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Reliability and Operational Excellence with What Tool? And When?


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This course will demonstrate how the best plants are able to compete globally through the application of a reliability strategy – one that combines the best elements of Lean Manufacturing, TPM, RCM, Six Sigma and other methodologies as well as excellence in operations and maintenance practices. Through extensive case study examples, instructors will show you the right strategy for maximum production capacity by making fundamental changes in the way processes and equipment are designed, operated and maintained. This course provides leading improvement methodologies used by companies around the world to improve their asset and business performance.


No courses scheduled at present. Please contact Customer Service at or 1-800-769-1199 for upcoming course dates, or request onsite training.





Who Should Attend:   

  • Leaders in manufacturing, including operations directors, site managers, change managers, operations and maintenance managers, first line supervisors, reliability leaders, and influential frontline operators and maintainers
  • Those who lead or influence the direction and success of manufacturing plants, including plant managers, production and maintenance managers, reliability engineers and support staff who have authority to drive the day-to-day processes for improving their plant’s performance.

Benefits of Attending:

  • Apply principles  to maximize process uptime, eliminate unplanned downtime, improve quality and minimize costs
  • Learn strengths and weaknesses of various approaches and their relationship with operations excellence
  • Learn how to develop a business case for operations excellence and win support from business leaders
  • Develop and implement an improvement strategy and prioritize the improvement efforts and how to align your leadership to a common strategy and engage your workforce in delivering your improvement plan
  • Understand the key differences between leadership and management and learn how to create a culture for operations excellence in your organization and how to sustain the efforts
  • Obtain key foundational elements for success – leadership, managing change and shifting the organization’s culture to supporting excellence, having proper measures to track success.
  • Learn how to select the right improvement areas and identify your biggest opportunities by applying Business Level Failure Modes and Effects Analysis (FMEA) to determine where your business has the largest and most quickly achievable opportunities, before you select the tools to use.
  • Understand the tools to help you align your organization for their use. Tools reviewed include: Lean Manufacturing, Six Sigma, Kaizen, Quick Changeover Methodology, Supply Chain Management, RCM, TPM, Predictive Maintenance, Root Cause Analysis, Performance Measurements Cascade, Maintenance Planning and Scheduling, and OEE as a measure of waste.

Duration: 3 days



Start/End Dates



Day 1: 8:00 a.m. to 4:30 p.m.

  • Part I: Reliability and Operational Excellence
  • Introductions & Introductory Comments
  • Manufacturing Business Excellence Overview – Low Cost Producer Profile
  • Asset Utilization/Overall Equipment Effectiveness, Loss Accounting
  • Safety and Reliability – Mutually Dependent – Consider the Data
  • Benchmark Data
  • Aligning the Marketing and Manufacturing Strategies
  • The Reliability Process: Design, Buy, Store, Install, Operate, Maintain, and Dispose
    • Designing for lowest life cycle cost vs. lowest installed cost
    • Buying for supplier reliability and total cost of ownership
    • Stores as a value adding asset and support function for reliability
    • Installing/starting up with precision; avoiding infant mortality failures
  • Workshop – Self-Audit of Management Support and Plant Culture
  • Operating with Care, Consistency, and Conformance
    • Causes of lost production – operations led reliability
    • Process conformance model
    • Shift handover practices
    • Operator care
  • Workshop – Self-Audit of Operating Practices
  • Maintaining with Care and Precision, and Imputing Reliability into the Plant: 
    • Preventive maintenance – time-based     
    • Predictive maintenance – condition-based 
    • Proactive maintenance – root cause-based
  • Workshop – Self-Audit of Maintenance Practices

Day 2: 8:00 a.m. to 4:30 p.m.

  • Review and Reflection on Previous Day’s Learning
  • Hierarchy of Improvement Tools
  • RCM and TPM – A Summary
  • Business Level FMEA – Process for Mapping Production Losses and Costs
  • Planning and Scheduling – Key Steps
  • Workshop – Self-Audit of Parts/Stores Management Practices (Optional)
  • Strategy for Implementation
  • Leadership and Organizational Issues
  • Aligning the Organization
  • Managing Cultural Change
  • Workshop – Top 3 (Each person will identify three actions they will personally take.)
  • Summary and Closing of Reliability and Operational Excellence
  • Part II: What Tool? When?
  • Introductions and Introductory Comments
  • Reliability and Operational Excellence – The Basics  Leadership, Teamwork, Change management
  • Workshop: Current Tools in Use, Benefits, Problems
  • The Hawthorne Effect; The Pygmalion Effect; The Beginning and End
  • Business Level FMEA – Selecting the Right Improvement Projects and Tools
  • Business Level FMEA – Case Studies
  • Lean Manufacturing
  • Kaizen, including the Quick Changeover Process
  • Total Productive Maintenance (TPM)
  • OEE as a Means of Measuring and Managing Waste
  • Workshop – Business Level FMEA

Day 3: 8:00 a.m. to 4:30 p.m.

  • Discussion, Questions and Comments
  • Six Sigma
  • Supply Chain Management – Two Approaches
  • Reliability Centered Maintenance (RCM)
  • Predictive Maintenance
  • Select one of the Tools Reviewed and Assess your Program
  • Workshop: Case Studies – What Would You Do? 
  • Root Cause Analysis
  • Performance Measurement Cascade
  • Workshop: Personal Reflection and Action Plan
  • Summary of Tools


Related Links



IMSIS is a new generation software tool for the collective, integrated safety and integrity management. 


ABS Consulting has assisted many clients with reliability and manufacturing improvement projects in a wide variety of industries, including consumer products, heavy manufacturing, chemical processing, and machining.

This course can be taught at your facility. Find out more.


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