OnePM®
Executive Summary
A major global chemical company was challenged by inconsistent approaches to Root Cause Analysis (RCA) which were delivering mixed results. The client wanted to embed a standard approach to investigations using OnePM® to provide visibility of learnings across multiple sites.
ARMS Reliability was engaged to lead this project which has involved training, change management, and the rollout of OnePM® to more than 40 sites across Africa, Asia, and Europe.
The client is now benefitting from more consistent and quality investigations as well as a connected data set which allows it to leverage learnings and solutions across sites. Additional results include:
- More than 220 investigations undertaken in nine months with 60% closed within the same period
- Millions of dollars in savings with one investigation alone resulting in savings of more than a half million US dollars
- Greater ability to apply solutions to like assets and prevent recurrence of problems
The Problem
The client’s previous approach to RCA was unstructured. There was no alignment on which events required an investigation and when investigations were conducted, and there was no common process to follow. Another issue was that sites lacked an effective way to track investigations through to resolution.
As an asset heavy business with mission critical operations, the client needed a standard approach for RCA that would help sites conduct quality investigations and generate effective solutions. It also wanted a system that would support the execution of solutions and prevent recurrence of problems.
The Solution
The client chose to adopt a standard RCA methodology that would produce an evidence-based understanding of problems and generate solutions that address proven causes.
ARMS Reliability worked with the client to drive the adoption of the RCA methodology across more than 40 sites in multiple countries. This involved establishing clear trigger points for when investigations should occur and upskilling more than 70 employees to act as RCA facilitators and subject matter experts. Most of the training was delivered remotely through webinars and complemented by internal user group sessions.
OnePM® was deployed to remove data silos and provide a centralized system for tracking and reporting on investigations and solutions. This has enabled RCA to be managed as a central activity and facilitated the sharing of knowledge and best practices. For example, the client can now apply learnings from one investigation to prevent the same failure from occurring to similar assets at other sites.
The Benefits
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