Learn & Do

Reliable experts, actionable advice

Knowing is only half the battle.

It takes more than just knowledge of key concepts and best practices to create or improve a reliability program. How many times have you attended a conference session and thought, “This is good information, but how can I actually apply it at my plant?” This year, Reliable Plant 2022 is designed to help you do just that.

Reliable Plant turns ideas into action.

Every Workshop, Keynote, and Action Session is designed to provide you with practical plans and actionable advice you can apply immediately back at the plant. Other session formats will also be available, such as live podcast episodes, debates, group exercises, games, tech demos and more.

Sessions

Bring your biggest challenges, goals, and burning questions. The industry’s top experts will be on site to help you solve problems and uncover opportunities in Panels, Case Studies, Discussion Groups, and more at Reliable Plant 2022.

Keynotes

Listen to industry experts share their decades of knowledge.

Panel: Building and Sustaining a Strong Reliability Culture Megan Johnson: Plant Manager, Blue Buffalo | Garrett Bapp: Sr. Technical Services Advisor, Petro-Canada | Nathan Wright: President of Transformational Performance Solutions LLC | Ryan Chan: CEO, UpKeep

This panel will bring together a cross-section of thought leaders in and around the reliability industry to hear their perspectives on what makes a strong and sustainable reliability culture. Panelists will cover questions like:

  • How do you sustain a culture when turnover is high?
  • How does culture impact day-to-day operations and overall reliability?
  • Does culture play a role in getting support or buy-in for reliability initiatives?
  • How does culture impact collaboration between maintenance & operations?
  • What are some examples of successes or failures of initiatives implemented?
  • What advice would you give to a plant who wants to build a positive workplace culture?

How to Get Your Plant Manager’s Attention Joe Kuhn, Independent Consultant

Joe Kuhn

Have you started a reliability journey with great enthusiasm and alignment only to have it paused, stopped, or just quietly die from lack of sponsorship by your plant manager? As a former plant manager himself and a successful reliability consultant, Joe Kuhn understands how plant managers think and what it takes to get their attention.

Usually, the problem is not the plant manager. Often the reliability or maintenance manager just needs better ways to communicate with top leadership in terms that they understand, that relate to their role in the organization, and that are supported by a clear business case. Often, maintenance or reliability leaders struggle with all three of these aspects. In this keynote, Joe will give you practical, actionable advice to start getting your plant manager’s attention and cultivating their support for your initiatives.

Asset Operations Management: The Future of Maintenance, Reliability, and Operations Ryan Chan: CEO, UpKeep

Ryan Chan

In today’s world, the majority of asset-intensive organizations are still stuck with complex, rigid, and sometimes antiquated technology solutions that simply cannot step up to evolving challenges and an ever-changing market.

Industries like manufacturing, agriculture, healthcare, and higher education are anchored by the performance of their facilities and assets, and companies operating in these spaces build teams around optimizing performance and preventing downtime. However, these teams—maintenance, reliability, and operations—while essential to production, have been labeled “cost centers” and overlooked as key candidates for digital transformation.

This keynote introduces asset operations management (AOM), an operating principle founded on the belief that asset-intensive organizations have much to gain by adopting new approaches to data, collaboration, and communication.

This session will also help attendees to:

  • Learn how maintenance, reliability, and operations teams can earn a seat at the revenue table
  • Learn how to digitally transform your team through solutions that build trust, reduce change management, and connect work to company KPIs
  • Learn the two things you can do to get AOM started today

Workshops &
Focused Tracks

Monday, July 25, 2022

Reliable Plant brings expert speakers from across the entire spectrum of reliability and maintenance industry topics. This year, we are offering five focused tracks of core material along with additional sessions covering other important industry topics.

Each focused track is overseen by a Reliable Plant advisor, who leads the opening workshop on Monday and curates the track of associated sessions and case studies.

Physical Asset Management
Advisor: John Ross, Maintenance Innovators

Key Concepts:

  • Risk management
  • Criticality analysis
  • ROI
  • Metrics
  • Lifecycle costs
  • Utility or energy management
  • Purchasing
John Ross

Monday Workshop

Putting Criticality and Analysis back into Criticality Analysis

How did your equipment become ‘critical’ and how was that calculated? Did you do it, and what was the process? Could it be that we’ve just come to label equipment as critical because it has been a nightmare in the past? What does critical even mean?

In this workshop, we will cover these questions and more to re-think how we define our most critical equipment and what that means for our asset management and reliability programs.

