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Industrial Business Solutions for Low Production Costs, More Production Throughput and Highly Reliable Equipment
How to Boost Your Industrial Business Productivity and Profits...
Combine Engineering Asset Management, Industrial Maintenance Management, Quality Management Systems, LEAN Manufacturing
and 6 Sigma Process Improvements to...
Get maximum productivity with quality, eliminate business process wastes, lower operational risk and business risk exposure, least maintenance costs, highest equipment reliability, more production throughput and new equipment uptime solutions
Welcome,
Learn where to put your resources and efforts to boost your industrial business performance and lift operational results for the least cost.
Use life-cycle engineering asset management, quality management systems, best-practice maintenance management, LEAN manufacturing and six sigma process improvements to slash your business losses, remove the lean process wastes and make your production and maintenance best-in-class.
Combining LEAN business process improvements, with a quality management system, precision maintenance practices, and world-class engineering asset management in a business growth strategy gives you a vastly more successful operation and profitable business.
You will make more profits, have failure-free equipment and improve the performance of your organisation and its people when you use best-practice 6 sigma business processes, LEAN manufacturing methods, top-class engineering asset management practices, value-adding LEAN maintenance management, and work quality assurance as your primary business improvement methods.
Take the opportunity now to contact us and ask to complete the 'Lean Business Performance 64 Point Review Questionnaire' and/or the 'Engineering Asset Management Performance 84 Point Review Questionnaire' to help you discover the treasure-chest of new business and profit growth opportunities you have. (Find our details at the Contact Us link.)
You are welcome to read any of our numerous articles and white papers favoured and renowned by peoples around the world on the topics of world-class maintenance quality, engineering asset management excellence and equipment reliability growth. (Use the 'Click for Free White Papers' links in the table). You will soon realise that we have a passion, and very specific requirements, for delivering successful engineering asset management, equipment reliability excellence, business process improvement, and the maintenance management processes and quality management systems that lead you towards world-class business performance.
Read and learn about our unique ways that improve your industrial maintenance and enterprise asset management efforts to quickly and surely move your industrial operation towards world-class performance:
- the simple Accuracy Controlled Enterprise quality management system that brings rapid standardisation and simplification to all your work processes
- the ACE 3T (Target-Tolerance-Test) method of writing standard operating procedures to control human error and provide work quality assurance in every task
- Profit Contribution Mapping finds all your business process losses so they can be fixed and let you keep the money that was wasted
- Defect and Failure True Costing to rate the business impacts of breakdowns and failures and identify your biggest opportunities to improve your operation's performance
- the 'Change to Win' Business Growth Teams where your people bring innovation and improvement into your company, and build a refreshed and strong commitment to improving the business; without management and supervision having to be 'on their backs' all the time
- the ACE Precision Maintenance Program, which builds you a world-class maintenance and operations group that gets you the lowest maintenance costs possible.
OUR RANGE OF SERVICES: Industrial Business Solutions for Lower Production Costs, More Production Throughput and Highly Reliable Equipment
1) Leaders in:
LEAN Maintenance Management – maintenance processes and practices that maximise life-cycle profit
Enterprise Asset Management - strategy development and the necessary supporting organisational processes and structures
Plant and Equipment Reliability Growth Practices - industrial maintenance management and equipment reliability growth for maximum operational plant uptime
LEAN Manufacturing Process Improvements - eliminating business and process wastes for maximum efficiency improvements
Business and Work Quality Management Systems - eliminating process variation to produce highly effective and efficient business processes
Industrial Organisation Change Management – aligning departmental and personal values and mindsets to achieve the organisational vision
2) LEAN Business Process Waste Elimination and Business Process Re-engineering for high-value effectiveness and efficiency improvements
Download Lifetime Reliability Solutions business solutions brochure |
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3) World-Class Training Courses and Training Products in best-practice skills, methods and knowledge of industrial asset management, maintenance management solutions, equipment reliability solutions, operational risk reduction, and LEAN business process waste reduction practices.
