Tag Archives: Maintenance

Manufacturing and maintenance environments are inherently high-risk, with heavy machinery, moving parts, and hazardous materials creating potential hazards daily. Over the past decade, technology has transformed how companies protect workers, reduce incidents, and improve operational continuity. The latest safety innovations integrate real-time data, automation, and smart systems to identify risks before they cause harm.

Real-Time Wearable Safety Devices

Wearable technology has moved beyond step counters and fitness trackers into highly specialized safety tools. Smart helmets, vests, and wristbands can detect environmental hazards such as dangerous gas levels, high temperatures, or excessive noise. Many wearables also monitor worker fatigue and heart rate, alerting supervisors if someone shows signs of overexertion or heat stress. This immediate feedback allows managers to intervene before a health event occurs, reducing both injury rates and downtime.

Advanced Machine Health Monitoring

Unexpected equipment failures not only disrupt production but can put workers at risk. Machine health monitoring systems use sensors and analytics to track performance metrics like vibration, temperature, and pressure in real time. This data helps maintenance teams identify early warning signs of mechanical issues, allowing repairs to be scheduled before breakdowns happen. Preventing sudden malfunctions protects employees working near machinery and supports safer, more predictable production schedules.

Collaborative Robots (Cobots)

While automation has been part of manufacturing for decades, collaborative robots represent a safer, more adaptable evolution. Cobots are designed to work alongside humans, performing repetitive or high-risk tasks such as heavy lifting or handling hazardous substances. Equipped with advanced sensors, they can stop immediately if they detect unexpected movement or contact, minimizing the risk of injury. Their adaptability also means they can be deployed in smaller facilities without extensive reconfiguration.

Augmented Reality for Maintenance Training

Augmented reality (AR) is changing how maintenance teams learn and perform complex tasks. With AR-enabled glasses or tablets, workers can see step-by-step instructions overlaid directly on the machinery they are repairing. This reduces the need for printed manuals or guesswork, lowering the risk of errors that could compromise safety. AR can also provide virtual simulations for high-risk procedures, allowing workers to practice without exposure to actual hazards.

Predictive Analytics for Workplace Safety

Data-driven safety programs use predictive analytics to forecast potential incidents before they occur. By analyzing trends from incident reports, machine performance data, and environmental sensors, safety teams can identify patterns that suggest higher risk periods or locations. Targeted interventions can then be deployed, whether that means adjusting staffing, scheduling maintenance, or adding protective equipment.

Technological advancements continue to redefine safety in manufacturing and maintenance. By combining automation, real-time monitoring, and data analysis, organizations can create environments where risks are minimized, productivity remains steady, and workers return home safely every day.

This infographic provides more information on the top technology improving safety in manufacturing and maintenance:

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Supply chain disruptions are an all-too-familiar phenomenon for modern businesses. Amid rising risks and awareness, many organizations have embraced disaster response planning, but unexpected scenarios are still both common and damaging. Much of the issue stems from being on the wrong side of proactive versus reactive problem solving.

Proactive vs. Reactive Problem Solving

Too many companies fall into the complacency trap of reactive problem solving. Between 2020 and 2022, investments in long-term supply chain resilience grew by 7% per year, but such action declined to 2% annually from then until now. That represents a massive risk when it takes an average of two weeks to plan and implement a response to any disruption.

Responding to emergencies once they arise requires less upfront investment and can lower the overall impact. However, it still results in considerable losses, especially considering how a business might have been able to avoid the situation entirely had it gone down another path.

Proactive problem solving, by contrast, seeks to prevent disruptions instead of improving responses after the fact. The best strategies still involve some disaster planning, as predicting everything is impossible, but even unforeseen situations are easier to handle when staving off more dramatic effects. When organizations experience between one and 10 disruptions in a single year, any improvement can yield substantial results.

How to Embrace Proactive Problem Solving

The need for proactive over reactive problem solving is clear, but how to implement it is often less evident. Specific steps may vary between supply chains, but a few best practices apply in all scenarios.

Use a Management Operating System

One of the most foundational steps is to build a management operating system (MOS). An MOS provides an organized structure of the company’s strategic goals and how smaller targets, actions and performance metrics fit within them. Supply chain leaders should use this reference to recognize where disruptions may arise and which situations would be most damaging to their highest priorities.

