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Tale of Contents

Executive Summary ..................................... 1

Business Case for Change .............................. 3

Sustained Reliable Operations......................... 5

Reliable Capital Delivery ............................... 9

Design/Build Services ................................ 10

Engineering Services ................................ 11

Installation, Commissioning,and Operational Support Services................ 12

Workforce Selection andDevelopment Support Services .................... 13

Reliable Maintenance Execution ..................... 15

Personnel Qualifications andWork Execution Standards ......................... 23

Training Classes ......................................... 25

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Executive Summary

GPAllied is the most diverse reliability and operations consulting and services company in the world. Combined, our unrivaledtechnical expertise, solutions portfolio and global reach help you achieve rapid bottom-line improvement and sustainedcultural change.

GPAllied’s diversity and expertise result from joining together firms with experts in Maintenance and Reliability, OperationalExcellence, and Workforce Development. This winning team allows us to offer you expertise in the fields of Lean, ReliabilityEngineering, Six Sigma, Condition Monitoring, Change Management, Maintenance Planning and Scheduling, WorkforceDevelopment and Maintenance Craft Skills training. However, only GPAllied can offer you solutions that fully integratethese specialties.

To ensure that GPAllied provides you with latest thinking and proven best practices, we have attracted recognized experts to ourteam, benchmarked best-in-class operations and connected with thought leaders throughout the industry. Furthermore, weensure that our project team members have technical expertise, as well as expertise as trainers and mentors through a rigorousqualification process and the establishment of work execution standards.

GPAllied has modeled their deliverables based on the following core beliefs:

1. The reason our clients are in business is to make money2. The first step to ensuring profitability is to have reliable “systems”3. The term “system” speaks to the combination of the people who operate the equipment, the processes they follow

to operate the equipment and the equipment itself4. The definition of reliable is: the ability to perform a given task, at a stated rate, for a given period of time, under a

given set of circumstances5. The organization must be motivated and prepared for any change to be sustainable6. Having successfully attained reliability, sustaining the improvements is paramount to on-going success7. Optimization is achieved through the use of a culture of continuous improvement8. Clients require a rapid return on investments

To that end, GPAllied offers you a complete suite of solutions in the following categories:

Driven by: Category: Governed by:

Certificationand Standards

Sustained Reliable Operations

Reliable Capital Delivery

Reliable Maintenance Execution

Optimization

Business Casefor Change

KPIs/BenefitsTracking

GPAllied prides itself on two (2) things: our passion for helping the client and the flexibility of delivery methods.

Our passion is driven by the satisfaction of seeing our company help our customers build, utilize and realize the power of theReturn on Asset Reliability (ROAR™).

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Our flexibility in delivery methods comes in any one of four (4) different ways. Each way specifically customized to meet theunique needs of the client. Those four (4) ways are:

TrainingGPAllied offers all of our deliverables as classes for the client who prefers to implement using their own people.

CoachingFor the client who wants more than a training solution, but still prefers to implement using their own personnel, GPAllied offersa combination training/coaching package. The training class is augmented by a regimen of coaching and mentoring by ourexperienced consultants.

ServicesSome clients prefer to contract out certain functions. GPAllied can deliver our services to the client in one of two forms:

• Project Based – GPAllied personnel are on-site for the duration of the project• Full Time Equivalent (FTE) – GPAllied personnel are on-site, full time as contracted employees

ConsultingWhether you are starting a major change initiative or looking for the best way to improve performance, GPAllied’s consultantsguide you as you set your direction, design and deploy your approach, and realize results.The GPAllied vision is to be the premier global provider of sustainable transformation driving improved customer operationaland reliability excellence. To that end, we believe the best way to make our vision a reality is to optimize customer businessperformance through customized solutions utilizing our experienced people, innovative processes, and proven technologies.Thus achieving operational and reliability excellence sustained through the use of cultural change management with therelentless pursuit to deliver the highest return on investment.

GPAllied’s expert team provides unparalleled solutions. You can count on us to provide the following:

• A strong foundation to ensure that your organization’s systems reliably meet customer needs with lower cost• A roadmap to build upon that foundation to streamline your processes and help you achieve a culture of sustained

continuous improvement• Consultants and trainers with technical expertise, interpersonal skills, and drive to work effectively with your team• Effective training to develop your people• Solutions customized to fit your needs, drawing from a diverse range of methods and services• A rapid return on your investment

This Capability Document outlines the key deliverables our team can provide.

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Business Case for Change

Establishing a business case for change is a necessary first step in most implementations. Understanding that the effectivenessand efficiency of the assets employed are what drive the financial performance of a company, a new metric called Return onAsset Reliability (ROAR™) shows the financial impact of uncovering the hidden potential in the currently installed asset base.With ROAR™, a higher return can be realized with little to no capital investment. ROAR™ is the primary driver behind buildingyour business case for change.

Recognizing that business needs vary, GPAllied offers several alternatives for developing your business case:

• Maturity Analysis (Levels of Achievement)• Theory of Constraint (TOC) Analysis• Value Stream Mapping and Planning·• Lean Opportunity Analysis• Change Readiness Survey• Benchmarking

Understanding the financial impact of system failures and inefficiencies are only part of the story, a complete analysis of thecosts associated with conducting an improvement initiative also involves items like:

• Internal Labor Costs (including Overtime) • # of Machines• Contractor Costs • Bill of Materials Accuracy• Downtime Costs • Repair Costs• Energy Costs • # of Planners• Scrap/Rejects/Return Costs • # of Engineers dedicated to Maintenance• Staffing Changes • # of PdM Personnel• Power Consumption • Amount of PdM Hardware and Software• Current PM Program Evaluation • Future PdM Design Changes• Evaluation of the Plant Culture • Length of Project• First Time Through Quality • Process Cycle Time• Rolled Throughput Yield • Product or Part Variety• Dock-to-Dock Flow Time • Lead Time• Inventory Turns • Total Production and Maintenance Space• Customer Demand

Maturity Analysis (Levels of Achievement)GPAllied’s maturity matrix provides an innocence-to-excellence rating for each element of excellent maintenance and productionsystems. It provides a baseline view and identifies gaps to the desired state for elements such as workplace organization, operator-led equipment care, maintenance work cycle, problem solving, continuous flow, inventory management, leadership, metrics,management systems, business results and many other elements. GPAllied provides this service separately or in concert with othermore-analytical analyses; and can provide it in a form that’s biased toward maintenance systems, or production systems, or both.

Theory of Constraint (TOC) AnalysisTOC analysis focuses on those problems which most directly affect the P&L statement, not simply where increased performanceis possible. When looking at the system as a whole, increasing individual performance may not increase the performance of thesystem. TOC analysis can be applied to the manufacturing and processing environment and to the sales, marketing andaccounting environments as well.

GPAllied provides this service to help you identify the constraints of your critical systems and focus your improvements effortsthere first.

• Transformational Analytics• Process Simulation Modeling• Key Performance Indicator Development• Process Waste Analysis• Day in the Life Of (DILO)

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Value Stream Mapping and PlanningGPAllied facilitates a comprehensive analysis and planning process that results in a detailed transformation master plan andbusiness case for improvement. This process, also known as shikumi, includes initial data gathering, current state value streammapping analysis, summary of the current state in terms of waste and key characteristics, targeted training, future state visiondevelopment, and transformation planning. GPAllied provides this service in several ways: performing the value stream currentstate analysis only either facilitating your cross-functional team, or via a series of interviews and observations, or facilitatingcompletion of the current and future states and transformation plan.