Attend our world-class training courses and discover the best practice lean maintenance management solutions, the key maintenance asset management methods and the critical precision maintenance quality assurance that mean production with quality, elimination of wastes, lower business risk, reduced maintenance costs and quick equipment reliability growth in your industrial plant operations.
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The Lifetime Reliabilty Maintenance Manual is Now Available
All our best methods and tools.
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Download our full industrial training courses brochure
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Examples of Our Clients' Successes
Maintenance and Asset Management Consulting and Maintenance Training
You will be happy to know that our clients are more than satisfied with the value we added to their operations through using our unique understanding, knowledge and expertise in lean process improvements, quality management systems and enterprise asset management.
Nickel West Smelter, in Kalgoorlie, Western Australia, called on us to develop an 'Authority to Maintain' accreditation system to gauge the knowledge and competency of their maintainers, and to provide guidance on their training and development needs. Unique in approach and thorough in content, it was soon used across the many Nickel West operations because it worked so well.
Fortescue Metals Group, the 'new force in Australian iron ore mining', commissioned us to train all their maintenance planners, both old and new, so that they had a full understanding of the benefits gained with the very latest maintenance management and reliability growth concepts. The unique content of our three-day maintenance planning and scheduling course was seen as advantaging their business. They continue to send their maintenance planners to our training to give their people the competitive advantages FMG needs to surpass their competitors in future.
Worsley Alumina Refinery, near Collie, Western Australia, requested us to train ten experienced tradesmen in reliability engineering basics, best practice asset management and world-class maintenance management for the newly created positions of Reliability Officer. They found our course content and training activities to be comprehensive and ideal for quickly bridging the knowledge gap needed to make the new appointees immediately effective and useful in their plant and equipment reliability improvement efforts.
LEAN Manufacturing and 6 Sigma Business Process Improvements
Smorgon Steel, the Australian concrete reinforcing steel specialists, commissioned us to streamline and speed-up the steel reinforcing bar fabrication and product distribution processes in their Western Australian manufacturing facility. We flow charted their production and despatch processes, then value stream-mapped the processes to find time and motion savings and to reduce the numbers of steps needed to do them.
P&H MinePro, the international mining equipment manufacturer and supplier, contracted us to find major time savings in their Western Australian mining shovel fabrication and parts machining operation. Adopting lean methodologies and six sigma tools we identified over forty opportunities to make significant time, distance and resources savings. Within twelve months the proposals adopted generated on-going savings of $480,000 annually.
P&H MinePro were so impressed with the size of the savings we found them, that the following year they contracted us to do the same investigation and analysis at their Mackay, Queensland, repair and maintenance workshop. There again we found many time and motions savings to help P&H MinePro reach their target of doubling throughput from the workshop.
Quality Management Systems and Work Quality Assurance
PDC Consultants, based in Perth, Western Australia, gained ISO 9001 accreditation on the first compliance audit with our guidance, which led them to new business opportunities and better performing internal drafting and business processes. They are now one of the largest design and detailing companies in the world servicing the mining, oil and gas, processing, and industrial sectors.
Vinidex, the PVC and Polyethylene pipe makers, had too many equipment stoppages and breakdowns on their Western Australian plant's production lines. A maintenance Pareto Analysis indicated wide-spread equipment failures across the operation. They had a work quality assurance problem. We showed them how ACE 3T concepts in maintenance job procedures introduce clear work quality targets and proof tests for job tasks. The Production Manager immediately saw that they would solve his breakdown problems and mandated that key equipment maintenance procedures be re-written to include ACE 3T Targets - Tolerance - Tests.
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Five Reasons Why You Should Use Lifetime Reliability Solutions
- The Right Expertise, Knowledge and Experience Brings You the Right Results
- We know machinery: how it's built, how it works, how it fails, how to get the best from it. That lets us give you the simplest answers to fix your maintenance and operational problems.
