Lean Management Coaching

Lean Management Coaching

PSW Integrity bring a world class ability to visualise, assess and translate business challenges in your organisation.

the inspiration for PSW Integrity came from a chance meeting between friends, who happened to have expertise within the fields of Enterprise resource planning systems and process driven lean management implementation. we noticed that projects within both areas of our exper tise shared problems of underperformance with an ironic twist; many lean thinking projects missed opportunities to integrate the benefits and life blood that organisations gain from their it systems; and many Erp implementations ignored major process improvement opportunities.

the result was the formulation of an approach to business improvement that was able to address it system transformation and management process improvement simultaneously.

PSW Integrity have grown rapidly since incorporation in 2008, acquiring new clients through the deliver y of their separate improvement disciplines (process driven lean management and Enterprise resource planning optimisation), plus the effective deployment of their unique ‘blended’ approach – lean Erp.

 

pswintegrity lean management coaching page6 image18Our Services

PSW Integrity are specialists at configuring and implementing Enterprise resource planning (Erp) systems that facilitate the flow and transparency of management information across all depar tments of an organisation faster, with the emphasis on speed and accuracy, resulting in more effective decision-making in order to optimise business performance and results.

the effective implementation of an Erp system into a business requires changes to be made to the processes and procedures throughout an organisation. if handled incorrectly, a poor implementation can cause the improvement initiative to fail, or even worse cause severe disruption and organisational trauma.

therefore, we have developed a unique approach to implementation using the principles of lean management thinking, which helps streamline the implementation process and engage all stakeholders throughout the project.this leads to sustainable change and performance.

We are able to implement both lean and Erp systems independently, however, the combined lean Erp approach has been developed over a sustained period of extensive research and experience and we truly believe we are unique in our ability to deliver such integrated transformational improvement.

 

Lean Management Coaching – Helping Others to Lead

Lean management thinking is principally about creating excellence by removing wasteful activity from processes so that they flow more efficiently and effectively to optimise business performance and increase organisational results.

implementation of transformational change within an organisation requires people to take ownership of the new processes, which is done by understanding and recognising the benefits that will be generated and then lead others to effectively implement the processes throughout an organisation.

At PSW Integrity we help generate ownership and leadership through our 3 stage coaching programme:

1. the theory - we teach the methodology and theory of lean management thinking so people can fully understand the principles of why and how it will benefit their business

2. practical implementation - through research and experience we have developed a comprehensive range of tools and frameworks that we teach people how to effectively implement the new processes

3. 1-2-1 coaching – we work closely with key stakeholders of the project at ever y stage of implementation to ensure we can effectively pass on our knowledge and expertise so that they can lead others to effective process changes this collaborative approach helps to create change that is not only effective, but is also sustainable as people within the business are proud to take ownership.

To find out how we can help you, contact us here...

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PSW Reliability Engineering

The Best Way to predict the future is to create it with a PSW Integrity Maintenance Programme

Reliability Engineering

 

At PSW Integrity, our certified reliability engineers are professionals who understand the principals of performance evaluation and prediction to optimise product, systems, reliability and maintainability. PSW-Man is a body of knowledge and applied technologies which delivers, however are not limited to, Failure Modes and Effects Analysis, understanding human factors in reliability, Planning and scheduling, KPI Dashboard, Training and the ability to develop Reliability facilitation over the entire product and system life cycle.

Walkdown - Asset Catalogue

An accurate and 'live' asset catalogue, developed by the relevant personnel, and verified in the field is considered best practice. An asset catalogue is the foundational element of any maintenance or reliability initiative and consists of not only the list of assets, but also
includes system descriptions, component configurations, component attribute data, hierarchy structure, etc. The reason an asset catalogue is considered ’foundational’ relates to effective management of assets. If there are errors, all maintenance and reliability initiatives will be
flawed, leaving assets without effective management.