A detailed MOS will also enable better adaptability in disaster planning, as it reveals what the business can and cannot sacrifice. Ensuring everyone refers to the same MOS during decision-making is also crucial. Miscommunication alone is a significant disruptor, costing U.S. organizations $1.2 trillion annually, so this alignment goes a long way.

Design With Resilience in Mind

Proactive problem solving should also reach as far back as product design, developing items to use materials and production methods that leave less room for disruption. Designs fit for silicone injection molding instead of machining are a good example, as injection molding virtually eliminates material waste and is highly automatable. Hence, resource constraints or labor challenges are less disruptive.

Efficient manufacturing methods are just part of the resilient design equation. Material type, scarcity and supplies are also impactful, and broader supply chain-level changes can yield significant results. Some companies have lowered costs by roughly 80% by changing one supplier, leaving them more able to absorb disruption.

Implement Proactive Maintenance Strategies

Manufacturers and logistics fleets can embrace proactive problem solving by implementing preventive maintenance. Equipment malfunctions may not seem as worrying as larger supply chain disruptions, but automakers lose $2.3 million for every unproductive hour, and such costs have quadrupled in the past five years.

Businesses must move away from reactive, run-to-failure practices. Regular scheduled maintenance offers marginal improvements, but even this involves significant waste. The best solutions are condition-based repairs and predictive maintenance, both of which rely on technology to only perform care as needed, minimizing both planned and unplanned downtime.

Maximize Supply Chain Visibility

Visibility is another key differentiator between reactive versus proactive problem solving. The only way to get ahead of issues before they arise is to understand their likely sources, which requires transparency across the supply chain. Most operations also have room to improve here, as only 13% of global businesses fully understand their sourcing networks.

Manufacturers must collaborate with their upstream suppliers to create a more detailed list of all involved parties. Full visibility typically requires technologies like blockchain or Internet of Things (IoT) tracking, as these can provide more in-depth records of all transactions and, in some cases, enable real-time updates.

Find Opportunities to Lower Risk With AI

Once leaders have established transparency across the supply chain, they can connect IoT systems and other data to artificial intelligence (AI) to find de-risking opportunities. Some areas to improve may be immediately evident, but AI outperforms humans when finding trends in vast datasets. As such, it is an indispensable tool for comprehensive proactive problem solving.

AI-driven risk management is relatively new but has already produced meaningful results. The Defense Logistics Agency has used it to identify counterfeit suppliers and other instances of noncompliance. Following suit can help private companies find and resolve potential hazards before they lead to disruption.

It Is Time to Move Beyond Reactive Problem Solving

Modern supply chains are too complex and the costs of volatility are too high to justify reactive problem solving. Moving to a more proactive approach may involve upfront expenses and complications, but it will produce savings and greater efficiency in the long term.

Only by anticipating and responding to risks before they cause issues can organizations ensure ongoing productivity.

*This article is written by Lou Farrell. Lou is a Senior Editor at Revolutionized and has covered topics in the fields of Manufacturing, Supply Chains, and Technology, cultivating a deep understanding and passion for these areas. Together with his love of writing, Lou enjoys being able to share his knowledge with others.

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Equipment reliability is a fundamental pillar in oil and gas production. From upstream drilling to downstream refining, operations depend on machinery that works consistently under high pressure, fluctuating temperatures, and corrosive environments. When a critical component fails, the disruption ripples far beyond the immediate site. It impacts production schedules, safety protocols, and profit margins. Maintaining uptime is not just a matter of convenience but a key driver of operational success.

Unplanned Downtime Carries Real Costs

A single mechanical failure can bring operations to a halt, costing thousands or even millions of dollars in lost production and emergency repairs. In highly integrated supply chains, even a brief pause can delay multiple projects down the line. Beyond direct financial losses, there is reputational damage and the risk of regulatory scrutiny. In an industry where timelines are tight and contracts are performance-based, reliability directly influences competitiveness.