- We apply sound methodologies and techniques that find new opportunities to improve your operation with the least disruption and cost. Often it only involves procedural changes and some on-the-job training.
- The people on your project are professionals, with a deep understanding and knowledge of their discipline so they can quickly grasp the issues affecting your situation and ask the right questions.
An Investment that Gives You Great ROI and Delivers On-going Returns
- We're ROI driven: Our best project to-date delivered 1600% ROI and earned the client $480,000 extra per year for a $30,000 investment. The same opportunities are there for your business too, and we will find them.
- Our recommendations are analysed financially and practically to make sure they generate increased profits for you. When you make changes you need to be sure that they can be done, and that they will payback quickly.
- We use modern business tools and systems - Lean Process Improvement Investigations, Reliability Engineering Analysis, Six Sigma Problem Solving Tools, Engineering Asset Management Strategy - that give you new insights into how you can improve your operation and make your business more profitable.
- Our recommendations make your business better by lowering your operating risks, reducing your maintenance costs, increasing your production throughput, boosting profits and lifting your plant and equipment uptime.
We Work to an Agreed Standard that Meets Your Expectations
- Flexible, multi-skilled people scheduled to meet the dates agreed with you so you can meet your deadlines.
- Professional project management methods to control progress on your jobs and make sure you get what you want.
- We use our know-how to keep things simple and practical in order to minimise your time and costs.
Competent, Quality Solutions Give You Better Systems and Processes that Solve Your Business Problems
- We take a life-cycle perspective and build-in sustainability, reliability and maintainability so that our proposals give your operation multiple benefits that continue to generate ongoing benefits.
- Our proposals remove your business problems and operating risks by finding and solving their root causes and give you confidence that they will not return later.
- We have open discussions and interactions with clients to ensure you get good outcomes quickly. The dialogue between us keeps you fully informed of our efforts, while making sure we deliver exactly what you want, in the shortest time possible, for the least costs.
World-Class Vision - Innovation Driven - Competitive Advantage Focused
- Our commitment is to be at the forefront of expertise and knowledge through on-going training and education that we apply on your work so you get the newest benefits too.
- We're passionate to stay world-class so you receive the best solutions that give you huge competitive advantage and provide greater security for your future.
- Unique proprietary methods and business solutions not matched by other consultants and trainers that get you positive, powerful business results fast.
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If you need help to implement world-class maintenance management solutions, use world-class reliability solutions, apply best LEAN waste elimination practices, or have successful work quality management systems, please find our contact details at Contact Us.
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My best regards to you,
Mike Sondalini
Director
Best Practice Maintenance Management and Industrial Asset Management Strategy Ebooks and Training PowerPoints
Equipment Reliability and Maintenance Management Excellence 3-Day Training Course PowerPoints: Over 230 maintenance management ppt slides on reliability and maintenance management practices, methods and strategy. Day 1 introduces you to the important equipment reliability concepts every industrial plant manager, maintenance manager and maintenance engineer need to know if they want to get best plant and equipment performance for least cost. Day 2 is about profit-centered maintenance. It is about running maintenance to make money. You will discover the six purposes of maintenance and how they are used to increase operating profits. Day 3 brings reliability and maintenance together into a life-cycle industrial maintenance management strategy that minimises your operating risks by giving you the right maintenance management tools to prevent problems. The whole focus of the course is to help you build failure prevention and defect elimination practices into your business from its early conceptual beginnings to its last day of operation. You want maximum profits with absolutely least waste and loss. This 3-day training course will show you how it is done. Equipment Reliability and Maintenance Management ppt Training Course. You should also get the Enterprise Asset Management ppt Training Course, which includes more on Reliability and Maintenance Management, to extend your knowledge.
