B-PRO™ Business Process Reliability Optimization

B-PRO is a proven methodology that many major companies have utilized to increase asset reliability and optimize costs. The seven-step process introduces improvements into your operation that foster creativity and acceptance. Significant results have been noted including 30% more work accomplished, 50% less overtime, equipment failures reduced 25 to 50%, and outages and turnarounds completed on time.

To implement the B-PRO Asset Reliability Model, a small team of plant leaders from maintenance, production, engineering and materials are involved in redesigning the asset care function. PCA's experience provides the team with the leadership and expertise to achieve results with accuracy and efficiency. We work with your plant personnel so that adaptability to changing market conditions and discipline to sustain “best practices” will continue regardless of key personnel turnover. Our goal is to keep the process moving and to get the job done.

Why is it that some plants can easily change to meet the changing demands of the marketplace? And why is it that some plants have the discipline to sustain their best practices over time regardless of key personnel turnover? PCA's Asset Reliability Model is a proven methodology that can be used to achieve results in your plant. This model methodology is the cornerstone of PCA's B-PRO product line of services.

The Asset Reliability Model methodology is a seven step process that introduces improvements into your operation in a manner that encourages creativity and acceptance, while ensuring discipline over the long term. The methodology is clearly aimed at increasing asset reliability and optimizing costs:

• The Leadership Workshop provides a guided process for the leadership team to define the expectations and guidelines for the plant's asset care and reliability functions. This challenging workshop is the first step for ensuring that everyone gets on the same track.
• The Design Team is a representative group from production, maintenance, engineering and materials whose job it is to creatively blend proven industry best practices together with the leader's expectations and plant culture. This team redesigns the detailed processes as needed to achieve the expectations of the leadership team.
• The Model Document is the vehicle for describing the work of the Design Team. This document essentially becomes the standard operating procedures, processes and roles and responsibilities for achieving asset reliability improvements.
• The Implementation Plan provides the approach for integrating the changes into daily operations. The implementation approach may be in a pilot area or may be plant-wide.
• The Training and On-the-Job Coaching are key factors in the acceptance of change. PCA's strategy for training and coaching has been demonstrated to be a critical factor in the implementation of change.
• Key Performance Indicators are another element in the successful implementation strategy. These measurements not only provide a bottom line measure of the results of the maintenance and reliability efforts; additionally, these indicators provide objective evidence of how well procedures and processes are being followed, as defined in the plant's Asset Reliability Model.
• Managing the Model is a process for ensuring that the standard operation procedures, processes and roles and responsibilities as defined in the Model stay intact over the long term. This process provides for the Model to be modified as needed and it ensures that personnel turnover does not adversely affect the discipline and results of the asset reliability processes.

Elements of the Asset Reliability Model

A small team of plant leaders from maintenance, production, engineering and materials participates in the exercise of redesigning the asset care function. PCA's experience provides your team with the leadership necessary to complete this redesign process with precision and efficiency. This effort addresses all the fundamental elements of asset care including work identification and control, job planning, scheduling, parts management, equipment reliability and outage coordination.

The Asset Reliability Model also describes each of these elements of maintenance in terms of:

• The process flow
• Detailed operating procedures
• Effective use of the computer systems to support the operating procedures
• Roles and responsibilities in the redesigned process
• Key performance indicators
• Implementation strategy

To learn more about how PCA's Planning for Performance can improve your company's bottom line, then please complete the request more information form and one of our consultants will contact you shortly.

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