Safety and Environmental Impact

Oil and gas sites often operate in remote or high-risk environments. When equipment breaks down unexpectedly, workers may be exposed to hazardous conditions during emergency maintenance. Malfunctioning valves, corroded pipelines, or faulty sensors can lead to environmental spills or gas leaks. Reliable systems reduce the likelihood of these dangerous incidents. Implementing proactive maintenance programs improves safety outcomes and aligns operations with stricter environmental standards.

Corrosion Control and Long-Term Performance

One of the silent threats to equipment reliability is corrosion, particularly in offshore and coastal operations. Metals degrade faster in harsh environments unless protected. That is where systems such as a cathodic protection system play a key role. By preventing corrosion from compromising vital infrastructure, these technologies extend equipment lifespan and help companies avoid costly replacements. Investing in preventative measures keeps long-term performance stable and predictable.

Strategic Maintenance as a Competitive Tool

Modern oil and gas companies are turning to data-driven maintenance strategies to extend asset life and minimize surprises. Predictive analytics and condition monitoring help teams detect wear and tear before failure occurs. Equipment logs, pressure readings, and temperature data create a clearer picture of what is performing well and what is at risk. Fewer unexpected failures mean fewer shutdowns and a steadier flow of product from well to refinery.

Reliable equipment forms the backbone of high-performing oil and gas operations. From cost control to worker safety to environmental responsibility, reliability is not an afterthought. It is a business necessity. Maintaining a strong maintenance culture and investing in technologies that protect critical assets can yield long-term advantages across the entire supply chain.

The below infographic provides more information on the challenges, the importance, and the methods and tools to improve O&G equipment reliability:

If you need help enhancing your maintenance reliability, contact USC Consulting Group today.

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Poor asset management can result in significant financial losses beyond the cost of replacement, with reputational damage, compromised data, and operational disruption a few of many risks involved. Effective asset management, on the other hand, is essential for businesses across industries, with advantages that include increased productivity, elevated asset utilization, and minimal downtime, The Enterprise World highlights. For organizations that aim to enhance their asset management process, the perfect balance of key strategies is a must — especially when the goal is to better manage the return and disposal of physical assets.

Preventative maintenance as a front line defense

For companies that manage assets like physical tech equipment, a strategy that focuses on maintenance is essential in order to maintain assets that are in optimal working condition at all times. Further advantages include asset longevity, reduced maintenance costs over time, and greater operational efficiency. Due to the value that preventative maintenance can bring, businesses must consider the strategy as a valuable front line defense in an asset’s life cycle.

While manual, routine inspections are crucial to an effective asset maintenance strategy, technology now plays an indisputable role in predictive maintenance and asset management as a whole. Artificial intelligence (AI) is just one technology that is gaining traction in asset management. For example, AI algorithms can process large amounts of data in order to predict maintenance issues and generate optimal schedules for maintenance — all the while factoring in an asset’s previous maintenance data. This can prove to be particularly beneficial for organizations that possess a significant number of assets (such as many laptop computers). When combined with efforts like manual asset tracking, businesses can rest easy in knowing that everything is accounted for, in good condition, and up-to-date on routine maintenance.

A streamlined return process

Effective equipment tracking is essential for any business with physical assets. Today, equipment management endeavors go well beyond a simple spreadsheet, and will typically involve the combined use of both physical tracking options (like barcodes or equipment tags). Software is another essential element, as asset management software provides a deeper look into the valuable details associated with physical assets. This technology will not only provide an overview of the assets that a business has, but details in regard to maintenance history and location (to highlight a couple of insights).

Businesses that have a well-defined asset tracking approach can easily overlook the complex nature of certain parts of the asset management process. For example, the return process can often involve several kinks along the way, such as employees that fail to send back company equipment, or inefficient shipping which can result in untimely delays. As such, effective equipment tracking does extend to a successful equipment return process. This is especially crucial for companies that routinely ‘loan out’ technology to their employees — a lost laptop is just one asset that can create a ripple effect for a business. In addition to lost productivity and the cost of replacement, the company may also have to shoulder the cost associated with a data breach, a factor that further underlines the importance of an effective return process. In addition to clear instructions, it’s essential that a business has a strategy in place to streamline the return. In addition to a trustworthy equipment management system and staying on top of paperwork (such as custom fees, etc.), aspects like consistent tracking updates throughout the shipping process can make a major difference.

