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Reliability and Maintenance: Performance Trends of Top Performers in the CPI

By Jeff Dudley, Solomon Associates |

Focusing on a ‘reliability culture,’ mechanical availability and optimum costs leads to top performance Three factors drive manufacturing performance in the chemical process industries (CPI). These factors establish an operational culture that creates maximum availability of assets (mechanical availability) at an optimum cost. Results from the International Study of Plant Reliability and Maintenance Effectiveness (RAM Study), conducted by the authors employer [1], show that top performers focus on all three of the following factors: A reliability culture Mechanical availability Optimum cost The RAM Study uses an overall metric that incorporates the impact of all three factors and is known as the RAM Effectiveness Index (RAM EI).* Organizations with top-quartile (Q1) RAM EIs (referred to here as top performers) have many common traits, no matter what product they are producing and regardless of the scale of their production operations or the age of their facilities. Industry trends show that top performers come from all sectors of the CPI: They include users of continuous and batch processes, manufacturers of commodity and specialty products, and organizations both large and small. The same is true for second-, third-, and…
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