Equipment Maintenance Plan

An equipment maintenance plan identifies what tasks should be deployed/implemented to most effectively manage the failure modes present in assets. Best practice programs plan and schedule at least 80% of the daily tasks to drive efficiency and proactive work. It is
proven that planned work is 50% more efficient and causes less infant mortality than reactive. A high percentage of daily work hours should be Planned Maintenance (PM), Condition Monitoring and also follow up work created from those inspections. All tasks must be
well written and designed to effectively eliminate, manage or inspect failure modes, reduce risk of human error, and deliver optimum feedback and history into the CMMS.

Criticality / Consequence Classification

Criticality / Consequence Classification is the most effective deployment of the limited resources (spares, manpower, time, condition monitoring) within an organisation. It is important to carry out criticality analysis on all assets to identify which have the biggest impact on operations, safety and environment. The best practice approach is to involve personnel from each area of the business (cross functional team) i.e. operations, maintenance, health and safety etc. to gain consensus. A criticality assessment must to be executed
by a cross functional team and can be facilitated by a PSW Integrity certified reliability engineer.

PM Evaluations (PME)

PSW Integrity has proven that most existing Asset Management programmes contain tasks which are not value adding, do not address failure modes and highly dependent on experienced personnel and can be changed to condition monitoring tasks. A best practice asset management programme is a failure modes driven programme. PSW Integrity will optimise existing maintenance programmes and compare the PM tasks with world leaders or best practice PM/CM and ensure all tasks; effectively address failure modes, reduce human error, drive repeatable and consistent results, maximise ability to plan and schedule/load level, identify the defect before it causes failure and enable senior personnel to make informed decisions based on scientifically proven technologies. Best practice asset management programmes have a balance of PM and CM and asset care routines to maximise reliability and operational integrity.

Spare Parts Optimisation

Organisations need a different approach to that of the classical min/max method in order to optimise spare parts. Knowledge of MRO (maintenance, Repair, Overall) items are critical for effective operations and cannot be merely left in the hands of a single person. It requires an integrated approach by all team members to solve the problem. PSW Integrity can facilitate this in helping you with the optimum approach in MRO analysis.

RCM - RCA - FMA - FMECA

World class organisations ensure that their maintenance programmes and tasks are failure modes driven. This approach enables them to understand the operation and optimise the performance and reliability. To develop these programs there is a need for RCM, FMECA,
RCA, etc. PSW Integrity have a proven track record of delivering best practice maintenance programmes using our methodologies and best in class tools for efficient and highly effective development.

 

Our Reliability Engineering Deliverables

Asset Catalogue Development
Criticality Analysis
RCA - RCM
FMA - FMECA
Equipment Maintenance Plans
Consequence Classification
Spares Optimisation
Workflow Optimisation
Maintenance Optimisation
Lean Manufacturing
Gap Analysis - (Operations & Maintenance)
Reliability Excellence
PAS 55 - ISO 55000

Our CM Deliverables

 

Vibration Analysis
Ultrasound Analysis
Infrared Analysis
Steam Trap Analysis
Oil Sampling and Analysis
Grease Handling
Fluid Management
Remote Control
Operational Checks
CM Assessments

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Condition Monitoring

The Best Way to predict the future is to create it with PSW Integrity Maintenance Programme

Condition Monitoring (CM) Programmes are the optimum approach towards improved equipment reliability for our customers. CM surveys, have been continually proven to detect the majority of machinery problems in the most cost-effective and timely manner. Early detection of defects allows for planning and repairs with a less reactive maintenance culture, whilst increasing asset reliability. PSW Integrity offers you a range of CM inspections which enable you to optimise/enhance your asset management programme.

Vibration Analysis - Remote Control

Correctly performed vibration analysis will provide a more in-depth insight into condition of new, existing and overhauled machinery. Vibration measurements are widely accepted as the most effective technology for diagnosing the condition of rotating machinery. Every machine malfunction generates its own unique vibration pattern, making vibration analysis the most widely used, reliable and proven diagnostic technology. Vibration analysis can detect imbalance, misalignment, looseness (mechanical/electrical), bearing issues, gear problems, capitation, resonance and electrical problems to name a few, which supports improved asset integrity when embedded
within the Maintenance culture.

