Navigating the reliability journey

Posted on 15 Oct 2024 by The Manufacturer
Partner Content

In today’s advanced manufacturing environments, the pressure to maintain uptime while managing complex operations has never been more intense. Unplanned disruptions, such as transport delays and supplier instability, are highlighted as a major risk in The Manufacturer’s latest Supply Chain Risk and Resilience Report and pose an ongoing threat to productivity, profitability, and business continuity. The modern approach to addressing this challenge requires a shift in mindset focusing on reliability as not simply a maintenance goal but a critical strategic priority. 

This shift is what we at ERIKS refer to as the “Reliability Journey”—a comprehensive, phased approach to managing critical assets. Rather than reacting to equipment failures as they occur, manufacturers can take a more proactive stance, embedding reliability into the core of their operations. This approach not only improves asset performance but helps build resilience in the face of supply chain volatility and growing customer demands. 

One of the most important elements of this journey is modern, integrated, approach to condition monitoring. By capturing real-time data on key indicators like temperature, vibration, and lubrication, manufacturers gain visibility into the health of their assets. With this data in hand, maintenance teams can intervene before small issues become major failures. But data alone isn’t enough. It’s the combination of smart, digital tools and expert, hands-on assessments that makes the difference. This dual approach ensures that maintenance decisions are both timely and effective, resulting in less downtime and more efficient operations. 

In more proactive approaches, preventative maintenance systems can be used by reliability service providers to monitor real-time data, address warnings before they escalate into critical failures, and ensure that necessary work is scheduled and costed for customer approval. Prioritising these tasks helps avoid disruptions, especially for those who may not always have the resources to act on potential issues quickly enough. 

With increasing adoption of digital technologies, Smart Asset Management (SAM) platforms have become a vital part of this equation. These platforms allow manufacturers to analyse the real-time performance of critical assets, moving beyond traditional maintenance schedules to predictive models. With these tools, businesses can anticipate potential problems and schedule maintenance before they disrupt production. This proactive approach significantly reduces unplanned downtime, extends the life of equipment, and enhances operational efficiency. 

Yet not every company is at the same stage in their reliability journey. The needs of a manufacturer just beginning to explore predictive maintenance are very different from those of a company with more established digital monitoring systems. A flexible, tailored approach is essential. For some, the process starts with basic condition monitoring and gradually evolves into a more comprehensive asset management strategy. Others may require fully integrated digital solutions and ongoing programme management to ensure long-term success. 

Customising reliability solutions to match a company’s unique operational needs ensures that no matter what stage a business is at, it receives the right level of support. This tailored approach allows manufacturers to move at their own pace, adopting new technologies and strategies as they see fit. It also acknowledges that some companies will need more guidance and expertise, particularly in interpreting data and making proactive maintenance decisions. 

However, technology alone won’t transform reliability. Long-term success depends on strong programme management and collaboration. Dedicated programme management is vital to coordinating the various aspects of a reliability strategy, from condition monitoring and data analysis to intervention planning and execution. Effective programme management not only ensures smooth implementation but also facilitates continuous improvement, helping companies stay ahead of emerging challenges and opportunities. 

A key challenge in improving reliability is fostering a cultural shift within an organisation. It’s not enough to rely on data or smart technologies; maintenance teams need to be empowered to make informed decisions, fostering collaboration across departments, and ensuring that the value of reliability is understood throughout the organisation. 

The reliability journey also aligns closely with broader sustainability goals, as reliable equipment operates more efficiently, reducing both waste and energy consumption. The approach encourages manufacturers to think in terms of long-term asset health, not just immediate performance, thus contributing to a circular approach that extends the life of critical equipment and minimises resource usage. 

As manufacturers continue to face rising operational complexities and the threat of supply chain disruptions, adopting a strategic approach to reliability is more important than ever. The question is not whether manufacturers should embark on a reliability journey, but how they can customise the approach to meet their specific needs and circumstances. By embracing a combination of smart technology, expert insights, and strong programme management, manufacturers can minimise downtime, improve operational efficiency, and secure their place in the future of resilient manufacturing. 


Navigating the reliability journey Pamela Bingham is the CEO of ERIKS UK & Ireland, a specialised Industrial Service Provider. With more than 25 years’ experience she is a qualified solicitor and has served as the turnaround CEO of an international manufacturing and building product supply businesses with a turnover of circa €500m. In addition, she has served as a NED in a FTSE 250 business as well as being an International Divisional Compliance Director for a Fortune 500 company.


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