1. BACKGROUND
As a result of interest expressed by members of the Industrial Maintenance Roundtable and the need that had been demonstrated through maintenance benchmarking studies, Ron Moore, an internationally recognised authority on Reliability Based Manufacturing strategies and their implementation, has now been brought to Australia by SIRF several times. Ron has conducted several 1 and 2 day workshops as well as carrying out direct consultative work.

Ron is president of RM Group and was previously President and CEO of Computational Systems Inc (CSI), a leading USA supplier of maintenance technologies and the "supplier of choice" to DuPont in this area. In addition to the workshops, Ron also conducts specific in-house activities, including plant reviews, de-bottle-necking, and uptime improvement exercises.

2. RON MOORE

Ron Moore, Managing Partner of The RM Group, is an internationally recognized authority on reliability and manufacturing strategies. His efforts principally focus on improving reliability of manufacturing plants, and therefore, increasing production capacity and reducing operating and maintenance costs. This is done through the strategic planning and implementation of various operations and maintenance practices, systems, and technologies. Ron is the author of Making Common Sense Common Practice: Models for Manufacturing Excellence, now in its 3rd edition, and of Selecting the Right Manufacturing Improvement Tools- What Tool?  When?  He has also authored over 30 journal articles.  Ron has over 30 years of experience working in the industrial manufacturing field and was formerly the president of a predictive maintenance technologies supplier.

3. WORKSHOP INTRODUCTION
Essentially all industrial manufacturers worldwide are under tremendous pressure to do more with less. The very best plants are able to accomplish this through the application of a reliability strategy. This strategy assures maximum production capacity at a minimum cost. Downtime costs 2 to 15 times as much as maintenance.

Reliability Based Manufacturing begins with an overview of the reliability strategy, the accomplishments of plants, which have applied the strategy, and the relationship between reliability and best maintenance practices. A comparison is made between the typical manufacturer and world class plants as to capacity levels, costs, and operational performance. Participants will then discuss the reasons for differences. A typical plant is producing only 50-70% of its theoretical capacity.

The reliability strategy is presented with case histories and results of studies. The strategy represents an optimal mix of reactive maintenance, preventive maintenance, and proactive maintenance. The best plants are driven by equipment condition assessment using predictive maintenance technologies. Maintain equipment only when it is required, and by doing only what is required.

The course includes a review of the technologies, systems, and methods, including the key attributes of technologies and their applications to achieve a benchmark level of performance for best practices. Technologies and critical characteristics to be reviewed include vibration, oil, infrared, motor current and ultrasonic analysis methods. Computerised Maintenance Management Systems (CMMS) will also be reviewed, covering their key attributes, and how to interface them with predictive technologies. A case study will be used to demonstrate the development of a continuous improvement plan for maintenance.

4. WORKSHOP OUTLINE

1. Introduction

• Global Competitive Forces
• Improving Capacity And Return On Assets
• Background Of Reliability Based Strategy
• Reliability Benchmarks and Best Practices

2. Reliability and Capacity Relationship

• Theoretical Production Capacity/Bottlenecks vs. Actual
• Sources of Lost Capacity
• Production Flows, Bottlenecks/Choke points
• Failure Modes, Frequencies, Effects

3. Current Reliability (Maintenance) Practices

• Reactive Maintenance - Run To Fail, Emergency, Unplanned
• Preventative Maintenance - Interval Based
• Predictive Maintenance - Condition Based
• Proactive - Root Caused Based
• Reliability Practices and Inventory Management

4. Key Features in a World Class Reliability Program - Review of Technologies from a Management Perspective

• Computerised Maintenance Management Systems
• Vibration Analysis
• Infrared, Ultrasonic, Motor Current, Oil Analyses
• Proactive Methods - Key Features

5. Organisational Strategy for Integration/Implementation of Reliability Practices

• Management Support
• Organisational Structure and Teamwork
• Communication Methods
• Training Requirements
• Performance Metrics for Measuring Success
• Technology

6. Case History - Whamadyne Chemicals

• Audit and Continuous Improvement Plan

7. Self Audit - Baselining Your Current Operation

• Benchmarks and Best Practices In A World Class Organisation

8. Development of Your Continuous Improvement Plan

5. WHO SHOULD ATTEND

Plant Managers
To learn how they can apply reliability principles to improve plant capacity, cut costs and become the low cost producer. The will learn how they can effectively organise for improved reliability, including the people, the capital and the training assets necessary. Facilitation of teamwork among their staff will also be covered. They will also learn how they compare to the best plants and how to be come a best plant. They will also learn those issues described below.

Maintenance Managers, Supervisors and Team Leaders
To learn the above, plus how to move away from reactive, repair, emergency maintenance practices to become an integral part of the production process and the business unit. They will learn how to communicate more effectively with production and engineering regarding their contribution and needs as part of making the organisation.

Production Managers
To learn the above, plus how they can more effectively work with and utilise the resources available in a world-class reliability based manufacturing organisation. They will learn how their operators and production personnel can more effectively work as a team with maintenance and engineering to improve reliability and reduce costs.

Engineering Managers, Plant Engineers
To learn the above, plus how they can more effectively contribute to improved reliability through improved understanding of machinery operating condition and repair histories. They will learn how to become more proactive in design and procurement methods and standards to improve reliability and plant capacity.

Maintenance Planners, Production Planners
To learn how they can more effectively contribute to their plant's success in competing on a global scale.

Purchasing Managers
To learn how they can become an integral part of improved production capacity and reliability through improved purchasing and procurement standards, that is, those, which are focussed on reliability, value, and life cycle cost more so than low bid.

6. WHAT YOU WILL LEARN

• Workshops have formal presentations but are highly interactive, thereby providing the opportunity for participants from different companies to learn from each other. In particular, the participant will learn the following:-
  
• Reliability principles, the various maintenance practices available, their strengths and weaknesses, their relationship to reliability, and how application of reliability principles can improve capacity and cut costs.
  
• How to apply those principles within your plant to eliminate unplanned downtime, reduce planned downtime, improve quality and minimise maintenance costs.
  
• Predictive technologies and methods for maximising knowledge of machinery condition, and therefore minimising the risk of unplanned downtime. How these technologies allow plants to become proactive in assuring equipment reliability.
  
• Key reliability benchmarks, how you compare to those benchmarks and how you can achieve a benchmark level of performance.
  
• Methods for improved organisations, communication, and teamwork for effectively implementing the strategy.
  
• Metrics to be used to measure the effectiveness of the reliability strategy as implemented at their plant.
  
• How your plant's actual production capacity measures against maximum capacity, those issues that are contributing to the difference and more importantly, how to address each issue which is limiting capacity through application of reliability principles.
  
• How your practices compare to reliability best practices and benchmarks, and an improvement plan of how to bring your world-class level.