asset management building a successful world class ... · serp (system equipment reliability...

Boxer Environmental1908 Creekwater Blvd., Port Oranage, FL 32128

Asset Management Building a Successful World Class Maintenance Organization

How do we measure success?

People – The Who

Processes – The What

Platforms – The Tools

Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128

Components of a Maintenance OrganizationComponents of a Maintenance OrganizationPeople - Who– Qualifications and Job descriptions

– Internal Communications

– Training

– Utilization

– Accountability


Components of a Maintenance OrganizationComponents of a Maintenance OrganizationProcesses - What– A balanced Maintenance Strategy

– Work Flow to execute the strategyWork Identification

Planning

Scheduling

Packaging

Execution

Close Out

– Continuous Improvement Methods

– Metrics


Components of a Maintenance OrganizationComponents of a Maintenance OrganizationPlatforms - Tools– CMMS

– PdM TechnologiesVibration

Oil Analysis

Thermal


Four Maintenance StrategiesFour Maintenance Strategies


Which to use depends on:• The equipment to be maintained

• The operational context

• The maintenance resources available

• Health & Safety compliance

• General Practicalities

• Cost

4 Strategies4 Strategies


• All FOUR maintenance strategies are required to make an effective maintenance plan

• All FOUR maintenance strategies have advantages when implemented correctly

• All FOUR maintenance strategies have disadvantages when implemented incorrectly

• The appropriate strategy can only be chosen when the reasons for equipment failures are fully understood

Maintenance Strategies - Key PointsMaintenance Strategies - Key Points


Assess condition of organization and determine stage of development of the reliability program in– Work Flow– Technology– Organization– People

Some Advanced strategies may be in place without having the basics in place. Costing more money than they should.

Develop a StrategyDevelop a Strategy


AUDIT

EXECUTE

SCHEDULE

PLAN

WORK ORDERSMaintenance Work In ProgressMaintenance Work In Progress


1. Consistent Top Management support for the program2. Develop and implement a Strategy 3. Standardize Work Flow Process4. Organized to support the Work Flow Process5. CMMS System that supports the Work Flow and Organization

Total Productive MaintenanceReliability Centered Maintenance

Reliability Based Maintenance

Predictive

Preventive

Reactive

World Class Programs (Relative % time/activity)


Advanced StrategiesAdvanced StrategiesSERP – System Equipment Reliability Prioritization -Method to rank all of a plant’s equipment.

Streamlined RCM – Streamlined Reliability Centered Maintenance – Process to determine the appropriate Failure Defense Plan.

Failure Defense Plan – Plan for each piece of equipment detailing the Maintenance Strategy (the big 4), frequency, resources, etc. to protect the equipment’s reliability.


SERP (System Equipment Reliability Prioritization)SERP (System Equipment Reliability Prioritization)A 3-tiered approach involving the ranking of– System Criticality, taking into consideration:

Process Throughput, Operational Cost, Product Quality, Safety Considerations and Regulatory Compliance

– Asset Criticality, involving:Operational Criticality Ranking

– Maintenance Priority IndexAsset Failure Probability Factors


Streamlined RCM ProcessStreamlined RCM ProcessA process to examine current maintenance requirements and validate them for probability, applicability and reasonability using operational and technological experience

–– PProbableEstablish The Need for MaintenanceEstablish The Need for Maintenance

–– AApplicableTask is Beneficial in Restoring or Maintaining Task is Beneficial in Restoring or Maintaining Inherent ReliabilityInherent Reliability

–– RReasonableEnsure Task is JustifiedEnsure Task is Justified


Failure Defense PlanFailure Defense PlanSystematic Review of all Maintenance Strategies for all criticalequipment and adjusting strategies based upon actual equipment failure history, ACR and MPI.Strategy adjustment includes:– Changing shutdown inspections to Condition Based running inspection

– Extending frequency of inspections

– Adding/deleting procedures as required

For plant with many PMs, expect a 20-30% reduction in PMs

For a plant with no PMs, this is a method to document them.

The Right Maintenance on the Right Equipment at the Right Time by the Right People at the Right Cost.


Industrial Example: Fossil PowerIndustrial Example: Fossil PowerMaintenance Practices Mix

Prior to Program ImplementationMaintenance Practices Mix

After Program Implementation

PdM - PredictivePM - PreventiveRTF - Run-to-FailurePAM -Proactive

PdM46%

PM35%

PAM3%

RTF16%RTF

42%

PdM12%

PM45%

PAM1%


Fossil Power Industry – Program SavingsFossil Power Industry – Program SavingsAverage Program Savings: $2.0M (ROI = 4.73:1)

ProductionCapacity

(Availability)65%

Parts Reduction(Inventory)

10%

EFORReduction

10%

Other5%

InsuranceReduction

1% LaborReduction9% (OT)

Savings by Classification


Fossil Power Industry - InvestmentFossil Power Industry - InvestmentAverage Program Investment: $423K

Labor62%

Technology26%

Consulting& Training

12%

Total Investment Mix


Steps to Reaching World ClassSteps to Reaching World Class

PM

RM

PDM

RM

PAM

PM

PDM

PM

RM

Adequate BestBetter

Elements In Place

•Maintain Status Quo

Elements In Place

• Management Support

• Right Personnel

• Work Flow Process

•Planning

• CMMS

• KPIs

•Accountability

Elements In Place

• All of “Better”

• Equipment Priority -SERP

• Failure Defense Plans on >30% of equipment

• Predictive Programs


Adequate

CMPM

Transformation - Adequate to BetterTransformation - Adequate to Better

Better

CMPM

PDM

CMMS

PdM concepts in place

PM starts to drive actions

Planning function staffed

Scheduling function staffed


Transformation - Better to BestTransformation - Better to Best

Better

CMPM

PDM

Best - LCP

CM

PM

PDM

PAM

CMMS

FDP has been done using SERP, FMEA, SRCM

Optimized Maintenance Program

KPIs identified and communicated

CBA in place

Planning function staffed

Scheduling function staffed

asset management building a successful world class ... · serp (system equipment reliability...

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