Asset disposal can be a sustainable process

The integration of technology can elevate an asset management strategy by enabling businesses to continuously optimize maintenance schedules and elevate the return process. In turn, companies can minimize the downtime of assets, and benefit from equipment that will go the mile. When assets are truly no longer useful, however, businesses must abide by an effective disposal strategy. In many cases, there are sustainable approaches that can underline further advantages, such as environmental benefits or supporting the local community.

In some cases, a business may wish to donate old equipment (like computers, printers, etc.) to schools in order to support the local community. Businesses may wish to explore other options as well, such as the ability to refurbish and sell their equipment. Recycling old tech is another solution, and can be a sustainable option for equipment that is truly at the end of its life cycle. Before old tech leaves the hands of a business, however, it’s crucial to gain a full understanding of the laws, regulations, and the additional considerations that are involved. For example, businesses that wish to recycle their tech will need to comply with e-waste disposal laws. Other tasks are equally as necessary, such as a thorough asset inventory, the proper and secure destruction of any sensitive information (including GDPR compliance where applicable). Enlisting the help of a certified and professional Information Technology Asset Disposition (ITAD) provider can be a great option that can help guide a business through the process.

Poor management of physical assets brings to light a number of stark consequences for a business, from unnecessary financial losses to lessened efficiency overall. A balance between technology driven solutions and smart considerations, however, can make for an elevated management process even where asset return and disposal are concerned.

*This article is written by Lottie Westfield. Lottie spent more than a decade working in quality management in the automotive sector before taking a step back to start a family. She has since reconnected with her first love of writing and enjoys contributing to a range of publications, both print and online.

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Over the next five years, mining and metals companies are expected to spend between $25 billion to $30 billion annually to maintain their assets.

Largely driven by efforts to improve operational efficiency, reduce downtime, immediately reduce costs, meet sustainability goals, and manage operational risks in an increasingly volatile market, mining and metals executives are motivated to start their asset management transformation now. Delaying this transformation could result in lost competitive advantages, higher operational costs, and increased regulatory or market pressures.

Over the next five years, the mining and metals industry is projected to invest heavily in the maintenance of fixed and mobile assets. Various reports indicate that the industry is expected to allocate a significant portion of its CAPEX to maintaining and upgrading its assets. A substantial part of this investment will be directed toward maintaining critical assets required to meet global demand for minerals essential for the energy transition. In a recent survey conducted by Global Data, 48% of the companies surveyed indicated they plan to increase investments in technologies like AI and IoT sensors for equipment upkeep over the next two years.

Investment in predictive maintenance is becoming a top priority for many mining operations. Companies are leveraging their EAM’s with advancing technologies like Digital Twins, AI and IoT, along with other reliability and planning applications, and significantly transforming asset management and the asset lifecycle. These advancements in technology are expected to reduce maintenance costs by 20-30%.

Mining and metals companies integrating Enterprise Asset Management (EAM), Computerized Maintenance Management Systems (CMMS), AI, and IoT are experiencing several quantifiable benefits, including:

• Improved Asset Reliability and Uptime: Utilizing a combination of AI, IoT sensors and Digital Twins provides continuous real-time monitoring of equipment health allowing companies to predict potential failures before they occur while reducing the reliance on reactive and scheduled maintenance – reducing unplanned downtime and fewer equipment breakdowns, increasing equipment availability and extending asset lifecycles.
• Cost Reduction: A predictive maintenance capability helps avoid costly emergency repairs and reduces unnecessary scheduled maintenance, saving on labor and spare parts. It also ensures that the right parts are available when needed, minimizing overstock and understock issues, which helps reduce capital expenditure tied to inventory. It optimizes the energy usage of equipment by adjusting operational parameters in real-time, leading to lower energy consumption.
• Scalability and Flexibility: Leveraging these technologies together, allows companies to scale their asset management strategies as they grow, adapting to changes in operational needs without significant disruptions. Maintenance scheduling based on asset condition rather than time-based intervals, ensures that resources are used effectively, reducing downtime and improving workflow efficiency. They provide a holistic view of all assets, enabling better coordination between teams while improving “wrench-time” productivity and the execution of maintenance and operational tasks. It delivers a single platform to access real-time data across the entire asset portfolio, improving visibility and control over operations for optimizing performance and recommendations for future operations.