Ultrasonic Analysis

Ultrasonic analysis has a wide variety of uses. There are numerous examples of applications for detecting failure modes on mechanical, electrical and stationery equipment and components. The data collection methods determine the types of detectible failure modes. Two main methods are contact (structure borne) and non-contact (airborne). Contact methods are used for mechanical applications such as bearing faults, lubrication issues, gear damage and pump cavitations. Non-contact measurements (Airborne ultrasonic analysis) includes pressure and vacuum leaks on compressed gas (including air) systems, hydraulic system defect detection and numerous electrical application to name a few. This highly versatile technology is effective in both Energy Management and Asset Integrity Programmes including slow speed equipment.

Oil Sampling and Analysis

Lubricants are the life-blood of equipment.. To ensure equipment integrity is good, it is highly important to analyse the lubricants (where applicable) to verify that the condition of oil is good and also prove the lubricant is free of contaminants. If contaminants are found, the material/type should be identified to pinpoint the cause of the contamination and rectify the defect. Not only to identify when the oil needs to be changed, but to optimise asset integrity and reliability.

Infrared Analysis (mechanical, stationery & electrical)

Infrared (electrical & mechanical) inspection is a highly effective technique that enables us to locate overheating in MCC's, switchgear, breaker panels, junction boxes and control cabinets caused by poor connections, corrosion, overloads, unbalanced loads mechanical issues and fatigue to name a few.

Steam Trap Analysis

Our team offers a comprehensive, unbiased assessment of your team trap stations with a goal of reducing steam trap failure rates. Our programme covers the complete steam trap station and encompasses: Steam trap testing, Root cause analysis of failures Proper sizing, Isolation valve operation and steam trap station design

Our CM Deliverables

Vibration Analysis
In-Situ Balancing
Ultrasound Analysis
Infrared Analysis
Steam Trap Analysis
Oil Sampling and Analysis
Grease Handling
Fluid Management
Remote Control
Operational Checks
Laser Alignment
CM Assessments

Our Reliability Engineering Deliverables

Walkdowns and Hierarchy
Criticality Analysis
RCA - RCM
FMA - FMECA
Equipment Maintenance Plans
Consequence Classification
Spares Optimisation
Workflow Optimisation

 

 

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Chevron (UK) Project

Chevron UK

 

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Chevron Offshore Adhoc Troubleshooting Solar Generator

Chevron UK Graphs

 

PSW & GEs Machinery Diagnostic and Condition Monitoring Services draw on more than 40 years of offering unbiased diagnostic assistance regardless of manufacturer. We have a proven reputation that we continue to build upon with each project and consultation, ensuring that we will always “call it as we see it” no matter who manufactured, installed, maintained, or operated your machine.

 

Our team is comprised of more than 150 Machinery Diagnostic Engineers, globally distributed, with decades of experience and over 10,000 MDS projects executed.

In January 2016, PSW were asked to carry out an offshore machine diagnostic survey for Chevron UK on their Captain asset. Our Senior CM Engineer mobilised with a 32 channel data recorder for this generator vibration troubleshooting diagnostic scope.

 


Results from scope:

  • No unbalance of the rotor was evident through diagnostics when loading/unloading the Generator
  • New recommendations were givens for Alarms and Gap Voltages
  • The generator train was fully compliant with regulatory VA requirements/monitoring points.
  • 30-40% of procedures improved with better detail, limits and tolerances.

 Chevron UK 2-4-2Chevron UK 2-4-7

PSW Integrity understand the principles of equipment performance and reliability optimisation. Using our proven tools, training and processes, PSW Integrity effectively deliver, in an accelerated approach, the ability to manage customers assets in the most effective, efficient and safe manner throughout the asset lifecycle.

PSW have an in-depth knowledge of asset management implementation throughout decades of experience within the PSW group. We have equipment failure and PM data /case histories from hundreds of global projects and this knowledge and experience is vital to all of our clients to ensure they have world class best practice maintenance within, based on statistics, benchmarks and global standards.

