When the equipment and systems you rely on don't operate at maximum efficiency-or even worse, fail-the time that you've lost can eliminate your competitive edge. Production capacity and product quality diminish, equipment and system life cycles decrease, and the environment, health, and safety of your employees could be compromised.

EMR's in-depth expertise in reliability centered maintenance (RCM) can help you improve your availability through increased equipment and system reliability while controlling maintenance costs. By combining the elements of reactive, preventive, predictive, and proactive maintenance, we can guide you in developing and implementing a maintenance management program that is life-cycle cost-effective and helps assure safety and product quality.

EMR's personnel have traveled the world over to perform maintenance assessments and to facilitate the long-term success of maintenance improvement programs in various industrial segments. Count on EMR to help you maximize productivity, compete strategically, control costs, and ensure safety. We have the right answers. Right now.

• Condition Assessment Surveys
• Maintenance Management Assessment
• Benchmarking
• Maintenance Templates
• Predictive Maintenance and Condition Monitoring
• Vibration Analysis
• Infrared Thermography
• Motor Current Analysis and Trending
• Equipment Failure Analysis
• Computerized Maintenance Management Systems
• Continuous Improvement Planning
• Training

• Development of Facilities and Utilities Maintenance Strategy for the U.S. Embassy in Kabul, Afghanistan
• Development of Reliability Centered Maintenance Programs for NASA
• Development of NASA Facilities RCM Guide
• Pilot Facilities Condition Assessment Study
• Liquid Natural Gas Plant Uptime Assessment
• International Pharmaceutical Plant Maintenance Management Evaluation
• Operations and Maintenance Training

Development of a Facilities and Utilities Maintenance Strategy for the U.S. Embassy in Kabul, Afghanistan

EMR is developing a maintenance strategy for the facilities and utilities systems being rebuilt at the U.S. Embassy in Kabul, Afghanistan. This high profile, $100 million design/build project involves construction of nine buildings housing consular offices, visa processing facilities, residences and dormitories, food service areas, and common spaces. The maintenance strategy will incorporate an analysis of systems and equipment being designed and a mix of maintenance procedures to optimize the equipment reliability. EMR will integrate RCM into the design of facilities and equipment as well as equipment commissioning and maintenance programs. Specific criteria are to be developed based upon the requirements of the DOS Reliability Centered Maintenance Manual for each building and system used.

Development of Reliability Centered Maintenance
Programs for NASA

The National Aeronautics and Space Administration awarded a 5-year contract to EMR to review its existing maintenance management programs and to implement RCM programs at NASA centers. Assessments include evaluating the RCM philosophy and strategy in each organization; considering facilities maintenance budgets; reviewing organization and staffing; and examining reactive, preventive, predictive, and proactive maintenance efforts. In our pilot RCM implementation project at NASA's 800,000-square-foot Dryden Flight Research Center, which also included analyzing the center's Unix-based Computerized Maintenance Management System, annual maintenance requirements were reduced by 20,000 hours with no impact on system availability. Four hundred thousand square feet of operating space was added with no increase in labor-force size, and more than $100,000 in maintenance subcontracting was eliminated.

Development of NASA Facilities RCM Guide

EMR developed the NASA Facilities RCM Guide, which provides comprehensive NASA-wide criteria for predictive testing and inspection to ensure the quality of installed or replaced facilities equipment. To develop the guide, EMR studied existing predictive testing and inspection criteria and analyzed data from 30 pieces of collateral equipment, including chillers, air handlers, cooling towers, vertical and horizontal pumps, and uninterruptible power supply systems. EMR recommended the best practices for proactive maintenance techniques, RCM processes, and collateral equipment repair. Technologies discussed in the guide include vibration analysis, electrical testing, thermography, oil analysis, airborne ultrasonics, equipment balancing, and laser alignment. EMR also developed acceptance criteria that helps NASA ensure that new facilities and collateral equipment are installed properly and are of acceptable quality.

Pilot Facilities Condition Assessment Study

NASA's Langley Research Center in Virginia asked EMR to develop an advanced template for conducting facilities condition assessments that make the maximum use of computerized maintenance management systems and condition-monitoring data. EMR's evaluation included a review of equipment history records and current facility condition assessment data, interviews with facility managers and maintenance personnel regarding facility condition, and a detailed evaluation of all facility components to identify where predictive testing and inspection, preventive maintenance, and run-to-failure techniques can be applied. The final template was then adapted for use at NASA's Lewis Research, Marshall Space Flight, and Goddard Space Flight centers.

Liquid Natural Gas Plant Uptime Assessment

EMR recently worked with a major liquid natural gas processing facility in Asia to assess potential shortfalls in future production. After analyzing unplanned shutdown data for a period of 10 years, EMR identified those systems where reliability is insufficient to increase overall uptime. We then developed the processes, procedures, and implementation plan necessary for maintenance and the engineering and logistics to increase overall uptime by 6 percent by the year 2000. When implemented, EMR's recommendations will save $150 million annually in operating costs.

International Pharmaceutical Plant Maintenance Management Evaluation

EMR identified best maintenance practices, condition-monitoring hardware and software, required training, and modifications to the organizational structure to improve uptime, address the design and commissioning process, and reduce maintenance expenses. As a result, the company's key plants, hourly headcount, site maintenance, and employee costs decreased between 11 and 19 percent, as did overtime costs by more than 6 percent.

Operations and Maintenance Training

EMR's RCM specialists are among a select group of professionals who have provided training for the University of Dayton's Reliability Professional Development Program. Graduates of the courses are awarded a World-Class License in Manufacturing Reliability.

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