Lean Opportunity AnalysisGPAllied provides an in-depth, analytical process to rigorously define the baseline of the current situation, assess the company’scurrent competitive needs, and to use Lean, Six Sigma, and Reliability principles to design a new set of processes that achievequantum-leap improvement in order-fulfillment (typical duration of 2 weeks). This process fully integrates the views of Lean, SixSigma, and Reliability. This results in a comprehensive redesign of operations, maintenance, quality support for production,inventory management, and may include the value chain beyond your facility. For example, this analysis may result inrecommended changes to facility layout, location and reporting relationships of quality and maintenance staff, actions forimproving equipment uptime, and other specific recommendations.

Change Readiness SurveySuccessful change is a function of elements such as leadership, vision, metrics, means, resources, and others. GPAllied surveysemployees and managers to determine the current perceived state for each of these elements. The analysis highlights differencesin perception between different organizational levels and work groups and provides direction on changes needed to ensuresuccess of the change effort.

BenchmarkingBenchmarking is a powerful way to see the potential for performance improvement first hand. GPAllied provides training in astructured benchmarking process and arranges and facilitates benchmarking study missions.

Transformational Analytics™The GPAllied team has quantified hundreds of millions in savings potential for clients using Process Reliability analyses todeliver measurable results focused to increase first-pass product yield, improve variable margin, capital effectiveness andcustomer satisfaction.

Strategically, the results have helped businesses optimize capital planning through realization of the hidden capacity potentialin their existing assets. Tactically, a single client site utilizing this approach helped identify specific improvements that arecurrently delivering $1M/year recurrent revenue in combined energy savings and capacity rate improvements. A one-timeinvestment of $10K realized these savings.

We have applied these analyses to a wide range of operations, from small plants to the larger corporations in the manufacturingsector. It has been our experience that when leadership is proactive and aggressively focusing to eliminate wastes and improveeffectiveness of work management and decision making processes, a company will realize their biggest return on investment.

Our approach will help you to find un-tapped potential in your existing assets (hidden capacity) and drive such results as:

• Enhanced Safety Management• Improved Production and Capacity Planning• Effective Prioritization and Resource Allocation• Setting realistic stretch goals for improvements• Challenging the “status quo”• Improving the effectiveness of Capital Planning

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Process Simulation ModelingAlternatively, when a client has invested to compile more detailed production failure data, they may also decide to aggressivelypursue a more in-depth analysis to define where to immediately focus improvement opportunities. The GPAllied team hasdeveloped a non-invasive approach that involves employing client failure data in conjunction with Monte-Carlo simulations todevelop priority setting and driving work on the RIGHT-THINGS-FIRST!

We will compile the results from the simulation and will assist the client to focus and strive to achieve sustainable improvements.Our integrated improvement approach utilizes proven methods such as:

• Lean Manufacturing• Six Sigma• Organizational Development• Reliability Engineering Principles

These improvement technologies will to help guide a company to drive effective implementation and reap the benefits ofimproved profitability.

Key Performance Indicator (KPI) DevelopmentFor any change that has been implemented, ensuring compliance is a critical part of understanding what changes were successfuland what changes still need to be made. GPAllied can help implement meaningful KPIs that show the progress of the changeinitiative and educate client personnel about the analysis and relevant use of the metric(s).

Process Waste AnalysisGPAllied works with you to “walk” your maintenance work cycle processes to identify common waste and opportunitiesincluding rework, unclear instructions, searching for information or parts, and other hidden wastes. The analysis results in aprioritized list of improvements.

Day In the Life Of (DILO) StudyThe DILO study focuses on individuals in their daily work and determines the amount of time spent performing work(“wrench time”), attending meetings, searching for parts or information, etc. It provides a different view than the waste analysiswhich follows the flow of a process; however, it also results in a prioritized list of improvements required to affect a person’sdaily effectiveness and efficiency.

Sustained Reliable Operations

GPAllied provides on-site operations management and process-improvement training, coaching, and facilitation for your specificneeds, timing, and budget. GPAllied supports implementation of a tool like 5S or a large-scale transformation. When doing so,GPAllied provides critical support during implementation of your operations solution, including the following:

• Building a business case for change• Selecting Key Performance Indicators and Developing Benefits Tracking Systems• Ensuring correct application of tools• Driving the transformation project forward• Developing your Implementation Team through Learn Do, or training and coaching your Green Belts and Black Belts• Teaching and coaching managers throughout your implementation to help them understand the process changes

and their changing roles

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GPAllied provides the following tools and methods separately or integrated within a transformation project:

Leadership and Change Management• Deploying an Initiative Workshop• Leadership Alignment Workshop• Leadership Boot Camp• Improvement Office Development• Implementer Methods Immersion• Leadership Team Coaching• Teaming for Success

Management Systems• Measuring What Matters• Guiding Principles• Production System• Daily Management System• Goal Deployment System

If your organization needs to transform operations, then GPAllied provides a transformation roadmap that applies the right mixof methods and tools to meet your organization’s needs:

• Select a value stream/pilot area and perform value stream mapping and transition planning• Implement improvements on the value stream/pilot area, and develop implementers and managers• Design and deploy the best practices for your operating and management systems• Establish and implement a plan for refinement, replication, and deployment

Leadership and Change ManagementSuccessful change requires committed leadership. GPAllied has woven change management methods into our solutions, and thesolutions listed here focus on engaging and aligning your leadership team. These solutions are included in the following:

• Fit for Purpose: Deploying an Initiative for Your Organization. This workshop helps you make key decisions aboutthe design and deployment of your Operational and Reliability Excellence initiative. Customized for your needs, theWorkshop covers Lean, Six Sigma, Maintenance and Reliability / TPM, plus the key management systems of DailyManagement and Goal Deployment required to sustain your initiative and map the way to achieving sustainedoptimized operations.

• Leadership Alignment. The Alignment Workshop focuses your management team or work group in a planned,common direction. Your organization will benefit when setting direction, initiating and deploying a major program, ordeveloping implementation plans.

• Leadership Boot Camp. This “immersion conversion experience” jump starts your company’s culture change andprovides practice with key leadership tools like teamwork, listening, and decision making. It is always organizedaround a major theme, which is specific for your company.

• Improvement Office Development and Deployment. An Improvement Office provides critical horsepower to speedyour transformation. During this Development and Deployment workshop, your management team learns about thepurpose, types, and personnel expectations of Improvement Offices and develops the design of your improvementoffice.

• Implementer Development—Methods Immersion. This intensive development experience prepares people selectedto act as Implementers or Internal Consultants to actively engage the transformation process. The Implementers canlearn Lean, TPM, Equipment Reliability Systems, Reliability methods, Six Sigma, or a combination of these methodsbased on the needs of your company. The Methods Immersion is designed to enable the Implementers to activelyparticipate during implementation of a transformation plan, under guidance of a sensei/coach as they put theirlearning into practice using Learn Do.

Performance Improvement• 5S and Visual Management• Standardized Work• Problem Solving: FFA, A3, and STP• Quick Changeover• Production Cells• Pull Systems• Leveled Production• Continuous Flow Processing• Error/Mistake-proofing• Job Methods and Job Instructions• Routine Equipment Care• TPM• Supply Chain Improvement

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• Leadership and Team Coaching. Whether supporting your problem solving method, changing your planning andscheduling process or changing your company’s culture, your people need to acknowledge habits that needchanging. Change requires a clear vision of what to change to, motivation, and repetition. GPAllied providesconsultants with senior-level industrial experience plus training and experience in coaching techniques to work sideby side with key individuals in your company to help them successfully change.

• Teaming for Success. The foundation for progress lies in teamwork; however, teaming effectively requires tools,common understanding and goals, and commitment. This two-day course provides opportunities to learn andpractice teaming skills such as chartering a team, recognizing the stages of development, identifying roles, writingan agenda, tracking action plans, and communicating effectively.

