Opportunity: A business sector within a manufacturing facility was experiencing annual production losses in the millions of dollars due to instrumentation related equipment failures. This facility was averaging 50 unplanned shutdowns per year due to instrument equipment technologies.
Solution: A team of subject matter experts analyzed historical downtime and implemented an Informal Root Cause Investigation process in where each unplanned event was broken down by using three simple steps, 1) Root Cause Identified, 2) Short-term Solution Implemented, 3) Long-term Strategy Implemented. This approach was combined with a comprehensive reliability program that focused on Reactive, Proactive, Reliability Centered Culture Initiatives and Instrument Engineering Projects (see video below for details).
Results: After the implementation of the new program, the business sector realized an 85% reduction in instrument equipment failures.
Impact: Millions of dollars in production and reduction of maintenance cost.