Example 3 -- From a Cement Plant - Change Management
Number of Plants under Reliability Improvement = 3
% Of equipment covered under Reliability Improvement Plan = 62 (most critical + critical)

Other benefits for the same plant:

• Seal failure analysis = presently no seal failure takes place
• Bearing failure analysis = presently no unwanted/premature bearing failure takes place
• Bearing selection = redesign for bearing that were giving inadequate life
• Gear failure analysis = presently no undesirable gear failure takes place
• Lubrication/WDA/Tribology = Lubricant cost brought down by 67%
• Heat exchanger study = No heat build up for any of the critical machines
• Vibration analysis = Accuracy of analysis increased to 98%
• Spare parts management = Reduction in the cost of spares thru lesser use
• Identification of training needs and SOP (Standard Operating Procedure)= Implemented for better operability and maintenance

The yield of a continuous casting plant (Stand Pig Casting Machine) could not be improved beyond 92 to 93% by any of the available improvement theories and techniques, like TPM (thru JIPM), Theory Of Constraints, TOP (McKinsey model), TBEM, TQM and Six Sigma etc with 4 years of continuous effort. However with the application of Design Out For Reliability (DOFR), the yield increased to 98% plus in barely three months with minimum effort, giving the company additional profit increase by 8% on a continuous basis (the reported profit margin of the company is around Rs. 35 crores).

Quality Improvement through DOFR

The yield of a continuous casting plant (Stand Pig Casting Machine) could not be improved beyond 92 to 93% by any of the available improvement theories and techniques, like TPM (thru JIPM), Theory Of Constraints, TOP (McKinsey model), TBEM, TQM and Six Sigma etc with 4 years of continuous effort. However with the application of Design Out For Reliability (DOFR), the yield increased to 98% plus in barely three months with minimum effort, giving the company additional profit increase by 8% on a continuous basis (the reported profit margin of the company is around Rs. 35 crores).

With sound understanding of the varied problems existing withing the working structure of the organization we are able to render excellent services pertaining to apt strategy and motivational leadership. The service has proved to be highly fruitful for many industrial companies.