USC partners with your organization and coaches your people to significantly impact performance outcomes and accelerate Operational Excellence

USC brings a tailored, structured, and disciplined methodology, along with a range of tools and techniques we apply collaboratively with client’s personnel. Whatever your challenge, we are the people who work with our clients to find full potential and unlock the hidden value.

USC help to identify waste, redundancies, and ineffective processes, and then rapidly recover the prioritized opportunities, and convert them to improvements in performance and operating profit. Further, our people embed with client teams to develop, enhance, prototype, validate and implement asset management strategies to drive, sustain and perpetuate improvements in asset lifecycles and equipment reliability, while changing how plans, schedules, and work is executed. In short, USC implements measurable, sustainable changes that drive asset performance and financial improvements.

• Increased Wrench Time (up to 25% improvement) – Reducing non-productive time through improved work-order generation and prioritization, maintenance teams spend less time searching for work-orders, tracking down parts or waiting for approvals.
• Reduction in Travel & Downtime (up to 20% time savings) – Optimizing the routing and scheduling of maintenance tasks and reducing travel time between jobs to maximize “time on tools”.
• Faster Work-order Completion (up to 30% efficiency gains) – Reducing delays in task assignment, approval and completion tracking, technicians can move quickly from one job to the next by ensuring all the necessary tools and parts are available at the work site, eliminating delays caused by missing resources.
• Optimized Spare Parts Management (up to 15% time reduction) – Faster access to parts and accurate spare part forecasting reduce time on sourcing, stocking and searching while ensuring tools & parts are available for tasks.
• Better Data-Driven Decision Making (up to 20% longer asset life spans) – Collecting and analyzing needed information provides actionable insights that support planning and allow for more informed and pro-active decision making, often delaying the need for capital-intensive replacements.

USC clients experience measurable operational and financial results that significantly improve both the efficiency and profitability of their operations. Benefits delivered may include a 10-20% increase in overall equipment availability due to reduced unplanned downtime and optimized maintenance schedules and a 10-15% improvement in equipment utilization as predictive maintenance reduces the time equipment is out of service.

USC Helps You Tackle Key Challenges

• Optimize maintenance strategies and increase equipment availability operational output
• Predict asset integrity and reliability needs and improve time on tools
• Mitigate risks through stronger stakeholder partnerships, while removing redundancies in the supply chain
• Overcoming cultural and communication issues with contractors, while ensuring quality expectations

Do you want to understand how prepared your company is to drive needed asset management performance and reliability improvements and what the key focus areas that will contribute to lower operating costs? Contact us today.

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The world is increasingly focused on sustainability, and the manufacturing sector is no exception. Consumers are demanding eco-friendly practices, and regulations are evolving to reflect this shift. This presents a compelling opportunity for manufacturers – by incorporating sustainability principles into the design of their machines, they can not only benefit the environment but also reap significant economic rewards.

The Benefits of Green Design

Sustainable manufacturing machine design offers a win-win scenario for businesses. By focusing on resource conservation and energy efficiency, manufacturers can significantly reduce their environmental footprint. This translates into a positive impact on the planet, aligning them with global sustainability goals. Additionally, sustainable design principles can lead to cost savings through minimized waste generation and lower energy consumption.

Beyond environmental and economic benefits, sustainable machine design can also enhance a company’s reputation. Customers today are increasingly conscious of eco-friendly practices, and a commitment to sustainability can be a major selling point. Furthermore, adhering to evolving environmental regulations becomes easier when sustainability is embedded into the design process from the very beginning.

Implementing Sustainable Design Principles

So, how can manufacturers translate these principles into action? A crucial step is integrating a life cycle assessment into the design process. This involves evaluating the environmental impact of the machine throughout its entire lifespan, from raw material extraction to disposal. This holistic approach allows engineers to make informed decisions about materials, manufacturing processes, and even end-of-life options.

Technology also plays a vital role in sustainable design. Advanced software tools like computer-aided design (CAD) can help engineers optimize both functionality and aesthetics, minimizing material usage and ensuring efficient operation. Additionally, simplifying design complexity can further reduce the environmental impact. Removing unnecessary components not only streamlines assembly but also minimizes energy loss during operation.

