Reliability Program


In the past, Hagen’s approach has focused on improvements that deliver immediate results, addressing breakdowns to prevent recurrence.

A long-term client that had achieved significant results using our methodology informed us they would like to start a reliability program to address breakdowns preemptively. Out of courtesy, they told us they were seeking a reliability partner to work alongside with. All of the organizations they approached were focused primarily on large, unplanned events with an undeveloped understanding of their priority versus other causes of loss. Our client asked for our help to customize an in-house reliability solution that would dovetail with everything we had achieved to date.

Together, we created a reliability program that both pays for itself and delivers rapid, reliable, improvements.


Results

These results were delivered within the first six months of initiating a blended Hagen Reliability program:

  • 34% increase in units produced per production hour
  • 54% reduction in emergency calls resulting in downtime
  • Productivity increase from 44% to 70%
  • Number of minor stops decreased by 38%
  • Decrease in overall safety risk, due to less unplanned machine interaction
  • Improvement in Employee Satisfaction, due to less unplanned work
  • Reduced staff turnover

Where do you need results like this in your organization?


Tools
C.A.L.L.




A rollout of Hagen’s sustainability initiative includes the usage of our Contamination, Alignment, Lubrication and Looseness standards, designed to provide a manageable way to keep the team accountable on the basics of the four common causes of equipment failure.

The C.A.L.L. card reinforces applying the principles learned in a one-week Hagen Reliability Boot Camp.

Usage of C.A.L.L. standards significantly increases the life of machines and machine parts. It focuses intently on eliminating anything putting unnecessary wear and tear on a process.


Maturity Matrix

  • Tool to achieve best-in-class performance
  • A gap assessment indicator, based on best in class
  • metrics, to assess an organization’s degree of maturity.
  • Provides a roadmap to achieve reliability goals
  • Builds a strategic action plan to follow, allowing for realistic, 6-12 month improvement targets