• Making Reliability Simple

      A proven approach to reduce your downtime by 90%. Just 4 Essential Elements.

      Start the Road to Reliability
      Planning & Scheduling

      Planning & Scheduling

      Increase your maintenance workforce by 35% without hiring anyone. Reduce costs, improve safety and increase morale.
      Preventive Maintenance

      Preventive Maintenance

      40%-60% of PMs add little value. Learn how to eliminate them to reduce workload, reduce costs, and increase uptime.

      Defect Elimination

      Defect Elimination

      80% of failures that occur in a plant, have occurred before. Fix them forever and stop forever fixing.

      Leadership & Culture

      Leadership & Culture

      70% of change initiatives fail. Without leadership you’ll get nowhere. Without culture you won’t sustain anything.
      Start the Road to Reliability

    • Ready to make a change?

      If you like what you’ve read and want to apply the Road to Reliability™ in your company let’s have a chat:

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      Online Training

      Online Training

      Education is key to success. With our online training, your team can access world-class training wherever you are.

      Coaching

      Coaching

      After education comes implementation. We provide proven frameworks, but some timely coaching can make all the difference.
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      Consulting

      When things need to get done and you need an extra set of hands or strategic advice. Who are you going to call?
      Success Stories

      Success Stories

      Want to see what you can achieve with our support? Read success stories and testimonials from clients across the globe.

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    • Together we achieve more

      The Road to Reliability™ can be lonely, especially in the early stages. Find like-minded professionals, know you are not alone, share experiences, and get help.

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      Insights

      Insights

      Read in-depth ‘how-to’ articles that cover all the areas of the Road to Reliability and more.

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      Resources

      A range of calculators, templates, infographics, and presentations. Download what you need and start Making Reliability Simple™.

      Coming Soon!

      Glossary & FAQs

      Glossary & FAQs

      Need a quick answer to a common question? Looking for an explanation or definition of an Industry term? Start here.

      Coming Soon!

      Webinars & Videos

      Webinars & Videos

      See our schedule of upcoming webinars and watch recordings of past sessions. Plus a collection of free course videos.

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Defect Elimination

Fix it forever.
Stop forever fixing.
Get Started

The Road to Reliability™
is full of defects

Even when you set out to improve the reliability of your plant you’ll continue to experience failures in your plant. We know from experience that some 80% of failures that occur in a plant have occurred before. That’s where defect elimination comes in.

What happens in most organisations that deal with repeat failures? We plan for these failures. We write job plans. We hold extra spares. And when then failure happens we can fix it fast. We get better and better at fixing failures.

That’s great, right?

Maybe. Chances are that you could be a lot greater if instead of fixing that failure over and over again you actually fixed the source of the failure. If you fixed the defect that is causing that failure.

Read More
50% of performance problems in power industry were associated with maintenance​
Read More
in 80% of in-flight engine shutdowns maintenance ​was a contributing factor
Read More
Read More
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Read More

You will get nowhere on the Road to Reliability™
without Defect Elimination

Ever wondered why you can’t stop the fire fighting?

Research done by Winston Ledet whilst working for Dupont in the 1990s has shown that when you implement Planning & Scheduling, Preventive Maintenance and Defect Elimination you can reduce your downtime by 90%.

About 30% of that reduction in downtime is because of Planning & Scheduling an Preventive Maintenance. And about 60% is the result of Defect Elimination.

Simply put, you’ll never become a Reliable Plant if you don’t get rid of those defects that keep generating failures.

You will always be fighting fires and working in a reactive environment unless you get rid of those defects.

Implementing Planning & Scheduling on its own is not enough. Implementing Preventive Maintenance on its own is not enough. Even implementing both is not enough.

You need to start applying Root Cause Analysis and establish a Defect Elimination culture to make big strides in improving your reliability.

Online training courses that teach your team
how to implement Defect Elimination & Root Cause Analysis

Developing & Improving Preventive Maintenance Programs

Learn the powerful principles of Defect Elimination and Root Cause Analysis and how both are essential on your journey to higher reliability.  

We offer a suite of courses on Defect Elimination & Root Cause Analysis tailored for those leading an implementation (DE100), practitioners like reliability engineers or supervisors (DE200), managers (DE300), and frontline staff like Operators and Technicians (DE400).

Explore CourseS

100% online. Take the course anywhere, anytime

Because the course is delivered via a 100% online, web-based learning management is system you can truly take this course anywhere in the world, any time of the day.

Practical training complete with tools & templates

To ensure you succeed where many have failed in the past we teach you a proven and comprehensive framework for implementing Defect Elimination & Root Cause Analysis.

We want you not just to enjoy this course, you need to get a real return on your investment – and that requires implementation!

Lifetime access

You don’t just get 2 days of classroom training and a bunch of slides.

You can watch the pre-recorded training videos as much as you want, whenever you want, and yes, you also get access to all future updates.

Defect Elimination improves
plant reliability more than anything else

Root Cause Analysis & Defect Elimination: Why you can’t do without

  • Erik Hupjé – 15 min read
  • Listen to Audio
  • Watch Video
  • Download PDF

With the Road to Reliability™ Framework you can reduce your downtime by 90%. And although you need all 4 Essential Elements to succeed the majority of your downtime reduction will come through Defect Elimination.

In this article, I will explain in detail why you need to apply Root Cause Analysis and establish a Defect Elimination culture to succeed in your journey to a Reliable Plant.

Tell Me Why

What effective Defect Elimination looks like

  • Erik Hupjé – 15 min read
  • Listen to Audio
  • Watch Video
  • Download PDF

Root Cause Analysis (RCA) and Defect Elimination are similar, but not the same. Root Cause Analysis focusses on getting rid of the 20% of issues that cause 80% of your breakdowns, downtime and costs.

Defect Elimination is all about removing the many small, niggly little issues in your plant. And it’s very much a culture change. In this article, I explain how Root Cause Analysis and Defect Elimination work together and what it looks like in a Reliable Plant.

Show Me How

How to implement Defect Elimination

  • Erik Hupjé – 15 min read
  • Listen to Audio
  • Watch Video
  • Download PDF

Knowing that Root Cause Analysis and Defect Elimination are critical to your reliability success is one thing. Implementing them successfully and sustaining the change in the long run is a very different story.

In this article, I will give you a detailed step-by-step implementation guide that adresses both RC techniques as well as building a Defect Elimination culture.

Show Me How

Your Defect Elimination toolkit

100% actionable articles, videos, easy-to-use tools, webinars. Created by a practitioner for a practitioner like you.

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