Material selection is another critical aspect of sustainable design. Opting for materials with lower embodied energy (the energy required to extract, process, and transport them) and those that can be easily recycled or reused can significantly reduce the environmental burden. For instance, utilizing high-efficiency, NEMA gearboxes, can not only improve overall system efficiency but also extend the lifespan of the equipment, reducing the need for premature replacements.

Safety plays a vital role not only for workers but also for the environment. Conducting thorough safety audits throughout the design process ensures the equipment operates safely and efficiently, minimizing the risk of accidents that could lead to environmental damage. Furthermore, integrating smart technologies like real-time energy monitoring and predictive maintenance systems empowers manufacturers to identify and address potential issues before they escalate into bigger problems.

Curious about the specific ways sustainable design can improve a machine’s environmental impact? The following infographic dives deeper into the benefits of sustainable manufacturing machine design, showcasing how each principle contributes to a greener future for the industry. By adopting these sustainable design principles, manufacturers can create machines that are not only efficient and productive but also environmentally responsible.

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Downtime – the dreaded halt in production that can cripple a manufacturing operation. It’s more than just an inconvenience; it’s a hidden cost that can eat away at your profits. A recent study revealed that nearly 82% of businesses have experienced unexpected downtime in the past three years, with the average incident lasting four hours and costing a staggering $2 million. The impact goes beyond just financial losses – downtime can disrupt customer deliveries, delay critical projects, and erode trust with clients.

The Potential Culprits

One major factor is neglecting preventive maintenance. Regular servicing not only keeps equipment functioning smoothly but also allows technicians to identify potential problems before they snowball into major breakdowns.

Another hidden source is outdated equipment. Obsolete machinery can be a drag on your entire production line. Imagine a slow, malfunctioning piece of equipment holding up the entire process. This can put undue stress on other machines, leading to premature wear and tear, and ultimately, more downtime. Upgrading to newer, more efficient models can significantly improve production flow and reduce the risk of breakdowns. Outdated software can also be a culprit. Running outdated software can lead to compatibility issues with newer systems and leave your facility vulnerable to security breaches.

Beyond equipment and software, a lack of proper training for your workforce can also contribute to downtime. If operators don’t fully understand how a machine works, they might misuse it, leading to errors and breakdowns. Investing in comprehensive training empowers your employees with the knowledge and skills they need to operate machinery safely and efficiently, minimizing the risk of operator-induced downtime.

Finally, the importance of data tracking cannot be overstated. Keeping detailed logs of equipment issues and production hiccups allows you to identify recurring problems and implement preventative measures. Think of it as a historical record that helps you anticipate and address potential bottlenecks before they derail your production schedule.

Finding the Right Solution for You

The good news is that there are steps you can take to combat downtime and keep your production lines humming. Conducting risk audits to identify potential problems, installing sensors to monitor equipment health (like a torque transducer that detects excessive force on a rotating shaft), and implementing a comprehensive preventive maintenance program are all crucial steps in the battle against downtime.

Investing in employee training and partnering with reliable third-party service providers can further strengthen your defenses. By adopting a proactive approach to maintenance and addressing the root causes of downtime, you can significantly reduce disruptions and ensure your manufacturing operation runs smoothly and efficiently.

Want to learn more about the specific costs associated with different downtime causes? The following infographic breaks down the financial impact of various downtime triggers, helping you identify areas for improvement and optimize your production process for maximum uptime.

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Mining and metals companies are implementing a range of strategies to enhance asset management and equipment reliability.

In today’s market, many senior executives leading natural resource companies hesitate in making additional capital investment and instead focus on what can be done to squeeze higher performance out of current assets. Consequently, companies are increasingly looking for ways to improve performance and returns with existing infrastructure.

