Reliability Academy

How it works

Escape the vicious cycle of reactive maintenance

The Road to Reliability Framework: a simple four-part framework to reduce your downtime by up to 90% and create a Reliable Plant. Implemented by your own team, not an army of consultants.

The problem

Why plants get stuck

Most plants start their life with lots of defects from design, construction and commissioning. Those defects lead to repeat failures. Add to that an ineffective PM program that consumes scarce resources unnecessarily. The result is low reliability and high maintenance costs.

Over time that creates a reactive environment. Firefighting becomes the norm, and productivity collapses: industry studies consistently put wrench time in reactive organisations at just 25 to 35%. So your crew is stretched doing the work in front of them, and there’s simply no time left to remove defects or fix the PM program.

This is the vicious cycle of reactive maintenance. And to break it you need to tackle three things: create a productive working environment, make your PM program effective, and eliminate your defects.

The vicious cycle of reactive maintenance

Beliefs hold you back

Why plants STAY stuck

Most organisations don’t stay stuck in the vicious cycle of reactive maintenance because they want to. They stay reactive because they’ve been convinced that improving reliability is complicated, that it can’t be done without an army of external consultants, and that it needs a big upfront investment. All three beliefs are wrong, and they push plants toward exactly the things that don’t work.

“Improving reliability is complicated”

So organisations look for silver bullets to tackle the reliability problem: they reach for new, expensive software or technology, but it adds complexity, instead of removing it.

“We can’t do it without an army of consultants”

So improvement gets outsourced. But the change management is skipped, and when the consultants leave, the knowledge and the improvements leave with them.

“It needs a big upfront investment”

So nothing starts until there’s a big budget. But done in the right order, each step pays its own way: you don’t need approval for a five-year program, you just need to start.

We see it differently. Reliability is simple when you get the basics right, your own team can implement it, and done in the right order it pays for itself as you go.

The framework

Four essential elements. Nothing more.

There are many frameworks for improving reliability. Most are unnecessarily complicated: the temples and pyramids with 20 or 30 acronyms that you’ve probably seen at conferences.

But the best performing plants in the world don’t get there by doing 30 things. They get there by doing the few basics that really matter, and doing them really well. That’s why the Road to Reliability Framework™ has just four Essential Elements:

Now, this framework is not just our opinion. In the 1990s, research spearheaded by Winston Ledet studied a very large group of manufacturing sites around the world, across many industries. That research found that reactive plants typically achieved an uptime of around 83.5%, while the best performing plants achieved uptimes in excess of 98%, by focusing on planning and scheduling, preventive and predictive maintenance, and defect elimination.

Waterfall chart of the research behind the Road to Reliability Framework. From a reactive-plant baseline of 83.5% uptime, planning alone adds 0.5 points and scheduling alone adds 0.8, while PM or PdM alone loses 2.4. All three tactics together reach 88.6%. Defect elimination adds a further 9.7 points, reaching 98.3% uptime in proactive plants.

Source: research spearheaded by Winston Ledet in the 1990s [Ledet 1994].

How we work

A series of focused sprints, not a multi-year program

You have probably been told that reliability is a marathon, not a sprint: years of effort, millions in investment, an army of specialists. We understand why people say it. But that marathon mindset creates two serious problems.

Most of us can’t run a marathon

You could train yourself to finish one, with enormous effort. Now try getting your whole team to run one. That is what happens to most multi-year programs: they lose steam somewhere in year two, people drift back to old habits, and the organisation concludes that reliability doesn’t work here.

Leadership won’t fund a marathon

In a reactive plant, maintenance is seen as a cost rather than a profit centre. Walk into that boardroom with a multi-year plan, significant money up front and payback far in the future, and you won’t get the yes you need. Most senior leaders are judged on quarterly results.

And it gets worse. When organisations hit the marathon’s brick wall, they start looking for shortcuts: a shiny new CMMS, advanced sensors, RCM across the whole plant. Those tools have their place, later. But none of them will fix a broken working environment. Silver bullets don’t exist.

The IT industry solved this exact problem years ago. They stopped running massive, multi-year software projects that failed more often than they succeeded, and moved to agile: a series of short, focused sprints, each delivering something of value.

We apply the same thinking to reliability improvement. Instead of one giant program, you run a series of Reliability Sprints™: shorter, focused improvement efforts, each targeting one element of the framework, each delivering measurable value in months rather than years.

The order

The order matters

So how do the four elements become a roadmap you can actually follow?

