Pioneer Engineering facilitated the use of Reliability Centered Maintenance techniques for Great Lakes Chemical Corporation in El Dorado, Arkansas. We used RCM II methods and Dyadem’s FMEA Pro software to document the results.

Over the course of two weeks, our facilitator and a team from Great Lakes Chemical analyzed approximately 300 assets. Although our techniques follow the RCM II guidelines, we stop listing modes at the asset level rather than the component level. This results in a much faster, more implementable analysis. Both Pioneer Engineering and our clients believe that although we may miss a small portion of the detail by stopping at the asset level, we make up for it by completing both the analysis and the implementation in a timely manner. Often, we won’t leave the conference room until the CMMS system has been updated to reflect the task optimization.

The results have been that this particular unit at GLCC went from 20% over budget for maintenance to 15% under budget in one year, a savings of $350K per year. This is due not only to the task optimization and PM reduction, but also to the increased reliability of the plant. Our charges to facilitate were $12K.