The key approach to this challenge lies in upgrading and improving asset management capabilities. Many organizations have failed to deploy optimal asset management practices. This is surprising given that asset spend frequently represents 30% to 50% of the overall operating expenses. Shifting to a best-in-class asset management program will consistently deliver improved plant or equipment performance, lower operating costs, extend asset life, and generate a higher return on capital. Most recently, companies have sought to implement a range of strategies such as:

1. Implementing Asset Management Systems: Utilizing robust asset management systems to track equipment performance, maintenance history, and lifecycle costs, allowing for better decision-making regarding repairs, replacements, and upgrades. Digital technologies like IoT sensors, AI-driven analytics, and automation further optimize asset management.
2. Enhancing Maintenance Practices: Implementing proactive maintenance strategies like conditioned-based monitoring and reliability-centered maintenance to address issues before they cause failures. Utilizing data-driven insights, mining companies can optimize “time on tools” by identifying patterns and trends in equipment usage, maintenance needs, and performance. This allows for more precise scheduling of maintenance tasks, reducing downtime and maximizing the time equipment is operational.
3. Investing in Training: Providing comprehensive training programs for front-line management, maintenance and operations personnel to ensure equipment is used and serviced properly, reducing the likelihood of breakdowns due to human error and that access to equipment is available. Training personnel to utilize data-driven insights enables management to make informed decisions impacting “time on tools” and leading to improved equipment utilization and overall operational performance.
4. Improving Supply Chain Management: Ensuring timely access to quality spare parts and materials to minimize downtime caused by equipment breakdowns and repairs. Some are adopting blockchain for transparent supply chain management and better tracking of assets throughout their lifecycle.

The level of performance improvement companies can realize by implementing key strategies such as enhancing proactive maintenance practices, investing in training to improve skills and capabilities, improving supply chain management, and leveraging digital technologies and data-driven insights varies depending upon factors like current operational efficiency, the scale of implementation, and industry conditions. However, many can expect significant improvements in:

1. Safety: Proper training programs and proactive maintenance strategies contribute to a safe work environment by reducing risk of accidents and equipment failures.
2. Productivity: Proactive maintenance and digital technologies can reduce downtime, increase equipment availability, and optimize process execution, leading to higher productivity levels.
3. Cost Reduction: Efficient equipment usage and maintenance practices can lower operational costs by minimizing unplanned downtime, reducing repair and replacement expenses, and optimizing resource utilization.
4. Quality: Improving the essential management skills and work place practices result improve the quality of maintenance execution.

Overall, these strategies can result in substantial performance improvements, enhancing competitiveness and profitability for mining and metals companies.

USC Consulting Group partners with your organization and coaches your people to significantly impact performance outcomes and accelerate Asset Management and Reliability Excellence.

USC’s experience helping clients to shift asset performance by transforming and optimizing asset management capabilities and processes has repeatedly demonstrated the need to focus on the key levers and enablers to asset management and reliability excellence. Our asset management framework is designed to be pragmatic rather than conceptual, thereby leading to accurate, practical decisions about a client’s assets and aspirational outcomes.

The primary goal of USC’s asset management framework is to help our clients to implement and execute of a robust set of integrated processes and tools to manage and maintain their operational assets at the targeted service levels while optimizing life-cycle costs and asset life. This is accomplished by recognizing the needs to:

• Improve safe execution of work
• Increase asset life and reliability
• Improve productivity and cost performance
• Improve operational predictability
• Control material asset risks
• Develop competitive advantage

Our asset management and reliability framework helps clients identify an organization’s asset management maturity level and the areas and gaps that need to be addressed, by evaluating their strategic, tactical and operational levers and the enablers that comprise each.

Strategic (Lifecycle Management): A tailored maintenance program for each piece of equipment translates overall strategic objectives into executable plans for equipment upkeep. Our framework helps to structure and prioritize critical assets while defining a baseline operational ‘plan of action’ by determining strategies for maintaining equipment based on analysis of equipment capabilities, required performance levels, failure frequencies, and cost objectives. Optimal maintenance strategies are frequently a blend of preventative, predictive, operator-maintained, and run-to-fail options.

Tactical (Business Processes): Business processes bridge the gaps between the initial, ideal plan and the reality of ‘day-to-day’ operations, so the maintenance and reliability organization can make adjustments. Historically, many maintenance organizations have been poor utilizers of labor resources that result in low “time on tools” and excessive delays in repairing down or poor performing equipment.

Operational (Enablers): Enablers help to identify needed support to manage assets throughout their lifecycle in alignment with organizational aspirations. Leading asset management teams have also made changes in their organization structures and management practices to foster more action-oriented leadership that focuses on operational excellence, which usually requires a culture shift that must be relentlessly supported by the leadership team over the long-term. A heavy emphasis on management behaviors and company culture can help organizations make this difficult transition.

