The intent of performing a thorough and professional on-site assessment is to recognize and reinforce the good practices in place and identify opportunities to improve your operation by making specific and meaningful improvements.  Most sites are interested in improving however, do not possess a prioritized and systematic roadmap from which to achieve success.

Compli’s assessment model encompasses three key areas:

• Assessment
• GAP Analysis
• Improvement Plan

Compli’s assessment process will aid in your site realizing the following benefits:

• Reduced Maintenance Costs
• Decreased Unscheduled Plant Downtime
• Extended Equipment Life
• Less Maintenance Overtime
• Reduced MRO Inventory $$$
• Fewer MRO Rush Shipments
• Greater Maintenance Technician Efficiency
• Improved Safety & Morale

The two most common asset care strategies are performing Preventive Maintenance (PM) and Predictive Maintenance (PdM) on critical plant equipment.  These approaches to maintaining site assets have been in existence for quite some time, however, when an equipment failure occurs, typically an additional PM strategy is generated and rolled out, never to be reviewed again resulting in the accumulation of a mountain of PMs to perform.  The Maintenance Team struggles to perform PM in the allotted time, which provides very little value in terms of mitigating equipment failures.

Preventive Maintenance (PM) and Predictive Maintenance (PdM) reviews are a continuous improvement, recurring event, typically performed by a cross-functional team, to review asset care strategies for critical equipment.

As issues with plant assets change over time, it is important to periodically review the Maintenance care activities being performed on the equipment base. Understanding how the assets fail and reviewing whether the Maintenance being performed is mitigating failures from occurring is at the core of this review. Other items the team will examine include whether a predictive task can be performed vs. a traditional preventive activity, whether the PMs are thorough and well-written and if the current craft, duration, special tools, and spare parts have been accurately assigned. Reviewing PMs, Job Plans and corrective work assignments is a key element located on the fourth level of the Asset Management Pyramid, essential in every site’s quest for operational excellence!

Although managing MRO spare parts is essential in achieving an effective, reliable and profitable operation, many organizations recognize that managing MRO is challenging.  The required time, resources or expertise are seldom invested in this critical area.  The following well-documented statistics confirm:

• 25% of a Maintenance Technician’s time is spent searching for parts
• 55% of Inventories have not moved in over three years
• 30% of stocked parts will NEVER be used
• 6% of MRO SKUs represent 90% of the annual spend
• Inventories are growing by 9% each year

Compli has adopted a comprehensive six-step model, resulting in a thorough yet practical approach to resolving your MRO challenges.  Our field-tested process has proven to provide innovative and sustainable value to our clients and includes:

• MRO Program Assessment
• MRO Data
• MRO Processes
• MRO Best Practices
• MRO Staff Roles, Responsibilities and Job Descriptions
• MRO Key Performance Indicators and Reports

Many companies are quick to claim their employees are their most important assets, however, statistics reveal that most organizations spend less than $1,500/year in training efforts.  Some entities defend this position by thinking if they train their employees, they will lose them.  The late Zig Ziglar reminds us, “the only thing worse than training employees and losing them is to not train them and keep them.”

Compli has adopted a comprehensive ten-step learning development model.  This practical yet innovative approach ensures your Maintenance staff receive training in the areas required to properly diagnose, repair, and maintain critical equipment at your facility.  This unique process includes the following areas:

• Training Needs Assessment (TNA)
• Job Task Analyses (JTA)
• Employee Skills Assessment
• Scoring/GAP Analyses & Mapping
• LMS and Scheduling Tool Training
• Training Library Development
• Vendor Qualification Training
• Coordination & Facilitation Training
• Metrics Training
• Skills Reassessment

Compli’s effective Maintenance Training Program will aid in your site realizing the following benefits:

• Reduced Maintenance Costs
• Decreased Unscheduled Downtime
• Extended Equipment Life
• Reduced MRO Inventory Usage and Spend
• Enhanced Worker Confidence, Safety & Morale
• Improved Technician Efficiency & Performance
• Greater Attraction of Motivated Recruits
• Increased Employee Retention
• Overall Increased Organizational Profitability

The value of developing, adopting, and utilizing a Maintenance and Reliability Scorecard is significant.  By collaboratively determining those elements to measure the performance of Maintenance, identify shortfalls and perform associated mitigating actions can be extraordinary! 