Business Management SystemsA business management system defines how production and maintenance are performed, drives change and improvement, anddirects how goals for processes are set, deployed and managed day to day. It weaves the way of doing work into the very fabricof the company’s culture. For each of the systems listed below, GPAllied provides a four-step process design system with amanagement team to customize and deploy training with integrated coaching to ensure continued application—to guide andspeed implementation:

• Measuring What Matters. A Performance Measurement System defines KPIs, establishes three views—strategic,operational, and improvement—and links to goal deployment and daily management.

• Guiding Principles. Guiding Principles augment a company’s vision and includes concepts like using visualmanagement to surface problems. GPAllied provides education and facilitates a leadership team in the definition ofthese principles.

• Production System. The Production System defines the key methods to ensure production reliability and includesprocesses like in-station process control, and continuous flow.

• Maintenance System. The Maintenance System defines the key methods for maintenance execution and reliabilityengineering and includes processes like the maintenance work cycle, routine equipment care, and others.

• Daily Management System. Daily Management ensures that output of a production or maintenance process meetsdaily requirements for quality, quantity, and safety; and includes processes like Job Instruction, Multi-Level Audits,Fast Failure Analysis, and Visual Management.

• Goal Deployment System. Goal Deployment, often called hoshin or policy deployment, links strategic goals tospecific action plans and includes goal setting catchball, annual action planning, and monthly plan reviews.

Performance Improvement

Lean Six Sigma ImplementationImplementing Lean Six Sigma might mean applying a particular tool like 5S or Operator Equipment Care, or it might mean animplementation of many tools in a Learning Line. In either situation, GPAllied can help your organization realize gains faster.GPAllied provides training and coaching during your implementation in the following tools:

• 5S and Visual Management• Problem Solving• Quick Changeover• Production Cells• Pull Systems• Standardized Work• Routine Equipment Care

• Leveled Production• Materials Management• Daily Management• Continuous Flow Processing• Error/Mistake-proofing• Job Methods and Instruction

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Rapid Improvementâ (Kaizen)A Rapid Improvementâ Workshop (RIW), also known as a Kaizen Event, is a method to achieve dramatic change in a specificprocess in only one week or less. Our method, carefully designed and refined for more than 15 years, includes four phases:Assessment, Planning, Workshop, and Follow-Up. A RIW can be used to streamline, standardize or redesign a process; or evento design and create a new process. GPAllied provides two versions, one for manufacturing operations and one for transactionalor service processes that include the following elements:

• Rapid Improvementâ Leaders Kit - Includes Leader’s guide, forms, and slides• Rapid Improvementâ Leaders Seminar - An intensive, interactive three-day learning and skill-building experience

that is the first step in certifying the Rapid Improvementâ leaders• Rapid Improvementâ Implementation - During Rapid Improvementâ Implementation, our consultant and your Rapid

Improvementâ leaders conduct the four phases of Rapid Improvement for your organization

5S and Visual Management5S and Visual Management are simple, visually-oriented systems of workplace cleanliness, organization, and communicationdesigned to facilitate greater productivity, safety, and quality. GPAllied offers media and consulting services for your manufacturingor service organization’s 5S and Visual Management implementation through:

• Five S: Creating the Productive Workplace books and instructional DVD• 5S and Visual Management Deployment Workshop - A one-day interactive workshop that helps you initiate your

customized 5S and Visual Management program• Rapid Improvementâ Workshop—5S and Visual Management. GPAllied provides detailed planning for and

implementation of a two-day 5S and Visual Management Rapid Improvementâ Workshop• Customized Programs

Problem Solving ManagementProblem solving is a fundamental process-improvement skill for operations, maintenance, and management. Problem solvingapplies to both failures that occur and opportunities to improve. GPAllied offers the following services to help you increase yourrate of process improvement problem solving through:

• Problem Solving Management. One of the benefits of working with GPAllied is our emphasis on the system orinfrastructure, and the standards and actions that managers and supervisors need to perform in order for problemsolving to be sustained for the long-term. GPAllied provides consultation, typically in a one-day workshop, to helpyou make and deploy decisions on your problem solving system.

• Problem Solving Methods. Just like there are different types of problems, there are different types of methods forproblem solving. GPAllied provides courses, coaching, distance coaching, and distance learning on these methods:- Fast Failure Analysis (FFA). FFA is effective for many typical failures and can be completed quickly. The core

of this method is to engage front-line workers in solving day-to-day anomalies with the 5-Why method.- A3.The A3 method, sometimes called the Quality Improvement Story (QIS), provides a more-robust approach to

solve more complex failures or develop solutions to opportunities for improvement. It can apply to chronicproblems and applies analytical tools in addition to 5-Why.

- RCFA. Root Cause Failure Analysis (RCFA) is thought of in two ways: a failure of a process (the way peopleinteract with each other and the machinery they operate), or an equipment failure. GPAllied’s RCFA methodaddresses both and draws from Reliability Engineering with rigorous development of root causes backed bysubstantial evidence.

- Situation—Target—Proposal (STP). STP is a direct and straightforward problem solving and decision makingmethodology that is especially useful for transactional environments and management decision making. UsingSTP, an individual or team factually describes the situation, states the desired future-state target, and proposesa solution based on analysis.

- Six Sigma. When problems are complex, then more advanced problem-solving tools might be needed. GPAlliedprovides training and coaching on these advanced tools as part of Six Sigma Green Belt and Black Beltcertification programs, or as targeted training (for example, training on Measurement System Analysis).

• Teaming and Problem Solving Skills. Even if your organization has established its problem solving system andprovided training in one or more of the problem solving methods, your people might still need fundamental skillsbuilding in how to team effectively and how to use problem solving tools.

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GPAllied offers services to build these skills such as:

Standard Work ProcessStandard work is fundamental to reliable operations and maintenance performance, and provides the basis for further improvement.Unfortunately, if your company is like many, you will find that different work groups, individuals, or shifts actually perform workdifferently; workers are indifferent toward following standards and using a disciplined process to improve standard work; andmost importantly, supervisors lack the skills needed to lead standard work execution and improvement. The Standard WorkProcess might well be the most important method for institutionalizing needed skill development and culture change. It engagesfront-line workers, front-line supervisors, and higher-level managers in ensuring that process performance reliably meetscustomer requirements. When followed, it leads to continuous process improvement. GPAllied provides solutions to help yougain the benefits of the Standard Work Process:

• Standard Work Process Management. GPAllied helps your organization make and deploy decisions on yourStandard Work Process, including how standard methods are set, job instruction is taught, work performance ismeasured and audited, and how performance anomalies are solved.

• Training and Coaching. GPAllied provides courses and hands-on coaching for each element of the standardwork process.

Reliable Capital Delivery

The difference between effective and ineffective launching of a new facility or installing a new asset is costly in terms of time,money, and customer satisfaction. People, processes, and technology—these are the essential elements of your industry. Whenit’s time to bring your business to a higher level, all three (3) must be ready. GPAllied provides a suite of services designed tomake your capital project launch successful. We categorize these services as follows:

Design/Build Services• Design Verification/Optimization• Life Cycle Cost Analysis• Construction• Construction Management• Procurement• Facility Layout for Lean Manufacturing• Design for Condition Monitoring

Engineering Services• Civil• Mechanical• Electrical• Chemical• Fire Protection• Environmental• Safety

Installation, Commissioning, andOperational Services

• Commissioning, Acceptance Testing andOperational Support

• QA/QC, Witnessing, Inspection and Test Plans• Warranty Claim Management• Spares Optimization• Quality System Implementation• Workflow Processes Development• Procedure Development• Project Management

Workforce Selection and Development Services• Employee Screening and Selection• Operator and Maintenance Training• Leadership Development and Culture Establishment• Custom Certification Programs• Training Center Construction• OEM Training and Documentation Coordination• Knowledge Management Systems

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Design/Build Services

Design VerificationEvery new facility is justified based on specific requirements for business performance. GPAllied uses powerful Monte Carlo-based simulation software to verify that facilities will produce the required safety, environmental, and operational performancebased on the impact of its proposed equipment’s reliability and maintainability. Changes can be easily implemented if thisprocess is initiated early enough in the design process.

