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Reliability Management

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BearingPoint provides a systematic approach to comprehensive reliability management by supporting sustainable equipment integrity and increasing process reliability.

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Reliability Management

  1. 1. Reliability Management A BearingPoint Accelerator BearingPoint provides a systematic approach to comprehensive reliability management by supporting sustainable equipment integrity and increasing process reliability.
  2. 2. Contents Market Drivers Our Approach Client Benefits References Contact Reliability Management | A BearingPoint Accelerator
  3. 3. Reliability Management | A BearingPoint Accelerator Challenges Trends Ongoing automation & digitalization • leads to higher complexity and thus higher susceptibility of equipment and assets to breakdown. Intensification of mechanization • leads to significantly reduced manpower on site. Processes need to be efficient and stable. Increasing requirements concerning quality, flexibility and lead times • require rapid operational response times. Operational availability and reliability are essential. Technological advance, methods & tools • continuous improvement, BPM, IoT and integrated software solutions are future key competitive factors to enable the transformation to a highly reliable organization. Lean management, total productive maintenance or digitalization • a comprehensive combination of these approaches with focus on production integrity is recommended. Performance reliability Process reliability Equipment reliability Comprehensive approaches to increase reliability are essential when coping with digitization, increased market volatility and ongoing automation Market Drivers
  4. 4. Reliability Management | A BearingPoint Accelerator The key challenge is to embed reliability management (RM) into both a company’s existing operations, as well as strategic and financial targets Operational challenges include embedding reliability management into existing structures and routines: • Creating an understanding and willingness to overcome challenges • Finding the right mixture of tasks/tools involved • Implementing new structures without neglecting daily business Configurational challenges of reliability management should neither overrate nor underrate reliability management: • Generating an adequate cost/benefit ratio, e.g., modernization of facilities • Combining quick wins with long-term benefits Sustainable implemented processes compete with existing company culture and routines • Creating easy and logical processes • Generating in-depth process understanding • Providing continuous trainings In all dimensions, reliability management faces a trade off between: Safety issues Costs Availability Market Drivers RM Configuration Sustainability Operations
  5. 5. Reliability Centered Maintenance • Statistical evaluations and FMEA vindicate and substantiate maintenance strategies • Priorities in allocating maintenance efforts are derived from criticality analyses. Spare parts are categorized accordingly Controlling & Analytics • Capturing crucial values within management dashboards enables the allocation of reliability efforts where they are required most • Advanced analytics support reliability and sustainability to enhance overall equipment availability/ efficiency Process Reliability • Process-FMEA and criticality evaluations provide a basis for effective business process management • Processual root cause analyses promote the streamlining of processes and support continuous improvement Technology Reliability • Implementation of engineering & analytics tools/ cloud solutions • Remote access and e-inspection • Examining process integration and assessing document and master data mgmt. in order to promote reliable technology support Reliability Management | A BearingPoint Accelerator Reliability Mgmt. BearingPoint provides a unique, comprehensive reliability management approach combining aspects such as machine configuration, environmental and organizational factors Environment Machine Human & organizational factors
  6. 6. Reliability Management | A BearingPoint Accelerator Step Target BearingPoint Tools Benefit Reliability Improvement Current State Analysis Identification of risks regarding reliability A standardized Quick Check Assessment of Potential Effective assessment of weak points and improvement potential Approved Maturity Model Target Definition Increase reliability considering crucial customer objectives and boundary conditions Reliability Toolbox Monitoring Control defined KPIs to support reliable processes and reduce risk Reliability Dashboard With BearingPoint’s approach, clients will be able to identify risks and specific crucial aspects for improving reliability. Adequate measures have to be defined to achieve tangible results.
  7. 7. Reliability Management | A BearingPoint Accelerator Production costs Unit costs Volume Market price Maintenance efforts Availability Quality Reliability In the long term, the overlapping, mutual reinforcement of positive effects leads to a high ROI and an increase in competitiveness. BearingPoint provides a comprehensive methodological and technological offer: • In-depth data understanding and experience with standard EAM/ APM systems • Close collaboration with BPM and predictive maintenance teams • BearingPoint combines broad industrial process understanding with in-depth IT knowledge and methods • Broad software experience, e.g., Cloud, ERP, Hypercube, APM (Meridium), RCM ++, APIS IQ-FMEA, Datalyzer
  8. 8. Reliability Management | A BearingPoint Accelerator Process reliability Business needs • Global technical leading practice documentation • More standardized processes for European • sites (end-to-end) • Improvement of the sourcing process to reduce the risk of stockouts for spares Our approach • Development of technical leading practice with approved tools & methods • As-is analysis and definition of the to-be processes with business process management • Implementation of a harmonized goods receipt controlling • Training of the global standardized process for the local users (key user concept) Client benefits • Global harmonized reccommendations for sites • Standardized and transparent end-to-end processes • Reduction of stockouts for spares increasing reliable uptime • Reduction of errors caused by human factor during the process Equipment reliability Business needs • Definition & design of efficient master data management processes • Increasing transparency and data quality of technical structures and spare parts • Very high SLAs • Avoidance of data redundancy and multiple entries Our approach • Evaluation of maturity levels according to the maturity of key areas • Data integration, IT-architecture, data quality, governance • Creating a basis for sustainable master data improvement by (re-)defining responsibilities • Installed base • Determination • Project management • Implementation/ migration Client benefits • Steps and measures taken to reach the next level of maturity are derived • Master data management follows standardized rulings • Technical equipment and spare parts can be clearly and easily identified and assigned (physically and technically within the system) • Redundancies are eliminated and multiple maintenance activities are reduced (harmonized master data) References
  9. 9. Reliability Management | A BearingPoint Accelerator Performance reliability Business needs • Replacement of current BW reports and Excel-based individual solutions • Significant acceleration and standardization of reporting content and visualizations • Promoting transparency over the reporting solutions of all sites Our approach • Analysis of the current solutions and definition of the target features and required reports • Collecting functional and textual requirements for target solutions and visualizations • Gaining transparency and a uniform understanding of defined KPIs Client benefits • Centrally maintained reporting layouts with standardized tables and visualization parts • Central access to the reporting solution over all sites • Controlling reports by use of function buttons • Implementing central reporting/ dashboard solutions with benchmarking possibilities for predefined KPIs Industries BearingPoint Reliability Management is a cross-industry solution. The references provided for improving reliability are from the process and chemical industry. The main drivers for improvement are equipment reliability, process reliability and performance reliability. References
  10. 10. Reliability Management | A BearingPoint Accelerator Andreas Buegers Partner BearingPoint Germany andreas.buegers@bearingpoint.com Sven Gehrmann Senior Manager BearingPoint Germany sven.gehrmann@bearingpoint.com Mirko Galonske Senior Business Consultant BearingPoint Germany mirko.galonske@bearingpoint.com Contact About BearingPoint BearingPoint is an independent management and technology consultancy with European roots and a global reach. The company operates in three units: Consulting, Solutions and Ventures. Consulting covers the advisory business; Solutions provides the tools for successful digital transformation, regulatory technology and advanced analytics; Ventures drives the financing and development of start-ups. BearingPoint’s clients include many of the world’s leading companies and organizations. The firm has a global consulting network with more than 10,000 people and supports clients in over 75 countries, engaging with them to achieve measurable and sustainable success. For more information, please visit: Homepage: www.bearingpoint.com LinkedIn: www.linkedin.com/company/bearingpoint Twitter: @BearingPoint © 2018 BearingPoint. All rights reserved