USC Helps You Tackle Key Challenges

• Optimize maintenance strategies and increase equipment availability operational output
• Predict asset integrity and reliability needs and improve time on tools
• Mitigate risks through stronger stakeholder partnerships, while removing redundancies in the supply chain
• Overcoming cultural and communication issues with contractors, while ensuring quality expectations

Do you want to understand how prepared your company is to drive needed asset performance and reliability improvements and what the key focus areas that will contribute to lower operating costs?

Want to find out more about how USC can help you uncover the hidden value lurking in asset portfolio?

For more information, let’s talk it through with a no obligation video conference call or a meeting with one of our executive team. Email info@usccg.com to arrange a call.

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The energy and utilities industry is in the midst of change.

Businesses are facing pressure from the government and consumers alike for more renewable energy while also balancing that with grid reliability and traditional energy sources. Meanwhile, electricity demands are expected to skyrocket. Other wild cards are supply chain disruption, labor shortages and more.

But within those challenges, we always see opportunities. Let’s take a closer look into the outlook for energy.

Continued focus on renewables. The demand for clean energy will continue to rise. Governmental regulations are mandating the focus on clean energy and decarbonization, including enacting green-friendly legislation and incentives for companies to transition to cleaner sources like solar and wind. The industry made great strides in solar power and the energy storage it necessitates in 2023, but more is needed and the focus will continue in 2024 and beyond. Consumers are demanding it as well, with climate change among people’s top concerns. All of it has led many companies to push the timeline to cut carbon emissions by 80% from 2050 up to 2030.

Energy storage. The push for solar requires an enormous amount of battery storage capacity to, in very simple terms, store all of that energy for times when the sun’s not shining. It means innovation in battery technology, and 2023 saw much of that, with storage capability doubling in 2023 and set to nearly double again in 2024.

Electricity surge. According to industry sources, the demand for electricity is expected to triple by 2050. It means planning now for this increased load on what is likely aging infrastructure, resulting in costs to shore up that infrastructure to ensure grid reliability. It’s also necessary to consider expanding the grid to meet that demand.

Aging grids + extreme climate.  We all saw the worst-case scenario play out in Texas when their grid failed when the state experienced a rare deep freeze. But weather extremes are becoming the norm, with heat, wildfires and drought on the one hand, floods and record snowfall on the other. The industry is modernizing the grid, and made progress in that area in 2023, but reliability is still a large concern.

Supply chain uncertainty. The recent geopolitical unrest in Ukraine and the Middle East has underscored the need to reshore this nation’s oil supply.

Labor shortages. Like many industries today, energy is battling a labor shortage and facing the double whammy of their most experienced workers retiring and taking institutional knowledge with them, and having too few younger people in the pipeline to pick up where they left off.

It’s a full plate for the energy sector in the coming years, that’s clear. But within these challenges, we see opportunities to bolster processes, making operations more efficient and guard against supply chain snafus. Reducing operating costs, improving productivity and increasing efficiency will help the industry navigate these challenging times.

This is where USC can help

Management Operating Systems. A solid Management Operating System is a must for efficiency, time savings, employee productivity and so much more. For a real-world example on how USC helped an energy producer save time and money by implementing an MOS, read “Energy Producer Generates Savings with Smarter Labor Practices.”

Reskilling employees. All of this innovation and growth in renewables, not to mention AI entering the mix, requires more workers with new skills. This can be very good news for your current employees, who can move up the food chain with new training, and the ability to attract highly qualified workers.

Resource planning. If you know anything about our company, you know we are great proponents of SIOP – Supply, Inventory and Operations Planning. It gives companies a roadmap to the future, so they’re not reacting to events, they’re anticipating them. With the exponential growth of the energy and utilities sector in the coming years, solid planning for the resources needed for that growth, like increased storage capacity and grid strength, is a must.

Bottom line, delivering reliable, affordable and sustainable energy is the goal for the energy and utility industry. It takes efficient operations, a handle on resources, and a clear eye toward the future. Contact us today to find out more about how USC Consulting Group can help.

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