Design OptimizationMinor changes in the design of a facility may yield high returns, but it is often hard to tell what that return will be in a complexsystem. GPAllied can model the complex relationships and help develop designs optimized to produce the highest businessperformance and the lowest cost of installed capital.

Life Cycle Cost AnalysisDeciding between business alternatives requires an understanding of the through-life cost of the alternatives being considered.GPAllied can show you the cradle to grave costs of ownership and through the use of Life Cycle Cost Analysis methods helpensure that your company picks the investment that best meets the business goals.

ConstructionFrom fuel station and alternative fuels construction to aerospace and water treatment plants, GPAllied has the industry insightand experience needed to meet stringent quality and safety requirements. When you hire us to construct your small to mid-sizedspecialized systems facility, you can rest easy knowing we offer:

• In-house, turnkey services for responsiveness and reliability• Proven, long-term experience to ensure deadlines and budgets are met• Multi-disciplinary capabilities in design and engineering, procurement, quality assurance, compliance, construction

management, and more for added peace of mind• Unmatched service, backed by a company known for superior quality work

Construction ManagementFrom individual task management and field office support to third-party oversight and comprehensive project management, youcan count on GPAllied to get the job done. Our multi-disciplinary experience in design and engineering, procurement, construction,inspection, maintenance, and repair gives us unique insight into construction management to help build specialized facilities.Add to that our certifications, skills, standards, accountability, and proven track record for on-time and on-budget delivery, andyou’ll see why we deserve our reputation for superior performance and quality. GPAllied specializes in construction managementfor heavy industry, process and chemical, utility, university, and government facilities worldwide. Our Owner’s Representativeand Guaranteed Maximum Price services include:

• Project and contracts management• Quality assurance support• Inspections, examinations, and tests• Certified welding consultation and procedure development• Project and contracts control• Procedure development• Third-party oversight• System validation

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ProcurementProcurement is one of the key areas that can make or break your budgets, timelines, and construction quality. GPAllied’sprocurement and purchasing services are backed by our end-to-end knowledge of design and engineering, construction, andconstruction management. We understand the issues that keep you up at night, and we know how to procure building materialsand supplies along proven strategies that maximize value and:

• Optimize materials and processes• Utilize well-honed negotiation skills to minimize costs• Maximize tax benefits• Help maintain productivity and efficiency throughout the job site

Facility Layout for Lean ManufacturingLayout of a facility—the location of equipment, work-in-process inventory, supplies and parts, tooling, support groups likemaintenance and quality—all determine the ability to meet customer needs with minimum cost. GPAllied’s 15-Step Plant LayoutProcess starts with agreeing to the manufacturing strategy, includes definition of performance metrics, designs equipment andsupport process locations to enable Lean processing, and develops an implementation plan.

Design for Condition MonitoringGPAllied can help ensure that your new plant design is optimized to take full advantage of all condition monitoring technologies.Whether it’s detailing the permanent installation of accelerometers for ease of routine vibration data collection or the use ofinfrared line scanners on rotating vessels, GPAllied can help.

Available continuous on-line monitoring systems available are:

• Vibration Analysis• Torque and Torsion• Infrared Thermography• Ultrasound• Motor Circuit Analysis• Oil Analysis• Process Parameters

Engineering Services

The more complex your plants and systems, the more you need an experienced and specialized design engineering company likeGPAllied. With complete in-house capabilities and proven expertise, GPAllied is uniquely qualified to serve the engineering anddesign needs of small to medium-sized plants and systems. From design, to construction, to improving the efficiency andreliability of your existing facilities, we offer registered engineers in the following disciplines:

• Civil• Mechanical• Electrical• Chemical• Fire Protection• Environmental Engineering• Safety

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Installation, Commissioning, and Operational Support Services

Commissioning, Acceptance Testing and Operational SupportGPAllied engineers can offer a number of services to assist with machine assembly and commissioning, as well as baselinecondition monitoring services. Some of the services include:

• Alignment• Balancing• Thermal Growth Analysis• Leak Detection Survey• Resonance Testing• General Machinery Acceptance Testing• Failure Investigation• NDT Inspections• Installation and Commissioning Quality Assurance and Quality Control (QA/QC) and inspections

- Personnel are available with extensive experience in QA/QC of process machinery assembly and overhaul- Assistance can be given with the development of commissioning procedures and collection and analysis of

commissioning data• Overhaul Quality Assurance and Quality Control (QA/QC)

- GPAllied has personnel experience in QA/QC Control of Equipment Overhauls- This work would involve developing overhaul QA/QC specifications- Developing overhaul procedures- Developing inspection and test plans- Witnessing inspection and test plans- Shutdown project management and supervision- Commissioning- Overhaul report writing

GPAllied senior engineers have extensive QA/QC experience with boilers, fans, gearboxes, pumps, HV motors, standard ACmotors and compressors.

QA/QC, Witnessing, Inspection and Test PlansPlant equipment modifications often are performed with little or no QA/QC during the modification, installation and commissioningstages of implementing a solution. GPAllied can assist by providing experienced specialists in all areas of solution implementationto develop inspection and test plans, for which expert witnessing and sign-off can be achieved, ensuring the solution designand implementation is performed to specification.

Similarly, this service offering can be performed on plant equipment that is undergoing planned maintenance and overhaul to ensurethe asset is returned to the original design specification, or if up rating, the plant equipment is modified to the modified specification.

Warranty Claim ManagementThis service is provided to manage RCA investigations and warrantee claims on behalf of the customer inclusive of provisionof expert witness services. The purpose of this service is to ensure that all reported findings are presented by the expert witnessas a representative for the customers to maximize on any loss claims.

Spares OptimizationThe base load of spares for new capital equipment depends on the failure modes present, the lead time for spares, and theequipment maintenance plan developed to battle the failure modes. GPAllied can help you minimize the investment in capitalspares required to operate the facility and achieve the best business results.

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Procedure DevelopmentWell-written procedures provide a consistent and safe method for performing job tasks and establishing a foundation on whichto improve process and safety performance. GPAllied provides the specialists you need for timely development of processsafety, operating, maintenance, mechanical integrity, inspection and test, quality assurance, start-up, and shut-down procedures.GPAllied prepares, in addition to documented standards, supporting materials such as system descriptions, alarm responseguides, job aids, and on-the-job training guides.

Quality System ImplementationQuality systems assure that customers receive the right shipment at the right time with the right quality. GPAllied providesquality systems design including product requirements, design and process FMEAs, standardized work, control plans, auditplans, quality records, and supplier quality improvement and assurance plans.

Workflow Processes DevelopmentUnderstanding how information flows around an organization is a key metric in determining its maturity. Non-value addedsteps, like unnecessary reviews, edits and approvals, drag down the efficiency of an organization to the point of beingineffective. Additionally, when people don’t know their role in the group and how their role affects others, further inefficienciesare created.

GPAllied can help. Our engineers and consultants have the right experience to help you re-engineer your processes andeliminate the non-value added steps and clearly define everyone’s responsibility with respect to different topics.