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JDC Drilling Project

JDC Drilling

 

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JDC Drilling RigPSW Integrity/JDC - Project Award

PSW Integrity Limited (Part of PSW Group) are delighted to announce the contract award from Japan Drilling Company, for full asset management implementation on HAKURYU 14 and 15 Jack-up Drill rigs. Both rigs are currently under construction by PPL Shipyard and KeppelFELS at the Singapore shipyard.

“We are delighted to be awarded two further rig contracts to support Japan Drilling Company (JDC) with our full asset management implementation ,using best practice asset integrity management processes” - Ron McKay (PSW Integrity Ltd).

One of our previous optimised asset management programmes, which has been implemented over the past 3 years (successfully completed in April 2015), on HAKURYU 12, NAGA1, HAKURYU 5, was recently evaluated by ABS who reported that over 90% of all technical barriers were effectively managed and assets were performing and managed well. PSW Integrity and JDC have an excellent working relationship, built on trust and integrity from previous rig implementations. We have worked together, reviewing and implementing workflows, optimising procedures, carrying out criticality analysis/consequence classification, failure mode analysis, RCM studies and writing Preventative Maintenance (PM) and Condition Monitoring (CM) programmes with our cross functional analysis teams to deliver world class asset management services, whilst conforming to all corporate, operational and regulatory requirements.Dashboard Readout

JDC has also purchased the cloud and iPad based, optimised operator care programme, developed by PSW Integrity and HASH mobile for the complete deliverable of asset integrity management. With our partner “Hash Mobile” we develop and manage a reporting platform to enable rig operators to easily report on asset condition based on daily/weekly routines. The data is collected using Hash Inspector and seamlessly synchronised with Hash Cloud where the data is visualised in an asset hierarchy and visual dashboard for easy trending of asset data to optimised rig operations.

PSW Integrity understand the principles of performance and reliability optimisation. Using our proven tools, training and processes, PSW Integrity effectively deliver, in an accelerated approach, the ability to manage customers assets in the most effective, efficient and safe manner throughout the asset lifecycle.

PSW have an in-depth knowledge of asset management implementation throughout decades of experience within the PSW group. We have equipment failure and PM data /case histories from hundreds of global projects and this knowledge and experience is vital to all of our clients to ensure they have world class best practice maintenance within, based on statistics, benchmarks and global standards.

 

 
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PSW Integrity Floatel RCM Project

PSW Integrity - Case History

 

Floatel RCM Project

 

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PSW Integrity/Floatel RCM - Project Award 

 

PSW Integrity Limited (Part of PSW Group) are delighted to announce the contract award from Floatel International, for RCM analysis of Fleet critical equipment. After carrying out consequence classification Floatel International identified that further analysis of their critical equipment was reqPSW - Japan Drilling Enduranceired to ensure the items and systems are managed correctly to meet operational and regulatory requirements.

PSW Integrity have evaluated 28 different systems. The RCM studies have identified many different actions which, when implemented, can deliver significant improvements in operation and reliability, including revised spares, redesigns and task optimisations/improvements. 

The results were developed through valuable input (based on experience and knowledge) from the Floatel staff and PSW Integrity facilitators, using the RCM tool and processes to optimise the results.


Results from execution of RCM analysis:

•    Significant man hours saved through optimised task  frequencies and content.
•    All new tasks address failure modes
•    Fully compliant with regulatory requirements.
•    30-40% of procedures improved with better detail, limits and tolerances.

PSW - Japan Drilling Superior

 

PSW Integrity understand the principles of performance and reliability optimisation.

Using our proven tools, training and processes, PSW Integrity effectively deliver, in an accelerated approach, the ability to manage customers assets in the most effective, efficient and safe manner throughout the asset lifecycle.

PSW have an in-depth knowledge of asset management implementation throughout decades of experience within the PSW group.

We have equipment failure and PM data /case histories from hundreds of global projects and this knowledge and experience is vital to all of our clients to ensure they have world class best practice maintenance within, based on statistics, benchmarks and global standards.

 

 

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