Industrial Plant Maintenance Planning and Scheduling for Maximum Reliability 3-Day Training Course PowerPoints: Our popular reliability-focused 3-day training course on best-practice maintenance planning and scheduling methods that build ultra-high equipment reliability into your maintenance activities. None of our secrets are left untold in this CD. Here are some comments from the people that have attended the training: “Very good – has changed the way I thick about maintenance planning.” - “Very informative. Eye-opener in some areas.” – “Usually I find if one thing of use is learnt per day then value is achieved; value has definitely been achieved! Also good notes, CD and risk analysis template.” – “Helped to give me confidence that I’m heading in the right direction in planning.” – “Some very good concepts to take back to work which could help our business.” – “Very interesting, more than enough information for a 3-day course.” – “The course members from industry were very impressed with the content.” – “Being a planner for only three months, I found this course excellent and relevant to my position.” - “Heaps of information put out.” – “Excellent – will help with future job prospects.” See the Industrial Maintenance Planning and Scheduling Training Course PowerPoints.
Enterprise Asset Management, Reliability and Maintenance Mastery 3-Day Training Course PowerPoints: The content of this Enterprise Asset Management ppt training course is exactly what you would see if you attended the actual 3-day Enterprise Asset Management System Training Course. This Enterprise Asset Management ppt Training Course is different from other company's courses because it is tailored from 30 years of real-life experience as a tradesman, professional engineer and Maintenance Manager. The first day introduces people to value stream mapping, Weibull reliability and other EAM concepts. It also covers defect analysis and measuring risk in some detail. Day 2 dives into the implications while building on the EAM concepts introduced in the first PowerPoint. Details including equipment life cycle concepts, enterprise management systems and change management are covered and then highlighted with two real case studies. Day 3 is about putting it all together to produce a successful 'Plant Wellness plan' (EAM System). This is followed by a section on how to justify use of best practices in an Enterprise Asset Management System. Logically, Day 3 ends with greater detail on change management needed to introduce the revolutionary concepts of 'Plant and Equipment Wellness'.
Enterprise Asset Management, Reliability and Maintenance Mastery Training Course PowerPoints. You should also get the 'Equipment Reliability and Maintenance Management ppt Training Course' to extend your knowledge.
Total Productive Maintenance: Total Productive Maintenance (TPM) is an equipment management program that emphasises operator involvement and ownership of equipment performance. The goals of a TPM program are to maximise equipment productivity, maximise equipment availability and make quality product by eliminating causes of equipment defects, losses and wastes through expanding and engage the knowledge, skills and abilities of the front-line people running the process.
This 85-slide PowerPoint presentation will help you to investigate if the introduction of TPM will help you reduce lost time on operating equipment to a tune of 30% or better. This is typical for plants who do not already have advanced Preventive Maintenance and Predictive Maintenance (PdM) practices in place. This PowerPoint will also help to ensure you meet the requirements for a successful TPM introduction to your facility. Improve your understanding of TPM with the
Total Productive Maintenance Powerpoints.
Production Risk Management with Equipment Criticality: Immediately improve your maintenance and production performance by identifying and classifying your plant and equipment in order of importance to the success of your operation. Those items of plant that are more important than others receive a matching level of maintenance care. This way you make sure your money is spent on the highest proirity equipment with the biggest pay-off to your business. Learn to select the right maintenance management strategies that will automatically deliver the equipment reliability, production performance and maintenance cost reductions you need! To accurately and reliably gauge and rate the importance of your plant and equipment to your business buy and use the Production Risk Management Using Equipment Criticality Analysis ebook.
Discover the Best Practice Enterprise Asset Management Tools: Start on the path to outstanding production performance success with the right asset management and maintenance strategies for your plant and equipment! Here is a great little reference book that simplifies Industrial Asset Management best practices and shows you when to use them. Grab a low-cost copy of the Industrial Asset Management and Equipment Reliability Tool-kit ebook.
