Reliability & Performance Transformation
Stop firefighting. Start managing reliability.
Transform maintenance into a driver of availability, output and profitability. Unplanned downtime is not simply a maintenance problem: it reduces saleable tonnes, increases cost per tonne, consumes skilled resources and destabilizes quality.
Diagnose | Design | Implement | Sustain
- Diagnose
- Design
- Implement
- Sustain
Maintenance is a business lever
Reliability directly influences plant performance.
More saleable tonnes
Reduce repeat failures, increase equipment availability and recover production capacity.
Lower lifecycle cost
Optimize preventive maintenance, spare parts, contracts, resources and equipment lifecycle decisions.
Stable process capability
Control the equipment conditions that contribute to process instability and product defects.
Safer, more resilient operations
Strengthen critical-asset controls, compliance and maintenance discipline.
A measurable plant transformation
Not another maintenance study.
The difference between a study and a transformation is implementation. ECONS does not stop after identifying the problems. We remain involved through the design, deployment and sustainment of the new reliability system, structured through defined stage gates so each phase has clear deliverables and a value check before the next step.
We do not leave you with a presentation. We help make the new system work.
01 / Diagnose
Understand the facts.
02 / Design
Build the right reliability system.
03 / Implement
Take the system live on the shop floor.
04 / Sustain
Transfer ownership and continuously improve.
Our reliability transformation services
Nine building blocks, implemented in sequence.
01
Reliability diagnostic
Downtime and production history, maintenance cost, manpower and contracts, asset register, CMMS data, critical spares, quality losses, energy and safety events, turned into a baseline KPI pack, value-at-stake, priority assets and an implementation roadmap.
02
Reliability maturity assessment
Eight capabilities scored from reactive to optimized: strategy and governance, organization and skills, work management, PM and PdM, spares and procurement, CMMS and data, shutdowns and projects, safety and compliance.
03
Reliability operating system
One system around the plant, not around departments: governance, asset strategy, work management, people, digital and CMMS, and supply chain.
04
Failure-mode-based maintenance
Stop maintaining the calendar, maintain the actual failure risk: criticality and functional analysis, failure-mode analysis, task selection, standardized job plans and optimized intervals.
05
Work management
Detect, screen, plan, backlog, schedule, execute, close and learn. Emergency-work governance, planner and scheduler roles, weekly scheduling, material staging and failure coding.
06
Reliability engineering
Bad-actor elimination, root-cause analysis, condition monitoring across vibration, oil, thermography, ultrasound and hydraulic health, precision maintenance and a structured defect register.
07
MRO and critical spares
Protect uptime without filling the warehouse: critical-spares strategy, min and max levels, repairable loops, vendor frameworks and obsolescence management with one, three and five year plans.
08
Implementation
Hands-on deployment and coaching, phased from foundations and critical assets to plant-wide, including CMMS go-live, PM optimization, RCM rollout and predictive routes.
09
Capability transfer
Build internal reliability capability across managers, reliability engineers, planners, supervisors, technicians and operators, with competency matrices, certification paths and quarterly audits.
Built for aluminium extrusion
The press rarely fails alone.
We understand how the parts of an extrusion plant depend on each other, so the production bottleneck and the interfaces between equipment are managed as one integrated system.
Log heating
Log furnace, hot shear, billet loader, temperature control
Extrusion press
Hydraulics, pumps, cylinders, container, die slide, PLC, safety systems
Run-out & handling
Puller, quench, stretcher, saw, conveyors, stackers
Ageing & heat treatment
Ovens, burners, fans, controls, handling systems
Surface treatment
Anodizing, powder coating, rectifiers, pumps, dosing, cranes
Utilities & tooling
Compressors, cooling water, gas systems, EOT cranes, die-shop equipment
Measurable results
Reliability must be visible in the P&L.
Leading indicators
- PM compliance
- Schedule compliance
- Planned vs emergency work
- Backlog readiness
- RCA closure
- Spares service level
Reliability outcomes
- MTBF
- MTTR
- Repeat failures
- Critical-asset availability
- Bad-actor closure
- PdM-detected defects
Business outcomes
- OEE and availability
- Saleable tonnes
- Maintenance cost per tonne
- Quality loss
- Energy per tonne
Reference benchmarks used within the programme
< 15%
Reactive work
> 90%
Schedule compliance
~ 55%
Wrench time
Rising
Sustained MTBF improvement
Near zero
Critical spare stock-outs
These are reference benchmarks. Client-specific targets are established during the diagnostic, based on the plant's actual baseline, equipment and business priorities.
What we typically find
Stop managing breakdowns. Start managing failure before it happens.
Many extrusion plants still operate in an environment where skilled maintenance teams spend too much of their time reacting. The result is a plant that may be producing, but not predictably.
- Recurring failures
- Emergency work dominating the schedule
- Preventive maintenance based on calendar intervals rather than failure modes
- Poor planning and scheduling discipline
- Inconsistent CMMS data
- Spare-part shortages
- Excess inventory in the wrong components
- Weak root-cause elimination
- Knowledge concentrated in individual technicians
- Limited condition monitoring
- Maintenance and production working reactively rather than as one system
Flexible entry points
Start where your plant needs it most.
2 to 4 weeks
Reliability diagnostic
Feasibility, maturity assessment, value-at-stake, priority roadmap
6 to 10 weeks
Reliability system design
Operating model, asset strategies, work management, CMMS, spares, KPIs
12 to 18 months
Plant-wide transformation
Phased implementation, field coaching, reliability routines, governance
Ongoing
Performance assurance
Quarterly audits, KPI reviews, RCA facilitation, remote expert support
Start small. Prove the value.
Start with a 2 to 4 week reliability diagnostic.
A focused diagnostic establishes where you are today, where production value is being lost, which assets need immediate attention, and what the reliability gaps and the value at stake are.