Project ManagementGPAllied develops complete project plans that provide our clients the insight needed to ensure a smooth project progression.We have saved our customers millions of dollars through effective Outage planning and facilitation. GPAllied implementsfacility outages using our qualified staff, knowledgeable and certified in the work required, or by providing project managementand facilitation to your staff. If training your people is your goal, we offer best-in-class Project Management for Engineers andProject Bottom Line Success courses.

Workforce Selection and Development Support Services

Employee Screening and SelectionProperly selecting and developing your employees is one of the most important considerations for ensuring reliable capitaldelivery. GPAllied specialists can employ a structured job and task analysis process based on your anticipated staffingrequirements and your facility specific equipment to identify the skills and knowledge your employees will need to reliablyoperate and maintain your plant. Using this information, we create job descriptions and legally valid skill and knowledgeassessments for use in screening qualified job applicants. Our specialists can conduct the screening or prepare your personnelto do so.

Operator TrainingBased on the information developed through the job and task analysis, GPAllied training specialists can develop and delivercustomized operator training programs specific to your facility. Depending on your specific needs, GPAllied can deliver thistraining through instructor-led sessions, self-study guides, computer/web-based training, or structured on-the-job training(OJT). GPAllied can deliver the training or can provide train-the-trainer sessions to prepare your subject matter experts todeliver the training.

Maintenance TrainingGPAllied can design, develop, and deliver complete maintenance training programs that cover everything from basic corecompetencies through high-level equipment specific training. Our maintenance training programs are described in more detailin the Reliable Maintenance Execution section of this document.

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Leadership Development and Culture EstablishmentInstallation of new capital is also a time to ensure that the equipment is run right and maintained right. Whether the equipmentis incrementally improved (like at Toyota), or deteriorates due to lack of maintenance depends on management culture andprocesses. GPAllied’s solutions start by providing managers with the motivation to manage differently through education,benchmarking, and coaching. That is coupled with establishing an agreed-to Daily Management System that shows managershow to manage well.

Custom Certification ProgramsIf you are looking for a way to recognize and reward your employees’ technical expertise and capabilities, but have not been ableto find an industry standard certification program that meets your needs, GPAllied can help. Our training specialists haveguided many customers through the process of creating legally-valid custom certification programs to support initiatives suchas pay-for-skills or multi-skilling. We employ a structured process to identify the critical skills and knowledge your workforcerequires to successfully perform their jobs. We then work with a team of your subject matter experts to rank these skills andknowledge requirements to create career progression paths for your defined job roles. Finally, we create legally valid skill andknowledge assessments that are used to verify your employees’ mastery of the skills and knowledge required for each step ofthe career progression.

Training Center ConstructionGPAllied firmly believes that for operations and maintenance training to be effective, it must be delivered in a hands-on trainingenvironment. In some cases, the most economical means to achieve this is through the construction and provisioning of an on-site training center. GPAllied is experienced in all phases of training center construction including design, constructionmanagement, outfitting of training labs, preparation of instructors and delivery and monitoring of training classes. Our turn-keysolution begins with the identification of the skill and knowledge requirements of your workforce. We then use that informationto design the training labs, prepare budget estimates, and identify and select building contractors/training equipment providers.GPAllied specialists then manage the construction of the training center, procurement of the training equipment, and outfittingof the training labs, providing you with a completely functional training center ready to support your personnel.

OEM Training and Documentation CoordinationCoordinating and ensuring the quality and consistency of the training and documentation provided by your equipment vendorscan be a huge challenge during a capital project. Fortunately, GPAllied has developed a proven process to overcome thischallenge. It begins with the development of a detailed training and documentation bid specification that is included with theequipment bid packages sent to the vendors. The training and documentation bid specification clearly outlines your expectationsof the training and documentation to be provided. As the capital project progresses, GPAllied specialists will work with yourvendors to ensure compliance with the bid specification and coordinate and monitor vendor training sessions and documentationsubmittals to ensure your employees gain the knowledge and skills they need to effectively operate your plant.

Knowledge Management SystemsGPAllied empowers your organization with the insight and knowledge you need to enhance or introduce enterprise e-learninginitiatives. Our experience and knowledge helps you evaluate your unique opportunities effectively and identify the optimalsolutions to meet those opportunities. Our recommendations take your e-learning requirements into consideration, as well asfuture growth, emerging possibilities, process refinement, implementation, support, and growth strategies. The result is the rightsolution for your people and processes—an infrastructure that delivers strong returns now and in the future.

GPAllied’s areas of expertise include learning management systems (LMS), portal development, learning content managementsystems (LCMS), content management systems (CMS), performance management systems, reporting, and talent management.We provide end-to-end services, including selection consulting, installation, and configuration, paying special attention tosystem integration, content integration, web interface design development, and data migration.

Because GPAllied is not in the business of selling our own, proprietary software solutions, we approach your recommendationsand implementations from the perspective of someone who uses these systems daily in our business—from the same perspectiveyou would have. While we have significant knowledge of each system out there, we remain software agnostic, workingdiligently with all leading suppliers and product developers to identify the best-in-class solution for you.

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Reliable Maintenance Execution

GPAllied provides on-site maintenance management and process-improvement training, coaching, and facilitation for yourspecific needs, timing, and budget. We work side-by-side with your management and crew to improve the entire maintenancework cycle and the processes that support it. GPAllied helps your organization clearly understand and improve maintenanceperformance; and streamline, agree to, document, and institutionalize your company’s best practices resulting in bottom-linecost reduction and higher equipment utilization. GPAllied provides critical support during implementation of your maintenancesolution, including the following:

• Building a business case for change• Selecting Key Performance Indicators and Developing Benefits Tracking Systems• Ensuring correct application of tools• Driving the transformation project forward• Developing the Implementation Team through Learn Do, or coach Reliability Green Belts and Black Belts• Teaching and coaching managers throughout the implementation to help them understand the process changes and

their changing roles

Reliable Maintenance Execution requires the creation/improvement of the following elements:

• Strategy Development: The analysis of predominant failure modes and their effects leads to the development/assignment of Proactive Inspections like Preventive Maintenance (PM) and Predictive Maintenance (PdM) tasks ascountermeasures.

• The Maintenance Work Cycle: The identification, prioritization, planning, scheduling, preparation, execution, andreporting of maintenance tasks; and the assessment of maintenance task performance and equipment history.

• Work Measurement and Execution: The cost-efficient and effective performance of maintenance tasks with peoplehaving the right skills and following maintenance standard work.

• MRO and Lubrication Management: The determination of quantities of spares, storeroom management, vendormanagement, and repair specifications; and the consolidation, labeling, and storage of lubricants.