Start with the destination. You need your three core work processes (planning and scheduling, preventive maintenance and defect elimination) implemented, working well, and supported by a culture that is focused on reliability. For most organisations, that is a long way from where they are today. And between here and there sits a lot of resistance: from leadership, from operations, sometimes from your own maintenance team.

That is why you break the journey into four Reliability Sprints™, in a logical sequence. And notice that leadership and culture is not a sprint of its own: it runs underneath the entire journey. Early on, the focus is leadership, driving the change. As you progress, the focus shifts to culture, sustaining it.

The roadmap to creating a reliable plant: five steps, starting with Reliability Strategy, then Planning & Scheduling, Preventive Maintenance and Defect Elimination, ending in continued improvement. Leadership and Reliability Culture run underneath all five.
  1. Sprint 1: Reliability Strategy

    Before you change anything, get clear on where you are, where you’re going and why. Without this clarity you will struggle to overcome the natural resistance in the organisation.

  2. Sprint 2: Planning & Scheduling

    Always the first work process to fix. It lifts productivity by up to 35%, pays for itself quickly, and creates the stable environment every later step depends on. Expect 6 to 12 months to make a massive improvement.

  3. Sprint 3: Preventive Maintenance

    With stability established, fix your PM program: cut the 40–60% of tasks that add little value, and close the gaps where critical tasks are missing.

  4. Sprint 4: Defect Elimination

    Now hunt down your repeat failures for good. You’ll steadily move from forever fixing to fixing forever, and your plant will tell you what to work on next.

Throughout: Leadership & Culture

Not a sprint of its own, but the thread that runs through every sprint. You lead the change, and you progressively build the culture that holds each gain in place.

Working proof from the plant floor.

TIP Trailer Services logo

TIP Trailer Services

Trailer rental · 140 workshops

16%

direct
productivity
gain

TIP Trailer Services trained 100 employees from Workshop Managers to Technicians in Maintenance Planning & Scheduling and saw direct workshop productivity increase by 16%, sickness ratio reduced by 33%, and profit increased by 7-figures.

Today we do exactly what is proposed in the course: a weekly schedule, backlog review and daily planning. Work orders are identified, prioritised, planned.
Didier Felice, VP Mediterranean Region

Case study 1 / 11: TIP Trailer Services case study

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4.5

/5

feedback rating

from 1,015 verified learners

92%

Rated 4–5★

930 of 1,015 ratings

98%

would recommend

to a peer in the industry

★★★★★

This course is really informative, with great materials, and Erik is hugely knowledgeable and a real industry expert.
MR

Mike Rooney

Maintenance & Reliability Manager · United Utilities · United Kingdom

★★★★★

I came away from this course with a structured approach to planning and scheduling, and real clarity on everyone's roles and responsibilities - especially between the planner and the supervisor.
FM

Fikile Mahlangu

Reliability Manager · Enstra (Kimberly-Clark) · South Africa

★★★★★

This course is well made, packed with material and genuinely engaging. The content is relevant and fully applicable - it even gives you the recipe for how to implement it. I've never seen anything like this before.
FZ

Francisco Zapata

Maintenance Manager · ERCO Worldwide · Chile

★★★★★

I've already recommended this course - we've enrolled four of our own people, including a senior supervisor and two superintendents, and I've passed it on to a mine I used to work at.
MB

Michael Buckley

Mill Senior Planner · Equinox Gold · Canada

FAQs

Frequently asked questions

Will this work for our complex operations?

Yes. The framework is designed for asset-intensive industries like mining, oil & gas, chemicals and heavy manufacturing, and is proven in the most reactive environments, with budgets of any size.

Do we need consultants to implement it?

No. That’s the point. The framework is built for your own team to implement. If you want support on the ground, coaching and sprints are available, but they’re optional.

How long before we see results?

First wins, like better schedule compliance and fewer surprises, typically show up in weeks. Measurable, sustained change takes 6–12 months, faster with coaching alongside the training. And embedding it so deeply that it survives staff turnover is a 2–3 year effort, which is why the training is built for your team to own, not for us to drive.

What if trained staff leave?

Our Turnover Guarantee means if a trained team member leaves within two years of starting a course, we train their replacement for free. And every enrolment is covered by our 30-day satisfaction guarantee: if the training isn’t a fit in the first 30 days, we refund every seat.

Where should we start?

Planning & Scheduling for most teams; a Reliability Strategy Sprint if you’re leading the change. If you’re not sure, the free scorecards will show you your weakest area.