Reliability engineers who maintained the assets, not advised from a distance
HolisticAM’s reliability engineering service turns your failure data into maintenance strategies that hold up on site: Weibull analysis, FMECA, RCM, RBD modelling and spares analysis, delivered by engineers who came up inside Rio Tinto, BHP, Alcoa and MMG operations.
Reliability is rarely one broken thing
The reliability of your assets is rarely down to one cause. It is the combination of maintenance strategy, data quality, execution discipline and engineering judgement that decides whether a fleet runs or fights fires. A consultant who has only ever seen the analysis side cannot weigh what a strategy costs to execute on a live site.
Our engineers write the Weibull models and have also stood in the workshops the recommendations land in. That is why our strategies arrive as service sheets and CMMS master data your planners can load, not findings your team still has to translate.
New to the discipline? Read the plain-English guide: What is Reliability Engineering?
Services built on seven core methods
Maintenance plan optimisation
Data-driven review of existing strategies: what to keep, change and kill, justified by failure history.
Maintenance plan development
New strategies built asset by asset from FMECA, delivered CMMS-ready.
RAM studies & assurance
Reliability, availability and maintainability modelling for design decisions and production targets.
Life cycle cost modelling
Whole-of-life cost of maintaining the asset, so replacement and upgrade calls are financial, not anecdotal.
Spare parts analysis
Critical and insurance spares determined by RBD modelling, as delivered for Hitachi EX5500/EX5600 excavator fleets.
Reliability audit & assessment
Where your maintenance function sits against good practice, and the roadmap to close the gap.
FMEA / FMECA
Facilitated criticality analysis that becomes the backbone of the strategy.
Reliability centred maintenance
Full RCM where the consequence of failure demands it, in ReliaSoft RCM++.
Life data analysis (Weibull)
Failure characteristics, MTBF and optimal replacement intervals from your own downtime data.
Root cause analysis
Apollo RCA facilitation for defect elimination, from certified trainers.
Reliability block diagrams
System-level modelling that shows which component reliability actually moves plant availability.
Training & mentoring
From reliability fundamentals to site-embedded mentoring, as delivered at Newcrest Cadia and Lihir.
Strategies that moved the needle on real fleets
Numbers as published in the linked case studies. The 4100XPC programme is the fully baselined result: planned-to-corrective ratio was 44:56 before implementation, corrective fell to 37% within six months.
Case studies in text, not just pictures
P&H 4100XPC shovels — data-driven turnaround
Downtime analysis, Weibull models and FMECA review delivered as a new strategy with customised service sheets and SAP master data. Corrective maintenance fell from 56% to 37% of total in six months.
Komatsu 930E haul trucks — fleet optimisation
Fleet-wide review across multiple Australian open-cut mines: Weibull life data analysis, service-day execution, MTTR and NPV-assessed OEM upgrades. Reported gains of 112 available hours per truck over six months and MTBF held above 90 hours.
ANSTO Synchrotron — regulated-environment RCM
Eight RCM and CHAZOP studies across six new beam lines, facilitated remotely in ReliaSoft RCM++, with five reports contributing to ARPANSA regulatory submissions.
Newcrest Cadia & Lihir — capability building
Bespoke training and mentoring for site reliability engineers: reliability fundamentals, life data analysis, RBD modelling and RCM, each participant working in ReliaSoft RAM Suite.
Featured Reliability Engineering Projects
Start with the data, not a retainer
Reliability assessment
A bounded review of your failure data, strategy coverage and maintenance mix. You see where the losses are before committing further.
Strategy build
FMECA, Weibull and RCM applied where the criticality justifies them, producing a strategy your planners can schedule.
Load, embed, assure
Service sheets and master data loaded, your team trained and mentored, results tracked against the baseline.
The first step maps to our existing Reliability Assessment offer.
Reliability engineering, answered
What does a reliability engineering consultant actually deliver?
We already have maintenance plans. Why are assets still failing?
Do you work with our CMMS or ERP?
What software do you use?
Can you build our team’s capability rather than just consult?
Which asset is costing you the most right now?
Bring the downtime data for the fleet or plant that hurts. We will show you what the failure characteristics say, and what a data-driven strategy would change.