GPAllied offers the following solutions:

• Shutdown, Turnaround, and Outage (STO)• MRO and Lubrication Management• Phase I Assessment• Phase II Development• Hierarchy and Master Equipment

List Development• Equipment Walk-Down• Criticality Analysis• Equipment Maintenance Plan (EMP)

Development• Preventive Maintenance Evaluation (PME)• Preventive Maintenance Optimization (PMO)• Advanced Machinery Diagnostics• Baseline Asset Health Audit

• Historical Failure Analysis• Reliability Centered Lubrication• Asset Health Management

- Condition Monitoring Work-Scope Generation- Analyst and Technology Specifications- Supplier/System Audit- Skills and Competencies Development

and Assessment- Contract/System Implementation

• Maintenance and Reliability Kaizen Event• Solution Design (Defect Elimination)• Solution Planning and Implementation• Sourcing Strategy• Maintenance Craft Skills Training

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Shutdown, Turnaround, and Outage (STO)Improving the efficiency and effectiveness of your STO events represents one of the largest opportunities for controlling yourmaintenance cost and improving equipment availability. GPAllied helps your organization implement or improve the executionof STO with the following solutions:

• STO “Current State” process mapping and opportunity identification• Facilitation and documentation of a Standard STO Model including forms, tools, and key-event timing• Targeted training to enable implementation of best-practice improvements• Facilitation of STO Risk Analysis and definition of Risk Mitigation Actions• Hands-on, best-practice implementation, coaching, and guidance• Simple Excel Gantt Chart planning tools• STO Execution Daily Management coaching and Action/Countermeasure management• STO Visual Management techniques — Preparation Matrix and Plan-to-Actual Status Wall• Facilitation of Post-STO Review of “Things Gone Right” and “Opportunities for Improvement” including

development and implementation of continuous-improvement Action Items• Specific training, simulations, improvement workshops, and custom solutions

MRO and Lubrication ManagementSignificant waste in maintenance execution occurs from inadequate management of spare parts and lubricants. GPAllied helpsyour organization implement or improve execution of STO with the following solutions:

• MRO/Lubricant “Current State” process mapping and opportunity identification• Facilitation and documentation of a Standard STO Model including forms, tools, and key-event timing.• Stores strategy and efficient layout planning and implementation• Visual management• Vendor management strategies

Phase I AssessmentThe audit is a structured evaluation of current maintenance and reliability practices as compared to best-in-class standards.The assessment is accomplished through several actions such as, current production analysis (to approximate the lostopportunities) and personnel interviews (to establish common practices).

Once the current state is determined, it becomes a lot easier to talk about the efforts required to move forward and improve.

Specific deliverables coming out of the Phase I Assessment are:

• 1-day Reliability Overview Training Class• Process Analysis of Current Production Data• Assessment Report Ranking Current Maintenance and Reliability Practices versus Best Practices• Return On Asset Reliability (ROAR™) Model Detailing the Business Justification for Change

The audit process confirms, conducts and evaluates the following:

• Group Reliability Structure• Predictive Maintenance Strategy• Plant Hierarchy Structure• Equipment Attribute Library• Plant Criticality Analysis• Equipment Maintenance Plan• Reliability Management Structure• Maintenance System Levels of Achievement

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Hierarchy and Master Equipment List DevelopmentHaving a functional equipment hierarchy is paramount to managing the information coming from the maintenance and reliabilityfunctions. Hierarchies have to be capable of rolling up both cost data and failure data to ensure meaningful analysis.

GPAllied uses a systematic method of verifying the equipment at a facility and organizing the equipment into a hierarchy that isuseful to both accounting and maintenance simultaneously.

Equipment Walk-DownFew maintenance planners and engineers have a complete set of individual component data required to perform their jobeffectively and efficiently. Most of the time, when a critical piece of information is required for parts ordering or job plandevelopment; someone is tasked with going into the field and finding that piece of equipment and documenting that information.

GPAllied uses a custom designed software application to help organize the information as it is gathered. This database is thenused for:

• PM Program Design• PdM Program Design• Job Plan Development• BOM Development• Lubrication Program Design

Examples of data that are collected and data-based are:

• Bearing numbers• Geartooth count• # of Rotor Bars and Stator Slots• Coupling type• # of Blades/vanes• Lubricant type• Power factor• Materials of construction• Nominal thickness

The data in the application can be easily loaded into the existing CMMS, making data management easy.

Criticality AnalysisThe intent of the site criticality survey is to rank all site equipment based on the aggregated risk of environmental, safety, capitalreplacement cost, history and cost of failure and production impact.

A rational equipment criticality coding system can greatly assist an organization in the setting of management, operational andmaintenance priorities when dealing with assets and equipment.

The Criticality review uses a simple qualitative analysis utilizing the knowledge of key site personnel with the data recorded ina software package. We use a ‘Risk-Based’ approach to equipment analysis and to the development of maintenance systems.

Many equipment criticality analysis approaches are consequence-focused rather than risk-focused. Consequence-focusedequipment criticalities tend to prioritize failures by consequence only, irrespective of probability of occurrence. Failure Risk foran item of equipment or process can be determined by the probability of failure occurring, multiplied by the likely consequenceof the failure.

The process used relies on key personnel to make qualitative judgments on a range of Criticality Factors for each piece ofequipment.

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The Criticality Analysis uses five qualitative variables:

• Safety Impact• Environmental Impact• Operational Impact• Customer and Quality Impact• Failure Frequency

The output is a fully documented report of the Criticality Review and machine rankings.

Criticality Analysis is a necessary precursor to the design/evaluation of any existing reliability program.

Equipment Maintenance Plan (EMP) DevelopmentThe PM and PdM tasks that are brought to bear on a given machine form the core of the Equipment Maintenance Plan (EMP).Typically, the balance between PM and PdM isn’t correct in the maintenance scheme. This imbalance creates a higher cost ofmaintenance and lower levels of reliability than what is possible, and certainly not what is expected of the system.

GPAllied can develop an EMP that reflects the proper balance of PM and PdM for a select number of machines or the entiresystem. The final product is delivered in electronic form for easy import into a CMMS. Characteristics of an EMP include:

• Failure Mode• PM/PdM Task Description• Craft/Operator Assignment• Task Frequency• Duration (Clock-Hours and Labor-Hours)

Preventive Maintenance Evaluation (PME)All too often, too much emphasis has been placed on the PM procedure and what results it can bring. There is a belief that anorganization can PM its way to reliability. Time and time again, this has proven incorrect for some of the following reasons:

• Intrusive inspections can introduce infant failures if proper procedures aren’t followed• Certain failure modes don’t follow a set time pattern• Task frequencies are incorrect based on a belief that if we just opened it up more often, we would catch the problem• Non-value added tasks have been added to the PM, building a false sense of increased security• There are tasks in the system that are not failure mode based• Too much reliance on OEM recommendations that do not take into account the operating context

A Preventive Maintenance Evaluation (PME) conducted at the task level of a PM program can identify tasks that need to be:

• Deleted from the PM program and the labor re-assigned• Deleted from the PM program and the task assigned to Operations• Deleted from the PM program and the task assigned to a Lubrication Specialist• Deleted from the PM program and the task assigned to PdM Specialist• Remain in the PM program, but re-engineered to make the task more quantifiable, executable and repeatable• Remain in the PM program, as written

Preventive Maintenance Optimization (PMO)Once PM tasks have been analyzed and determined that they are to remain in the PM program, but need to be re-engineered, theoptimization process is ready to begin. The optimization process involves recreating the task in such a way as to guaranteeconsistency of execution. This guarantee is accomplished through the use of best practice techniques designed to make thetask description clear, concise and free of ambiguity.

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The litmus test for whether or not the PM task has been optimized is this: Can the 2nd year craftsperson and the 19th yearcraftsperson complete the PM tasks with the same results?

If the answer is yes, then the procedure is a good one. If no, then there is improvement left to be had.

Advanced Machinery DiagnosticsWith the use of the latest technology in vibration analysis, thermographic imaging, lubricant analysis, motor circuit analysis andultrasonic analysis, our team of industry recognized experts can assist clients with the identification and solving of theircomplex machinery defects on highly critical machines and machines that have exhibited chronic failures.

