Total Process Reliability: Going Beyond TPM

What is Total Process Reliability—“TPR” ?

Total Process Reliability (TPR) is an organizational approach to improving operational reliability of major assets; in-turn improving overall equipment effectiveness (OEE), increasing production capacity, reducing costs and growing the effectiveness of the relationship between maintenance and operations. TPR combines the proven tools and techniques of Total Productive Maintenance (TPM) with an effective organizational change model to establish a vigorous and structured improvement process leading to operational excellence. 

True TPR is philosophy adopted and practiced across the organization; it is NOT just a maintenance initiative.

TPR goes beyond our historically proven and effective Total Productive Maintenance (TPM) process.  Let's quickly review Total Productive Maintenance. TPM is a process designed to improve machine efficiency and reliability by involving all affected employees in the care, purchase and improvement of our equipment.  TPM is implemented by concentrating on the reliability, effectiveness, and efficiency of equipment through five key elements: 

  1. Maintenance Excellence
  2. Basic Equipment Care
  3. Equipment Improvement
  4. Knowledge and Skills
  5. Equipment Design Excellence

TPR is the next step in the journey to achieving “World Class” status beyond TPM and uses key tools to support effective Root Cause Analysis (RCA), Preventive Maintenance Optimization (PMO).

Key to successful adoption of TPR is leadership support and sponsorship. Leaders must show visible support for TPR and endorse the philosophy; not just pay lip-service. Although short-term wins are necessary to maintain passion for TPR, a long-term implementation approach must be taken in order to change the culture within an organization.  

This approach is proven; it has shown high impact, and produced highly visible quick wins while sustaining major business process improvements. In summary, Total Process Reliability combines the proven tools and techniques of TPM, the recognized best practices embodied in World Class Maintenance, and an effective organizational change model to establish a vigorous and structured improvement process leading to Operational Excellence.

Many benefits can be realized in a reasonably short period of time; however, some benefits may be realized in the long-term.  In either case the numbers usually prove significant. For example, below are a few client results gained through the implementation of the Total Process Reliability methodology.

Hydrocarbon Business

  • 40% Reduction in maintenance costs (1999-2002) 
  • 25% Increase in injection reliability 
  • 7% Increase in well on time reliability 
  • One formal RCA event netted a USD 1.5M savings 
  • Maintenance budget reduction of USD 3M in one year 
  • Increased Mean Time Between Failure (MTBF) on a compressor unit from 56 days to 210 days and still counting 
  • One formal RCA event netted a USD 118K savings
  • One Equipment Improvement Team project will generate an annual deferment reduction of 296,000 boe
  • (USD) 848K savings from Breakthrough Team activity

Discrete & Process Industry

  • Return on investment (ROI) is 10:1 over implementation costs
  • More than a 400% improvement in Mean Time Between Failure (MTBF)
  • Maintenance budget reduction of USD 1M in the first 1.5 years
  • 6% productivity improvement in one facility
  • More than USD 740K reduction in operating cost (3 facilities)
  • 22% reduction in maintenance budget
  • 17% reduction in manufacturing costs
  • 20% reduction in storeroom inventory
  • Moved from 90% reactive to 15% reactive
  • MTBF increased by 91%
  • Cost per hour to operate equipment has decreased by 65%
  • USD 1.5M reduction in maintenance labor cost
  • USD 750K reduction in material costs
  • 25% improvement in planned work
  • Reduced maintenance costs by over 60% in three years
  • 27% Improvement in productivity
  • $1.5 M reduction in maintenance costs in one year.

I certainly hope this post has helped your understanding of Total Process Reliability. If you have particular questions you would like to ask, please leave them in the comments box below. We will cover other key Total Process Reliability discussion areas in future posts.


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