How to Really Make Standard Operating Procedures Work for You: It is a strategic task of maintenance and production management to give the people on the 'shop floor' the right knowledge to become the very best operators and maintainers they can be. It is they who have to deliver the maintenance strategy to the plant and equipment! A great way to pass the operators and maintainers the skills and knowledge that give them the power to achieve world-class production performance is through using standard operating procedures (SOP) with check steps. Take a look at a new and unique way of doing Training and Development With Standard Operating Procedures.
Focus Operations and Maintenance Performance with Key Performance Indicators: Another quick way to develop people is through using key performance indicators (KPI) in your operation. With them your people can manage themselves and their actions. KPI's will let you and your people measure current production performance and set new targets to aim for in the future. Using KPI's will gradually change people's thinking and habits. They will come to understand what they must do to master their equipment and production processes. You and your people develop your own KPI's together. They must be meaningful to the users if you want ownership. Learn how to develop relevant, meaningful and truly useful KPI's by using the Business Strategy Management with KPI. ebook
Best Practice Industrial Maintenance Training to Lift Work Force Competency: To make lasting, long-term production performance improvements and get reduced maintenance costs in your operation, train your people to be truly competent and recognise and solve equipment reliability problems themselves. If you want to save yourself time and trouble in future teach your operators and maintainers basic maintenance management training and plant engineering. Use the Best Practice Maintenance Management and Engineering Reliability Training Program for plant operators, maintenance crews and new maintenance engineers and watch them deliver outstanding production and maintenance performance! See how to convert the engineering information in the training program into your own in-house training documents by looking at these free training examples FREE Maintenance and Engineering Workforce Training Examples.
Boost Equipment Reliability with Root Cause Analysis: Your maintenance work order history contains truly valuable information that can be used to improve equipment reliability and stop equipment failures. Learn how to find and get rid of the repetitive problems that keep coming back time after time. Spot recurring problems and fix them for good by finding the root causes! Sometimes you need to be sly and creative in looking for evidence of root cause problems. You may have to develop methods to classify work orders into types so the root causes jump out at you. Get more information on how to analyse maintenance work orders so you can get rid of root cause problems and boost equipment reliability from the Discover the Goldmine in Your Maintenance Work Order System Through Analysis ebook.
Discover Your True Total Lost Production Down Time Costs: Every stoppage causes lost production. Each lost production incident is far, far more expensive, terribly more expensive, than you realise. Your accounting system does not even come close to pricing the total, true value of a lost production incident to your business. It does not matter why production stopped, every minute of lost production is costing your business hugely. You can now identify the total true down time cost to your operation and justify spending the money to fix the problems that cause production loss once and for all. Read the Down Time Cost Analysis ebook and find-out the terrible truth of your production loss incidents.
New Way to Defect Elimination and Failure Prevention - The Accuracy Control Enterprise: Until every standard operating procedure task (SOP) contains 'the 3T's of defect elimination and failure prevention' you have no sure method of delivering defect elimination and failure prevention in your operation. When you incorporate accuracy-controlled practices into every step of every operating and maintenance procedure will you be able to guarantee top quality workmanship and spot-on results from everyone. Read the Accuracy Controlled Enterprise ebook and discover how to become an ACE by using the 3T's of failure prevention - Target, Tolerance, Test - to guarantee defect elimination and deliver certain production risk control everytime.
The Total Cost Way of Making Better Risk Based Decisions: The risk equation, Risk = Chance x Consequences, must be accurate when you use it to make risk management decisions and equipment criticality decisions. The true cost of failure is the figure to use for the 'Consequences' value in the risk equation. Your failure consequences must be fully-costed otherwise you under-rate the real cost of risk to your operation. Without knowing the defect and failure true cost (the DAFT Cost) you cannot make the right choices and so you will not properly control your business risk. The added benefit of knowing the full cost of failure is that you can justify higher expenditure to control the risk of failure. Read the Defect and Failure True Cost ebook and learn how to cost the total true cost of risk to your operation.
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