All reports identify maintenance recommendations, which allows for the prioritization of maintenance activities. Typical mechanicaland electrical anomalies would include:

• Misalignment• Unbalance• Soft Foot• Gear Meshing• Journal Bearing Faults• Belt Drive Faults• Mechanical Looseness• Switchgear and MCC faults• Pump Faults – Blade/vane pass and cavitation• Critical speed analysis• Beat Frequencies

Baseline Asset Health AuditThis is a snapshot of the health and condition of the assets as identified through the use of visual inspection and predictivemaintenance technologies and involves:

• Vibration surveys• Thermal Imaging surveys of electrical, mechanical and stationary equipment• Oil Analysis surveys of oil lubrication systems (basic tests only)• Ultrasonic Surveys of pressurized plant equipment

The Audit is intended to:

• Rapidly produce a broad overview of plant and equipment condition• Identify conditions of immediate concern• Validate the existing PdM program• Identify immediate Root Cause Analysis (RCA) opportunities for critical equipment• Set the workshop with key client personnel to develop solution activities for rapid return

on investment through failure avoidance

Historical Failure AnalysisUnderstanding the nature of how the machines in a given system have failed paints a very clear picture about any futurechanges that may be needed. GPAllied engineers can help you find trends and patterns in your failure data to better understandthe required action items.

Using simple tools like Pareto analyses and distribution reports to complex simulation modeling, the nature of the failures can beidentified and action plans developed.

• Insulation integrity• Electrical phase unbalance• Hot Bearings due to incorrect installation or lubrication

practices• Blockages and Dead Spots in circulation systems such

as the cooling tubes of heat exchangers can be identifiedwithout the need to ‘crack’ lines

• Vessel integrity checks on furnaces, autoclaves,mills, kilns, etc

• Gas Leaks• Electrical Discharge• STEAM Trap Auditing

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Reliability Centered Lubrication DevelopmentIt has been found that poor lubrication can result in a loss of 10-15% of a plant’s maintenance budget. Much of this time can beattributed to poorly designed lubrication PM’s that have no engineering reasoning behind them. GPAllied provides an approachto lubrication that allows for equipment reliability and personnel optimization. The Reliability Centered Lubrication planaddresses the key components of a lubrication program such as:

• Standards and Procurement• Storage and Handling• Sampling• Contamination Control• Training• Oil Analysis

Asset Health ManagementCondition Monitoring (CM) Work-Scope GenerationEstablishes CM Standards and serves to provide the following:

• Identification of machines that warrant monitoring• Identification of typical failure mechanisms• Failure Mode Symptoms Analysis (FMSA) for critical plant only• P-F interval (via interview with key client staff) for each of the machines identified• Most appropriate primary and correlation CM techniques• Defined monitoring frequency• Identification of in-line/on-line monitoring requirements• Consideration for safe access for PdM activities

The process relies heavily on the interviews with key client staff and is conducted as per a “Greenfield” site with no referenceto any existing program or capability.

Analyst and Technology SpecificationsThis process involves the development of the technical specification required for the implementation of a standardized program.This process is also known as OP-1/OP-2 development.

The specification covers, but is not limited to, the following:

• Safety and Site Access• Analyst Certification and Qualification• Data Collection, Analysis and Alarming specifications• Reporting Standards• Communication Protocols• Contract Performance Criteria

Supplier/System AuditThis process involves the auditing of the program against agreed-upon standards for each condition monitoring technique, thegenerated work scope and the technical contract conditions.

This program identifies the deficiencies and areas of improvement for work scope, monitoring strategy, test regimes, databases,reporting, safety guidelines and management systems and structure.

This process also serves to confirm staffing levels, skills, competencies and certification requirements for the service personnel.

• Re-lubrication Practices• Program Management• Procedures• Program Goals• Continuous Improvement

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The final report identifies areas of risk, and deficiencies in:

• Management• Technology• Reporting• Communication• Personnel Skills and Competencies• Safe Work Procedures

Skills and Competencies Development and AssessmentThis task involves the development of the PdM Skills and Competencies system and career development plans, inclusive of thefollowing elements:

• Phase 1 – The introduction of the Skills and Competency Assessment Process and Tool and the initial completionof templates for further development by each team

• Phase 2 – The completion of the Template Skills and Competency Assessment Tool for each team and modificationof the Behavioral Competency profile component with customer requirements

• Phase 3 – The development of a Skills and Competencies Management System that outlines the procedures andprocesses for using and maintaining the Skills and Competencies Assessment Process

Contract/System ImplementationThis process involves verifying that the implementation of the Condition Monitoring (CM) Program is in compliance with ISOstandards, the generated work scope and the technical contract conditions. This process also involves the verification ofdatabase structures and designs as well as data communication protocols.

Similarly, it also serves to verify that appropriately qualified and certified service provider personnel have been assigned to theservice provision.

Program ManagementAn ongoing function, the primary function of the Program Manager is to ensure the integration of the information coming fromthe PdM program with the daily management scheme of the facility. This is accomplished through a combination of tasks.Those tasks include:

• Ensuring that reporting mechanisms, database structure, alarm level settings, collection specifications, includedmachines are all in accordance with agreed upon standards

• Identifying and setting training programs for technical staff and prioritize same• Training/coaching on communication protocol and quantification of success of the program• Educating plant personnel about the effectiveness of the PdM technologies.

Phase II DevelopmentOnce a Phase I assessment has been completed, a plan to close the identified gaps must be developed. This detailed plan(including ROI calculations) encompasses the elements needed to not only close the gaps, but close them in such a way as tomake the changes sustainable.

Root Cause Analysis (RCA) ManagementRCA is the heart and soul of any improvement initiative. The desire and ability to sort through the static and identify what couldhave been done differently to avoid the failure is what separates the companies who see step changes in performance and thosethat see mediocre to no improvements.

RCA is typically thought of in one of two different ways. Either a failure of a process (the way people interact with each otherand the machinery they operate) or an equipment failure. While the philosophies of these two techniques are precisely the same,the methodologies are a little different. GPAllied has experts in both types.

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The majority of the time, the biggest problem with RCA is lack of follow-through on the action items that come out of such ananalysis. GPAllied’s RCA courses have strong components for the management of those action items.

The management of root cause analysis projects typically involves a two-tiered process. It consists of a response plan ofmanaging the tasks immediately after a failure occurs, including but not limited to:

• Resource management (mandate by senior management to use specific personnel and equipment for the project)• Time management (available time-frame to carry out RCA)

The next steps involve the project management of the RCA including but not limited to:

• Information and evidence gathering before and/or during restoration/overhaul of equipment• Systematic process of development of root cause statement(s) that is backed by substantiated evidence

Maintenance and Reliability Kaizen EventThe M&R Kaizen events are designed to deliver a high degree of value to the client in a very short period of time. Understandingthat simply performing a series of analyses (like PdM/RCM/RCA) isn’t enough for most companies to see change/value.

The M&R Kaizen event has but one intention…stabilize one or two bad actors to a point where reliable operation isactually possible.

Activities performed during this one-week engagement include:

• One-day Reliability Overview• Baseline Asset Health Audit• PM Program Evaluation and Improvement• Lubrication Procedure Review and Improvement• Operator Care Tasks Review and Improvement• Equipment Maintenance Plan Review and Re-Design• Design for Maintainability Study

Solution Design (Defect Elimination)Failure mode elimination consists of a process of designing solutions around design, manufacturing, installation, operational,and maintenance (DMIOM) systems and processes to avoid recurring failures. The solutions can address one or a combinationof these DMIOM areas to avoid recurring failures.

The Solution Design process provides a method for:

• Specifying what the solution(s) will accomplish• Specifying the minimum solution requirements• Evaluating solutions• Understanding the benefits and risks associated with each solution or a combination of thereof

Solution Planning and ImplementationSolution implementation is one of the final steps of the RCFA process that involves the facilitation and project management ofthe solution design implementation to eliminate identified failure modes. The outcomes of the solution implementation phaseinclude:

• Installation QA/QC• Commissioning QA/QC• Implement Monitoring Strategies and Systems• Baseline Readings

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Sourcing StrategyIt can be difficult for an organization to decide how to staff an initiative. There are always three options, in-house, contractedor hybrid. Which is more advantageous? Which is more troublesome? What are the advantages and limitations?

