Company Brief, Reliability Management Consultant

Company Brief

Reliability Management Consultant is a pioneer in the field of Equipment Reliability, Plant Availability and Operating Performance. We go to the heart of the reliability issue that is: enhance the life of the equipment and maximize the operating time of the equipment free of any fault, failures and breakdowns. Established ten years back, our aim is to help industrial clients (process and engineering industries) create & sustain dramatic transformation in equipment reliability (enhanced life without failures), plant availability (with the minimum assurance of 98% or over) and operating performance (productivity, quality, energy, costs, safety and profitability).

Our Promoter

Mr. Dibyendu De, Managing Director

My basic areas of interest and research for the last 28 years after obtaining a first class Graduate Degree in Mechanical Engineering followed by a first class Post Graduate Degree in Machine Design and Analysis from premier institutes in India was to have a very deep and wide understanding into the nature and dynamics of any ‘failure’ or ‘industrial problem’ and find innovative cost effective means to eliminate them forever.

It was therefore, quite natural that my search led me to deal with failures and industrial problems of all sorts, sizes and shapes in mechanical, electrical, instrumentation, quality, safety, productivity, processes, factory designs and profitability for various types and sizes of manufacturing industries (both process and engineering) operating under various conditions.

However, the ultimate clarity of the dynamics and the nature of failures happened when I studied under my Guru Prof. Tim Henry of Manchester University, U.K. After years of patient study of thousands of different failures and guidance from my Guru I came up with the final and clear understanding that system imperfections, arising out of the interplay of physical laws and principles, are the fundamental causes of all failures that take place in a seemingly random manner. It naturally follows, that any innovative solution that would correct these imperfections would prevent all industrial problems and failures permanently. This answers the dream of eliminating failures and enhancing productivity, performance and profitability of manufacturing industries that engineers from the beginning of industrial revolution have been ardently pursuing.

This radical breakthrough thinking, which is holistic in nature and aims at innovative solutions, is a sharp departure from the traditional mode of thinking that tends to treat in isolation the symptoms rather than the fundamental ‘imperfections’ that cause repeat productivity problems, repeat failure and repeat maintenance. Manufacturing industries that adopted this breakthrough thinking called ‘Rapid Innovation’ gained benefits for years with their one time effort to identify ‘imperfections’ and find a permanent cure to eliminate them forever and create more fool-proof systems.

Aim

Create dramatic transformation in 3Ps (Productivity, Performance and Profitability) of our clients for life through wide and deep Knowledge, Innovation and Design.

Industries Catered

We have helped in the successful transformation of various industrial plants within specified time frame, budgets and manpower resources.

Industries that have benefited from our services are as follows:

•Chemical
•Cement
•Steel
•Power
•Aluminum
•Oil and Gas
•Paper
•Rubber
•Plastic
•Aerospace
•Engineering
.FMCG
.Electronics

Our Services

•Enhancing Plant Availability to a minimum level of 98%•Enhancing Plant wide reliability of equipment •Innovative solutions to eliminate problems and failures for life. •Life enhancement of equipment•Re-designing existing machines for higher productivity and profitability
•Education and Certification •Training – in company and public for developing Knowledge, Skills and Attitudes
•Continued interactive and internet based education to enhance talent and knowledge of people. •Design and implementation of Condition Based Maintenance in the plant
•Reliability assessment of equipment and plant•Optimizing spares and consumables
•Creating an optimized maintenance plan.
•Design Reviews for creating the right specifications of new equipment at procurement stage so that they are reliable right from the start •Designing Plant layouts for enhanced productivity and cost reduction •Residual Life Assessment .Product Reliability Testing .Factory Design and Architecture

Our Methodology

We believe that problems create opportunities for more learning and improvements. For solving specific technical problems, we follow time tested techniques and methods that are not only unique but also result-oriented. Effective techniques and methods save time and lead to better productivity. Some of the methods that we adhere to are summarized below :• We always take a holistic view of the problems and apply the principle of moving up at least one level higher than the present level – the concept of ‘whole' to the ‘part'.• We adopt effective solutions for addressing multiple disconnected issues. This helps in solving not only the main problem but also other related problems. • The principle of discovering & eliminating inherent imperfections helps us to give long lasting and high impact benefits to the clients.

Expertise

Our team has unparalleled strength to generate innovative solutions for nagging issues of our clients. Our team is made up of unique experts who are Engineering consultants, Behavioral consultants, Trainers, Designers, Creative personnel and Administrative personnel who significantly contribute to the smooth running of the business.

We continue to work on the frontiers of knowledge and continually extend our knowledge and expertise through applied research and continual training.

Features that sets Us Apart

The qualities that set us apart are:

•Once we have selected a project and engaged ourselves we always deliver 100% results within the specified time period, budgets and resources

•Our multiple solutions that are mutually exclusive are designed for life – hence gives the clients benefit for years to come.

•We explain our actions, solutions, reports and recommendations in clear, concise and fundamental manner.

Benefits to our clients

British Aerospace

Use of improved design review process for equipment selection ensured a reliability of 95% right from the start and Overall Equipment Effectiveness (OEE) of more than 85%. Thus doubling their productivity. This helped them save 1 million GBP a year.
Investment: 15,000 GBP over a period of 3 months.

ROI > 6000%

Larsen & Toubro Ltd

Following RCM+ + and ROMS reliability improved by 20%, downtime reduced by 50%, specific energy consumption reduced by 25%, wastages became 45% less, production volume raised by 11% and workload was reduced by 60% giving a substantial cost benefit.

ROI: 5000%

Vikram Cement

Wear Debris Analysis and bringing about Tribological improvements that enabled savings of lubricant cost by 2/3 the previous cost.

ROI > 6000%

CFCL

Implementation of Integrated CBM & ROMS helped to operate the process at 129% of its design capacity & reduce breakdown or failures by almost 100%. Accuracy of analysis was over 90% and the plant could be operated by 5% less manpower. It also reduced total maintenance costs by 50% over a two-year period.

ROI > 2500%

Les Moulins de la Concorde, Mauritius

Implementation of Vibration Monitoring System done over a six month period helped the company to reduce their breakdowns by around 80% with an accuracy of the expert system, devised for them, running at over 98%.

ROI: 8000%

Greaves Ltd (Gearbox Manufacturer)

By using our ROMS system the client was able to save 15% of the cost of manufacturing gearboxes, save on supply costs and manufacturing time, save on warranty costs, offer better reliability of their products and gain market leadership position, thru cost leadership.

ROI > 7900%