ReliableToolKit ™ Method Seminar
John J Martin – After working nineteen years for Major Corporations, including six as a Reliability Applications Engineer and World Wide RCM Trainer/Facilitator, Mr. Martin began providing training, facilitation and consulting services in Reliability Centered Maintenance, Manufacturing Reliability Measures, and Failure Reporting and Corrective Action Systems as President of Reliability Solutions Inc. In his fifth year, Doug has now provided Reliability Training and services to numerous companies, large and small, including Fortune 500 companies. He has been a featured speaker at the Society of Manufacturing Reliability Professionals national conference, MARTS, the International Maintenance Conference and is noted for having developed the ReliableToolKit ™ method.
Mr. Martin has made key contributions to standard reliability measures for manufacturing, and reliability training programs for engineers, technicians, and skilled trades. He has trained numerous client RCM Facilitators and performed RCM root cause analysis on hundreds of pieces of manufacturing equipment through out the world. Mr. Martin has worked with Colleges to help develop three Reliability Engineering Courses that are now offered Reliability Engineering Certificate programs.
Background - The ReliableToolKit ™ Method
From the Instructor:
In my first two years of instructing and facilitating Traditional RCM, the number one complaint I received was the process had great value but was much too slow. The typical cycle for an RCM analysis at the time was three to six months to complete the analysis and implement the tasks. In a time where companies need change and reliability improvement needs to happen at an accelerated rate, the traditional process fell short of these goals. The challenge at hand was to develop an RCM process that delivered a thorough analysis in a much shorter cycle. It was from this challenge that the ReliableToolKit ™ Method was created. It’s a powerful, cutting-edge reliability tool that completes the Traditional RCM analysis cycle in seven days or less, and delivers actionable tasks in the first day of the analysis!
John J Martin
The ReliableToolKit ™ Method
The dramatic RCM analysis cycle reduction is accomplished by combining advanced facilitation techniques with the Traditional RCM thought process. The advancement in facilitation came from the idea of Co-facilitation and the use of a real time RCM Database. These advancements made it possible to facilitate the RCM analysis and enter information into the database at the same time. While one person facilitates the other captures information. This provides the RCM team and their company with more accurate information and a complete RCM report with prioritized and assigned action items at the end of the analysis cycle. This change in the facilitation technique allowed us to make improvements to the Traditional RCM process that made our ReliableToolKit Method even more thorough than the traditional process. Our process now includes four major improvements than make it not only the fastest process available but it now is the most thorough!
First we changed the standard FMEA portion of the RCM process to a FMECA. This change helps the RCM team to focus on failure modes that have a higher probability of occurring and greater consequences to you business should they occur.
The second improvement was the addition of the consequence reduction tasks. The decision process in Traditional RCM often leads to the “No Scheduled Maintenance” or “Run to Failure” for failure modes that can’t be predicted, prevented, or eliminated. Coming from a manufacturing and maintenance background, we knew this strategy was not only real but frightening. Unscheduled downtime costs add up quickly. The best way to reduce these costs is to reduce the downtime cycle by having consequence reduction tasks in place. Make sure you have the right procedures, spare parts, and resources in place the repair the failure in the shortest possible time.
Third was the addition of the spare parts decision process. No maintenance strategy is complete without the proper spare parts in place. The ReliableToolKit process includes a complete report on the spares necessary to make your process reliable.
Finally, came the addition of the ReliableToolKit troubleshooting report. Upon completing an ReliableToolKit analysis the RCM database will produce a troubleshooting guide that is second to none! This report will assist operators and maintenance people in quickly locating and identifying failures on your equipment and reducing the mean time to restore for each and every failure.
Here are Specific Benefits of ReliableToolKit
- Learn the history of RCM, where the process was developed and why it works in manufacturing.
- A clear understanding of how and why we use a proven structured process to develop a maintenance strategy.
- Learn how to select what equipment or processes ReliableToolKit ™ should be performed on to maximize return on investment.
- The key pieces of up-front information needed to start an effective RCM analysis.
- Identify whoshould be involved in an RCM analysis and why their involvement in the process is critical for success.
- Learn how to enter data into the ReliableToolKit ™ Database.
- Understand why it is important to identify and understand equipment or process main and support functions.
- Learn the six age-related reliability patterns and the types of equipment that falls into each.
- How to identify Functional-Failures of your process and why this in important in developing a good maintenance strategy.
- How to identify and write Failure Modes at a level that maximizes equipment reliability.
- The importance of clearly describing and writing Failure Effects in a way that accelerates the ReliableToolKit ™ decision process.
- Learn how to prioritize your action tasks based on the probability and consequence of each Failure Mode.
- Learn the proven RCM decision process that looks to predict, prevent, eliminate, or reduce the consequence of each failure.
- Why in many cases “No Scheduled Maintenance” (Run to Failure) is an unacceptable maintenance strategy.
- Learn when and where predictive and preventive maintenance should be applied.
- Learn how to use root cause analysis software