By incorporating the use of Maintenance Scorecards, organizations often realize the following benefits: 

• Enhanced Operational Communications 
• Increased Maintenance Technician Efficiency 
• Reduced Maintenance Costs 
• Decreased Unscheduled Plant Downtime 
• Increased Production Throughput  
• Enhanced Continuous Improvement 
• More Informed Decisions 
• Improved Safety & Morale 

Our Asset Management consultants have developed a comprehensive 12-Step approach which has proven effective in executing multiple successful Maintenance Scorecard projects: 

• Facilitate a Strategy Session to select Key Performance Indicators (KPIs)
• Select indicators to utilize in the Scorecard
• Assign Champions for measuring and reporting selected metrics
• Develop KPI Target Goals
• Create formulas for each metric for accuracy
• Develop format to communicate Scorecard results

• Develop Scorecard schedule for consistent frequency
• Create Scorecard Distribution List of essential personnel
• Perform comparative data analysis and communicate insights
• Develop and communicate pertinent mitigating actions
• Execute recommended corrective actions
• Identify new KPIs

The intent of developing, adopting, and training on best-in-class Work Management Processes and SOP narratives is game-changing to an organization. By investing the time to thoughtfully discuss and agree on how you want to manage Maintenance work at your facility, document those steps and implement them with pertinent team members elevates the integrity, morale, and ability to perform consistently at a high-level.

By utilizing standardized Maintenance Work Management Processes, organizations often realize the following benefits:

• Enhanced Operational Communications
• Improved Safety & Morale
• Increased Maintenance Technician Efficiency
• Reduced Maintenance Costs
• Decreased Unscheduled Plant Downtime
• Increased Production
• Enhanced Continuous Improvement

Having served in a variety of key M&R-related site roles, our Asset Management consultants understand the value of forming cross-functional teams to discuss and agree on best-in-class processes to adopt at your site. Additionally, the written SOPs serve as excellent audit and training tools to aid the sustained reliability of the operation. Compli has adopted the following comprehensive 6-Step approach which has proven effective in executing multiple successful Maintenance Process Workflow projects:

• Strategy Session – Management Process Awareness
• Identify Work Processes to Develop Cross-Functional Team
• Workflow Development Sessions
• Assign, Schedule and Complete SOPs
• Review, Approve & Add to Site Playbook
• Adopt, Train and Audit

Compli’s Asset Management & Reliability consultants have been performing Asset Criticality Ranking (ACR) for over 20 years!  ACR is a team-based exercise that provides a customizable process to consistently measure and easily document the criticality of every maintainable piece of equipment within the production and utilities areas in your facility.

Every asset within your site does not possess the same value or has the exact same consequence of failure.  While it is common for Operations leaders to believe the assets located in their department are the most important ones at the site, the fact is that not all assets are created equal.  As most organizations have a limited number of resources dedicated to maintaining their assets, there is a need for identifying the most important ones to ensure they are being cared for at a higher level.

There are several different reasons why companies conduct an Asset Criticality Ranking and Compli’s ACR process can aid in your site in realizing many the following benefits:

• Objectively determine the sites most important assets
• Gain knowledge of which assets are most critical
• Ensure future improvement initiatives are focused on prioritized equipment
• CMMS or EAM system clean-up to reveal existing asset performance
• Master Equipment List and associated Work Order review to identify deficiencies

We recognize your operation is unique.  You have special assets to maintain, different Maintenance and Operations personnel overseeing them, and distinct client demands in delivering your products to the marketplace.  These uncommon circumstances require a customizable solution and that is exactly what Compli provides!