Workforce Development
Advisor: Alejandro Trujillo, Pabelon

Key Concepts:

  • Culture
  • Training
  • Human analysis
  • Behavior
  • Responsibility
  • Ownership
  • Certification
  • Employee involvement
  • Retention
Alejandro Trujillo

Monday Workshop

How to Create a Training Plan for Technicians

This workshop focuses on developing a training plan/guide for maintenance and reliability professionals. Using a simple methodology that gathers competences and skills from many different areas such as international standards or certification bodies of knowledge, we will craft a plan that can be used by a technician or their manager to plan out their training path and career goals that benefit both the technician and their company.

Join us for a practical guide to developing training plans that increase employee value, drive better retention, and set your reliability or maintenance team up for success.

Change & Sustainability
Advisor: Joe Kuhn, Independent Consultant

Key Concepts:

  • Failure analysis tools
  • Big data
  • Data distributions
  • Asset data (collecting, storing, using)
  • Weibull, pareto, availability analysis
  • Critical thinking
Joe Kuhn

Monday Workshop

Creating Your Action Plan: Live Coaching for R&M Managers

Discussing R&M best practices is fairly easy to do, but crafting a reliability or maintenance action plan that will work in your culture can be difficult. Let’s be honest – 99% of new reliability or maintenance efforts fail.

In this workshop, Joe will bring 4 R&M managers up with him and give a coaching session live. Each participant will go through the steps to create an executable plan they can begin following on Monday. You will see A3 thinking, know how to really understand current state to develop quick, sustainable, scalable and impactful actions and how to sustain sponsorship in good and bad business cycles.

Leadership & Communication
Advisor: Tor Idhammar, IDCON

Key Concepts:

  • Goal setting
  • Targets
  • KPIs
  • Budgeting
  • Mission
  • Vision
  • Responsibility
  • Motivating/influencing people
Idhammar

Monday Workshop

Effective Maintenance & Reliability Leadership

The question of how to improve as a leader of reliability or maintenance teams comes up often at conferences and with clients. Many hope there is a simple list of to-do items that can be done in the same order at any plant in the world. Unfortunately, it is not quite that simple.

In this workshop, we’ll divide the different factors into two aspects: “technical” and “cultural.” While we will discuss technical work processes along with areas like lubrication, alignment, planning, scheduling, or condition monitoring, we will focus on the cultural aspect.

Culture improvements are the most neglected and most often misunderstood, but they are often more important. Join me in this workshop to discuss where to start with technical improvements and how to lead improvements to maintenance or reliability culture.

Condition-Monitoring Strategies

Key Concepts:

  • Preventative approaches
  • Predictive approaches
  • Proactive approaches
  • Condition monitoring tech
  • CBM
  • Oil analysis
  • Ultrasound
  • Vibration
  • Thermography
  • Motion amplification
  • Inspections

Monday Workshop

Optimizing Your Condition Monitoring Efforts: Panel & Workshop

You take your car in for its regularly scheduled maintenance and discover a wiring problem. Two weeks later, it breaks down due to a completely different issue. Just like cars, machines failures can be difficult to predict and factors can combine in many different ways.

Reliability-centered maintenance and predictive maintenance are based on the principle that failure isn’t always linear and requires analysis of several asset aspects to detect possible failure indications. This is why condition monitoring (CM) is so useful: it lets you monitor multiple facets at once using techniques like ultrasound, vibration, oil analysis, thermography and others.

In this workshop, we will bring together a panel of condition-monitoring specialists who will discuss the different strengths and weaknesses of different CM approaches and technologies. Then, we will break out into discussion tables to work on building a plan to optimize and prioritize CM activities back at the plant.

Precision Maintenance
Advisors: Phil Hendrix & Mike Turrentine, Hendrix Precision Maintenance Services

Precision Maintenance – Exponentially Extending Life of Rotating Equipment

Category: Asset Reliability

Additional Tracks

These additional tracks offer learning opportunities in other areas of reliability, but do not include a Monday workshop like the focused tracks.

