive maintenance | Condition Based Maintenance
Condition monitoring | Vibration analysis | Ultrasound | Oil analysis | Wear particle analysis | Infrared analysis | Motor testing
Shaft alignment | Soft foot | Balancing | Lubrication | Contamination control
* To learn more about the detailed topics, please click on the iLearnReliability Content button above.
How iLearnReliability Works
When you purchase iLR [E] we will create a Web-based learning management system just for your organization. We will customize the Web address in the form http://companyname.ilearnreliability.com All of the training modules are available on that site.
We will provide a person from your company with access to the administration functions of the site. This will enable you to create accounts for other people. We have made this task because we created 30 common profiles: reliability engineers, condition monitoring technicians, plant-floor craftspeople, and more. You simply create an account and assign them to one of these profiles and they will have access to the appropriate training modules.
But you have total control. You provide people with a little bit of training at a time. You can decide to give people more or fewer training modules. And you can decide who should take quizzes and who should not.
And you can track the progress. You can see who has been assigned to what, and you can see who has completed their training. And you can see how they did in the quizzes.
The only limitation is the number of users. We offer subscription packages, and if you buy a license for 20 users, then you cannot create 21 user accounts.
When you create an account for a person they are sent an e-mail with a link. They simply click, log-in, and click to learn!
See iLearnReliability in Action
Ready to see it in action? We have provided access to three of the “Essential Elements” modules that cover the topics of:
You will see how they are presented and all narrated making the study process very easy. They contain lots of animations and often “simulators” that allow you to interact a lot. Click here to go to our demo site.
Rather than offering a stagnant, static training product, iLearnReliability [Enterprise] is not purchased outright; you can either pay for it on a monthly basis or an annual basis. And because different clients have different plant sizes, you will pay according to the number of people you wish to access iLearnReliability [Enterprise].
Please note that in most plants there will be some people who access a lot of the iLearnReliability training modules, and others who only access a few modules. Our pricing does not distinguish between them. We know that in order to achieve buy-in and the desired “reliability culture” you will need to train a lot of different people who have different needs. The pricing model ensures that it is very affordable for everyone.
And we understand that your training needs may change. You may like to start by training a small group of people who will lead the reliability improvement initiative and then add a much larger group of people as you roll out the program. Your subscription can follow suit – smart small and grow it later.
iLearnReliability [Enterprise] is very affordable, especially if you consider the time and expense associated with attending individual courses (or the cost of purchasing all of the books and the time to read them).
You can click here to view our subscription levels, and even subscribe via credit card, or you can contact our US office via email@example.com or phone us at toll free in North America at (877) 550-3400, or worldwide at (+1) 615-216-4811.
PLEASE NOTE: If you learned about iLearnReliability [Enterprise] via a sales engagement with an authorized Mobius reseller, please either purchase it through them or inform us of who that reseller is – it is only fair that we pay them their commission.
End the Waste
How it Works
See iLearnReliability in Action