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When your operation faces constant breakdowns, it’s easy to assume that all you need is more effort from your maintenance team to get things back up and running. But what if the real issue isn’t effort? What if it’s the lack of a reliability-centered maintenance system? This was true for one of our clients, who was stuck in a cycle of constant downtime. After working with our team, they found that what they needed wasn’t more effort. They needed better structures and systems. We helped align their leadership using the Society of Maintenance and Reliability Professionals (SMRP)’s Five Pillars of Reliability. This ultimately shifted their protocol from reactive maintenance to a system that connected daily work with their organizational goals.

Here’s how we did this: Pillar 5: Work Management — We showed their team how to standardize work orders. We also fine-tuned their maintenance planning and scheduling process, and we built dashboards for Preventive Maintenance compliance. Pillar 2: Manufacturing Process Reliability + Pillar 4: Leadership — We worked alongside management to optimize their daily routines. We also helped them determine escalation protocols and build accountability systems. Pillar 3: Equipment Reliability — We implemented real-time downtime tracking with ASPEN/MADERA. This gave them an accurate Pareto analysis and root cause disciplines. The results? They speak for themselves. Our client had a record annual production in the first year at both production locations. Their on-site sustainability doubled its production output, and maintenance costs dropped as throughput increased and they reduced reactive work. The lesson? Reliability is not a maintenance program. It’s a leadership system supported by tools, behaviors, and processes. At Osorno, we assist organizations in making this shift. And we can help you transform firefighting into sustainable reliability and a competitive advantage.