Work Management Advisor: Bennett Fitch, LubePM

Key Concepts:

  • Workflow management
  • Planning/scheduling
  • Work execution
  • Procedures
  • Prioritization
  • CMMS systems
  • Work order best practices
Bennett Fitch

Asset Reliability Advisor: Ryan Chan, UpKeep

Key Concepts:

  • Lifecycle reliability analysis
  • Reliability prediction methods
  • Program management
  • Reliability goals

Root Cause Analysis

Key Concepts:

  • Conducting RCA
  • Data collection
  • Problem assessment
  • Pareto charts
  • Fishbone diagrams
  • Failure Mode and Effects Analysis (FMEA)
  • Other types of analysis

Environment, Health, and Safety (EHS)

Key Concepts:

  • Circular economy
  • Oil recycling/reclamation/regeneration
  • Materials disposal
  • Standards/regulations
  • Environmental impact
  • Energy conservation
  • Safety in reliability

Maintenance Optimization

Key Concepts:

  • PM optimization
  • Preventive maintenance
  • Proactive maintenance
  • Storeroom management
  • STO (Shutdown, Turnaround and Outage)

Emerging Trends, Practices, & Tech Advisor: Robert Skeirik, I-care Reliability Workshop: Avoiding Artificial Ignorance – The Pitfalls of Machine Learning for Machine Diagnostics

Key Concepts:

  • AI-enabled solutions
  • IIoT
  • Industry 4.0
  • Trending technologies or approaches
  • New types of sensors
  • Prototypes
  • Proofs of concept
Robert Skeirik

If not carried out properly, IIoT implemented for rotating equipment monitoring creates more problems than it solves.

Poor implementation of technology and basing automated analysis on incomplete or even inaccurate data will lead to frustration, disillusionment, and ultimate failure of the program. It can also mean significant losses in terms of production, profitability, and even personal reputation.

This workshop will present an understanding of what is required for AI and Machine Learning to be successful – both in a pilot program and a broader widescale implementation. This presentation will include:

  • The central importance of automated diagnosis
  • Required inputs for accurate analysis
  • Functional requirements for proper measurements
  • Application and limitations for traditional vibration analysis
  • New technologies required to identify and categorize the most serious mechanical issues
  • Case histories: Traditional Vibration vs. Event Monitoring
  • Classifying the nature and severity of events

Data Analytics & Machine Health

Key Concepts:

  • Failure analysis tools
  • Big data
  • Data distributions
  • Asset data (collecting, storing, using)
  • Weibull, pareto, availability analysis
  • Critical thinking

Special Workshops

Lubrication for Reliability Leaders: Building the Business Case Wes Cash, Noria

Wes Cash

Lubricants themselves are often a relatively small line item on plant budgets, but their impact on machine asset lifecycle costs, overall reliability and maintenance costs is enormous. Leaders who learn to recognize lubrication opportunities in their plants can unlock significant savings by addressing the root causes of machine failure and implementing best practices to stop incipient failure in its tracks. A lean team equipped with the right knowledge and a few simple tools can transform a lubrication program from a liability to an asset. Companies in all industries are taking control of reliability by reinventing their lubrication programs — and they are seeing bottom-line results.

How to Double the Life of Your Rolling Element Bearings Mark Barnes, Des-Case

Mark Barnes

While the preferred method for simple plain bearings (bushing), in most circumstances, is pumping grease into the bearing until grease purges out, applying a similar approach to rolling element bearings – particularly in high-speed applications such as motors and fans – can result in a 70% to 90% reduction in bearing life. In fact, more high-speed bearings fail due to over lubrication than under lubrication. This is just one example of many factors that impact bearing life significantly, leading to many early bearing failures and the associated repair expenses, added work orders, and unplanned downtime they cause.

But it doesn’t have to be that way. By improving certain practices related to lubrication, contamination control, and other key areas you can mitigate all the problems that come with frequent bearing failures and spend more time on efficient, proactive maintenance and reliability activities. In this workshop, Mark will help you understand your current state and make a plan to start improving that fits your plant goals and resources.

Frequently asked questions

Are the workshops included with my registration??

Yes, Reliable Plant 2022 is offering five focused tracks of material, each beginning with a workshop on Monday. Access to the workshops is included with any full delegate registration, but we do encourage you to indicate which workshops you plan to attend during your registration process. Seating and registration for popular workshops may become unavailable as we approach conference week.

Are submissions still open for speaking and presenting?

While the window to submit your abstract for our 2022 show has closed, we do have a waiting list in case of cancellations and are always accepting submissions of quality material for next year’s conference.

How do I become an advisor?

Reliable Plant advisors are selected via invitation only. The best way to be considered for an advisor position is to apply as a session speaker to the show and bring your best material. We take attendee feedback and audience response seriously when selecting Reliable Plant advisors.

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