Plant Hexcellence™ Model 2017-08-25T05:03:09+00:00

Our Plant Hexcellence™ Methodology


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Plant Hexcellence™ drives culture change. People drive sustainability.

Your organization’s success starts with your people. Our 5-facet approach will give your people the skills to drive sustainability. Sustainability is a struggle all companies face at one time or another, and chances are you’ve found yourself in a difficult situation regarding the sustainment of asset management and reliability. The best way to sustain these efforts long-term is through people. For some companies, that may require a culture change, while others may need to start with an assessment of the organization’s structure. Regardless of where you begin, creating a sustainable model requires your people to have the right skills, mindset and knowledge. The Plant Hexcellence™ Model, based on adaptability, applies the “Fit for Purpose” philosophy and methodology to all facets of the People cell, and serves as a backbone for sustained change within your organization.

Areas of assessment:

  • Organizational Structure
  • Organizational Development
  • Mission / Vision
  • Assessment / Training
  • Change Management
  • Continuous Improvement
  • Sustaining Philosophy
  • OpEx Strategies
    • Lean
    • TPM
    • 5s / 6s
    • Six Sigma
    • Self-Empowered Work Teams

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Maintaining physical assets, facilities and equipment is critical to your organization’s success. The Plant Cell encompasses more than just physical assets–it also includes the methods, risk evaluation and mitigation strategies you’ll employ to keep your plant performing optimally. Your asset management plan should allow you to answer the following: What to maintain? How to maintain? When to maintain? Who to maintain? Where to document what was accomplished? What is the cost involved? What is the consequence of non-conformance?

Areas of assessment:

  • EAM / CMMS
    • Evaluation & Selection
    • Implementation
    • Optimization
  • Risk-based Criticality Analysis and Ranking
  • Mitigation Strategies Development
    • Reliability Centered Maintenance (RCM)
    • Failure Modes Effects Analysis (FMEA)
    • Condition Based Maintenance (CbM)
    • Predictive Maintenance (PdM)
    • Maintenance Task Analysis (MTA)
  • Preventive Maintenance Program Optimization
  • MRO Inventory and Spare Parts
    • Critical Sparing Strategy
    • Inventory Accuracy
    • Max/ Min Calculations
    • ABC Methodology
    • Cycle Count Strategy and Engagement
    • FIFO/LIFO
    • Warranties
  • Physical Asset Program
    • 3 and 5 year Capital Plan
    • Capital Budget
    • Turn Around / Outage
  • Asset Integrity Management Programs
    • Process Safety Management (PSM) Compliant

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Improving, creating and mapping processes will allow smoother, more consistent execution of asset maintenance and reliability. The Processes Cell focuses on improving productivity, reducing operating expenses, mitigating risk and improving safety through coordinated efforts to create and execute a sustainable, long-term plan.

Areas of assessment:

  • Work Flow Mapping and Implementation
  • Work Identification
  • Planning
    • Planner Training and Certification
    • Turn Around / Outage Planning
  • Scheduling / Coordination
  • Work Execution
  • Post Work Audit / QA/ QC
  • Requisition / Purchase of Spare Parts
    • Max / Min
    • Direct / Indirect Approval
  • Startup / Shutdown
  • Management of Change (MOC)
  • P&ID Update and Redlining

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The Plant Hexcellence™ Model drives organizations to standardize policies, procedures and methods of delivery across all locations. Policies and procedures allow world-class organizations to achieve consistent delivery and execution of best practices. Though often ignored, policies and procedures are effective ways to save your organization time, money and even lives.

Areas of assessment:

  • Safety
    • PSM
  • Incident reporting
  • ISO
    • 55000
    • 14000
    • 18000
  • Process Safety Management (PSM)
  • Good Manufacturing Practices (GMP)
  • Federal Drug Administration Validation (FDA)
  • Root Cause Failure Analysis (RCFA)
  • Management of Change
  • Engineering, Design and Drawing Specifications
  • Document Management
  • Asset Naming
  • Permitting
    • Lock out / Tag out (LOTO)
    • Confined Space Entry
    • Hot Weld

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Related to performance, “if you can’t measure it, it doesn’t exist”. That being said, it is easy to overwhelm and distract an organization with too many or the wrong KPIs. There are well over 150 commonly used KPIs in the industry, but it would be impractical to track them all. Using the Plant Hexcellence™ model, we will identify, define and document the most effective KPIs suited to your needs so you can make the best informed decisions concerning your plant.

Areas of assessment:

  • Manpower
  • Maintenance
  • Methods
  • Machines
  • Money
  • Materials
  • Mandatory

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Proactive Maintenance is key to successful organizations’ long-term strategies for managing costs and equipment. Using modeling, analyses and audits in conjunction with proactive maintenance measures can ensure smoother operations, resulting in less downtime and money.

Areas of assessment:

  • RAM Modeling
  • Weibull Analysis
  • Assessment / Audit
  • Preventive Maintenance
  • Operator Basic Care
  • Predictive Maintenance
    • Visual Inspection
    • Vibration
    • Thermography
    • Tribology
    • Ultra-sound
    • Motor Current Analysis

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