Reliable operations is a key business objective for nearly every manufacturing plant due to global economic pressures and increasing Process Safety Management (PSM) requirements. Pacesetter sites that have been successful in achieving long-term reliability are characterized by Business Units empowered and accountable to meet their reliability targets. Structured work processes, with specialist support, provide the foundation for Business Unit Reliability Improvement Plans. We find that sites that lack the organizational readiness and expertise languish in the 3rd or 4th quartile for reliability performance.
Becht Engineering Company subscribes to a holistic risk management philosophy through a Reliability Management System (RMS) that crosses all major departments at a facility. This approach separates us from our competitors who offer Risk-based Inspection (RBI) tools, which is only one element of the program. Experience indicates that programs such as ours comply with the intent of PSM regulations and drive efficiency in maintenance dollars. In fact, Oil Majors have identified significant “lost opportunity costs” from unplanned downtime in upstream and refining operations. RMS systems enabled them to minimize their lost opportunity costs.
Additionally, the skills and diversity of our available staff sets us apart from our competition. We have over 800 advisors (SMEs), most with 25+ years of refining and production experience. Our equipment expertise covers Materials and Corrosion, Vessels, Machinery, Storage Tanks, Piping and Fired Heaters. A majority of these SMEs have held technical and leadership positions at operating facilities, providing a unique lens for addressing our client’s business objectives. We provide engineering services from an Owner’s perspective.
A RMS consists of core and supplemental elements. Core elements include:
Supplemental elements in RMS can have exponential impact on reliability and cost savings. These elements cross functional groups (Process, Mechanical & Technical) within the plant. They focus on main touchpoints with the process and equipment – proper design, proper operation, and proper maintenance.
Becht Engineering Company’s Reliability Services Department has experts who are knowledgeable of these element’s functions and interdependency; their strengths and their limitations. We have created core element tools to ease implementation and sustain the RMS. Our people are experienced in analyzing the current work processes, identifying gaps, counselling on gap closure plans, training and providing direct technical support in order to develop the RMS that meets our client’s needs. Partnering with Becht to build the right RMS is the first step toward capturing the reliability prize.
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Joseph Salus has worked 15 years in the Petrochemical Industry serving clients across the globe. Prior to joining Becht Engineering Reliability Group, Joseph worked in numerous technical positions across ExxonMobil Research & Engineering and ExxonMobil Refining & Supply companies. His diverse ExxonMobil experience includes various levels of technical solutions, project management, work process coordination, and risk management. His background in finance at Morgan Stanley and nuclear power in the U.S. Navy provide him a unique perspective for evaluating complex manufacturing situations.
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