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Frequently Asked Questions
Performance Consulting Associates Inc.
3700 Crestwood Parkway
Suite 100
Duluth, GA 30096
770-717-2737
info@pcaconsulting.com
What is PCA's definition of asset reliability?
The predictable ability to consistently achieve the maximum rate of quality, product or service, at optimal cost.
What is required?
True Asset Reliability requires that all business functions be viewed as having an impact on capacity and quality of product or service. This impact may be immediate or delayed. Every aspect of the business must be aligned for the common goal of producing product, at desired and sustained levels of safety, compliance, output, quality and cost.
Is Reliability Centered Maintenance (RCM), a comprehensive asset reliability process?
We believe that RCM provides advanced tools for asset reliability - tools that must be applied correctly and used in combination with other opinion to achieve results. RCM will provide results, but if used alone can give the impression of "just another maintenance program." Asset reliability must be applied as a total comprehensive process across the entire organization to be truly effective.
What is PCA's approach towards the RCM training and tools necessary for asset reliability?
Using a participative and team-based approach, we train your operations and maintenance personnel in the concepts of RCM-style equipment failure analysis and prevention. This training is followed by hands-on, in-the-field applications and implementation. Specific triggers, both before and after equipment failures, are used to initiate reliability team activities. These teams will then employ failure modes and effects analysis, root cause failure analysis, statistical process control, and process improvement techniques. Most importantly, our model ensures that your routine business practices of work identification, planning, scheduling, and outage coordination are fully integrated with the opportunities that are identified by PCA's reliability focused maintenance process.
What is the difference between A-PROTM and B-PROTM services?
A-PROTM (Asset Performance Reliability & Optimization) uses three separate focuses to improve asset reliability:
- PCA's Reliability Focused Maintenance (RFM), utilizes a combination of RCM and various analysis tools to identify and attack the leading contributors of unreliability at your facility. Throughout the entire process, PCA's RFM experts coach, counsel, and assist in the development of a business case for the elimination of performance problems. Your reliability team is guided and instructed, both in classroom and in-the-field settings.
- The actual schedule will be based upon the progress of the assigned reliability team. Typically, the time required is distributed over an extended number of months. Follow-up is performed when not on site, via telephone, fax, and e-mail. Additionally, PCA provides supporting documentation and software to trigger, manage, and measure the process. Much of this documentation and software can be blended with the development of any work flow redesign documentation.
- PCA uses a highly-participative team approach to develop structured and standardized “practices, processes and procedures” documented in the form of an Asset Reliability Model™ that serves as the reference successfully implementing needed change across one or multiple sites. We utilize current client “best practices and Procedures” along with those adopted in the current PCA Asset Reliability Model™ to develop the format for sustainable change.
- B-PROTM focuses on work management systems, and their interaction with each other and with A-PROTM. PCA has experience with virtually every CMMS/EAM and database management system currently in use. Our diverse and comprehensive experience in various industries will provide many (often unique), solutions for your problems.
Why does A-PRO have three different levels of implementation?
Each of the modules in the A-PRO model has three distinct levels of application. Each module begins with a gap analysis and leadership workshop. This allows PCA to provide clients with a comprehensive process that will be tailored to their specific needs and culture. We believe that there is no "one way" to achieve asset reliability. We can provide you with very specific solutions based on our many years of experience and practical application in asset reliability and optimization.
We feel it is equally important to provide your site leadership with enough understanding of the process to enlist their active participation. A leader's checklist is provided as a tool to gauge process effectiveness. We recommend that all staff functions receive this level of training.
Level two is conceptual but includes actual field exercises. These exercises quickly transition to real pilot projects that provide measurable improvements during level three implementation.
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