GPAllied has a facilitated session that walks an organization through a series of questions and scenarios designed to clarify anunderstanding of the culture of an organization and help decide which of the three sourcing options is the best choice.

Maintenance Craft Skills TrainingThe diverse needs of today’s maintenance workforce can’t be met with a single canned solution. Producing multi-skilledmaintenance technicians demands a multi-tiered solution that addresses diverse skill gaps and training needs. GPAllied’ssolution, based on years of maintenance training, allows us to deliver the best training solution to your maintenance techniciansregardless of their level of need. It all begins with a needs or gap analysis, followed by a training strategy design and customizedcourse development and delivery. Our depth of experience and qualified maintenance experts ensure a highly-targeted programthat transcends the limitations of canned approaches, and is based on a progression through four competency levels:

• Level 1: The Core Competencies level provides the basic essentials for new hires or entry-level employees, andfocuses on core math, print reading, and technical skills to ensure that they can perform at the higher levels.

• Level 2: The Fundamentals level introduces much of the theory, such as Kirchhoff’s Law and Pascal’s Law,associated with the maintenance processes and includes basic concepts of hydraulics, pneumatics, pumps, PLCs,motors, etc.

• Level 3: The Advanced Fundamentals level transfers the theory and knowledge elements into practical applications.This level ensures that your maintenance professionals are trained to perform all of their required tasks and givesthem the hands-on learning opportunities to practice these critical skills.

• Level 4: The Equipment Specific Training level ensures that your maintenance team is fully capable and well trainedon the use and maintenance practices specific to your equipment.

GPAllied, your total solutions partner, provides the following services:

• Assessment and Planning. GPAllied provides Program Evaluations, Training Needs Assessment, Delivery ModeAnalysis, Curriculum Architecture, and Training Plan Development.

• Training Development. GPAllied provides review of prior training, and the analysis, design, development, andevaluation of customized training.

• Training. GPAllied provides structured OJT programs, Train-the-Trainer Programs, On-Site Instruction(classroom or hands-on), Computer/Web-Based Training, and a large number of maintenance skills andmaintenance systems courses.

• Training Center Management: Apprentice programs. GPAllied provides employee testing, screening and selection;establishment, staffing, and management of craft training centers; training administration and logistics; structuredon-the-job training; and certification programs.

Personnel Qualifications and Work Execution Standards

Personnel QualificationsBefore a GPAllied person is deemed Task Qualified on a particular deliverable, they must meet a specific set of criteria. Thecriterion are based on the knowledge and experience required to maintain the highest standard of execution. The detailedqualification standards contain the following:

• Background• References/Body of Knowledge• Qualification Levels• Education, Training and Experience Requirements• Certification

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For each of GPAllied’s processes and accompanying tools, there exists a training and qualification process which must befollowed to ensure the integrity of the overall concept and process deliverable. GPAllied has developed a four (4) tieredapproach for the qualification of delivering and utilizing our processes and tools.

• Level I (User): This level of qualification is accomplished through successful completion of the training class orworkshop associated with the process/tool. During the training session, each participant will be taught theconcepts behind each process and/or accompanying tool. After the session, field homework is assigned toreinforce the concepts covered in the classroom. Successful demonstration of the ability to use the process/toolwill constitute qualification as a Level I User.

• Level II (Coach): This level of qualification is accomplished through the successful completion of a one week,process and tool specific, targeted training session. Each process requires a combination of course training and on-the-job (OJT) training and one day of task observation. During the course training both the process and toolrequirements will be explained in detail to ensure the trainee has the ability to perform each task appropriately. TheOJT training is utilized as an evaluation method, specific training objectives and observation materials will be used.This training is structured to properly evaluate an individual’s knowledge, skills and abilities to perform the desiredtask. Upon demonstrating their ability to perform the given task(s), they will be qualified as a Level II User. TheLevel II training develops a more thorough understanding of the intricacies of both the tool and the process thanLevel I.

• Level III (Instructor): This level of qualification has a pre-requisite requirement that the individual has beenthrough either the Level I or Level II qualification process and is a GPAllied employee. The participant will beevaluated through their performance of carrying out the desired task unassisted. The evaluation process is used todetermine not only the individual’s ability to perform the task unassisted and thus demonstrating their knowledge,skills and abilities, but also to determine their ability to respond to any abnormal conditions that might occur. Uponsuccessful demonstration of the ability to perform the given tasks, without assistance, they will be qualified as aLevel III User.

• Level IV (Discipline Leader): This level of qualification has a pre-requisite requirement that the individual hassuccessfully completed Level III of the qualification process. The Level IV User not only has mastered both theprocess concepts and tool applications, but the user also has the administrative authority to modify integral toolfunctionality. Each GPAllied process has a Level IV Discipline Leader which owns the Management of Change(MOC) process and understands how that process integrates with other GPAllied processes.

Work Execution StandardsThe execution of all of GPAllied’s specific deliverables is guided by a specific work execution standard. This standard is in placeto guarantee one thing…consistency of execution. Whether you are working with us in North America or Malaysia, the deliveryof a class, a workshop or a specific consulting project, will be done to the same exacting standard.

Contained within the Work Execution Standard for each of the key deliverables will be items like:

• Scope and Purpose• Terms and Definitions• Key Concepts• Process Overview• Specific Procedures• Process Exceptions• Key Performance Indicators

Stakeholders inside of GPAllied follow a common MOC procedure for getting modifications made to the standardized deliverable.This is not to say that flexibility of delivery isn’t possible. In fact, flexibility is required for your success. But fidelity to the coreconcepts of the deliverable is the cornerstone of attaining successful results.

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Training Classes

At GPAllied, we understand that you are not interested in “training for training’s sake”. You need hard-hitting, impactful trainingthat addresses the specific need of your employees, delivers value for your training dollars, and produces bottom-line results.That’s what we deliver.

In today’s increasingly competitive business environment, your training investment only makes sense if it yields a tangibleimprovement in KPI’s like:

• Production efficiency• Asset downtime• Employee retention• Labor costs• Quality control• Safety

With over 200 courses that can be easily customized to your equipment and processes, we are the one-stop shop for all of yourtechnical and change management training needs. We offer these classes on-site at your facilities, for your employees; orperiodically around the world on an open-enrollment basis.

Please contact us for more specific information on training in the following areas:

• Asset Health Assurance• Reliability Engineering• Lean• 5S• Six Sigma• Change Management• Leadership and Management Systems• Operator Maintenance• Electrical Maintenance• Mechanical Maintenance• Instrumentation and Control Systems• Planning and Scheduling• Shutdown, Turnaround, and Outage Management• Project Management• Safety and Environmental

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For more information:

1.888.335.8276or email us at

info@gpallied.com

4360 Corporate Rd. Suite #110North Charleston, SC 29405

Visit our web site at www.gpallied.com

www.gpallied.com

GPAllied is the most diverse reliability and operations consultingand services company in the world. Our technical expertise,product portfolio and global reach are unmatched. This diversityis our considerable strength. It enables us to develop significantvalue propositions for you by delivering solutions acrossdifferent industries, different geographies and, even moreimportantly, across different aspects of your operation.

In our constant strive to deliver greater value to you, we havesourced recognized industry experts to join the GPAllied team.We have extensive experience across all industry sectors and inthe specialty fields of Lean, Reliability Engineering, Six Sigma,Condition Monitoring, Change Management, MaintenancePlanning and Scheduling, Workforce Development andMaintenance Craft Skills training.