Reliability & operational excellence

Reliability engineering
for plants that can't
afford downtime.

The asset management and operational excellence practice of large regulated manufacturers, brought to small and mid-size plants — without the consultancy overhead that puts it out of reach.

Start a conversation What we do
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Every asset in your plant sits somewhere on this scale.
Most sites cannot say where. That is where we start.
10+
Years in reliability and asset management
CMRP
Certified Maintenance & Reliability Professional
MS
Master's in Engineering Management
GxP
Regulated pharmaceutical and medical device experience
Services

Four things, done properly.

Each one stands alone. Most clients start with an assessment, because you cannot improve a maintenance program you have never measured.

01

Reliability program assessment

Where your maintenance program actually sits, and what the gap to where it should be costs in labour hours and dollars.

  • Full equipment asset register with condition and criticality coding
  • Current state benchmarked against a defined maturity ladder
  • Gap quantified in hours per year and fully loaded labour cost
  • Prioritised roadmap, not a document that sits on a shelf
02

Preventive maintenance build-out

Task lists written failure-mode first, on frequencies your team can actually hold.

  • Job plans drawn from a library of over 1,300 equipment classes
  • Time-based PM, condition monitoring and calibration schedules
  • Criticality-weighted frequencies, tuned to your staffing reality
  • Loaded into your CMMS, or into a system we set up with you
03

Facility condition assessment

What your buildings and utilities will cost you over the next ten years, and when.

  • Condition survey across structure, envelope, HVAC, electrical and utilities
  • Facility Condition Index and deferred maintenance backlog
  • Ten-year capital renewal plan by year and by system
  • Drone survey of roofs, facades and thermal where access is the obstacle
04

Operational excellence coaching

Building the internal capability so the improvement outlasts the engagement.

  • WCM and TPM pillar structure adapted to plant scale
  • Loss analysis, OEE definition and measurement that survives scrutiny
  • Energy and utilities cost reduction
  • Coaching maintenance leads and operators, not just writing procedures
Method

Measure, quantify,
sequence, embed.

Most reliability programs fail at step one. A plant cannot prioritise what it has never counted, and a maintenance schedule built on assumption gets abandoned the first busy week.

Step one

Count it

A complete asset register with make, model, serial, condition and criticality. Walked and recorded, not estimated from a spreadsheet someone inherited.

Step two

Price the gap

Current maintenance effort against target, in hours per year and in dollars. A number a plant manager can take to a budget conversation.

Step three

Sequence the work

Condition severity weighted by criticality. The broken thing in the production line outranks the broken thing in the storeroom, and the plan says so.

Step four

Hand it over

Schedules, job plans and the register live with your team in a system they can run. If it only works while we are on site, it has not worked.

Sectors

Where the experience comes from.

Regulated pharmaceutical and medical device manufacturing, heavy industry, and building products — plus healthcare facilities, where equipment uptime is measured in something other than dollars.

Pharmaceutical & GxP manufacturing Medical device Building products Primary metals Food & beverage Healthcare facilities Animal health Light industrial
Client tools

Survey Platform

The field tool behind the assessments. Asset registers, condition coding, photo evidence, maintenance planning and gap analysis — built to run on a tablet in a plant with no signal.

Restricted access — clients and staff only
Open Survey Platform
  • Over 1,300 equipment and instrument classes
  • Printable job plans and technician work lists
  • Maturity gap and cost analysis
  • Drone and photo evidence per site
  • Works fully offline once installed
Contact

Tell me what's breaking.

wallacebarasa@gmail.com (269) 267-5870

Connect on LinkedIn

On site where it matters, remote where it doesn't.
Surveys and coaching happen in the plant. Assessment analysis, program design and reporting are done remotely.
First conversation is a call, not a proposal. If the fit isn't there, you'll get told that rather than sold something.
Typical first engagement: a two to four day reliability assessment at a single site, producing an asset register, a quantified gap and a prioritised roadmap.