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  • 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

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

    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

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

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

    PdM TechnologiesVibration

    Oil Analysis

    Thermal

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

    Four Maintenance StrategiesFour Maintenance Strategies

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

    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

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

    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

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

    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

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

    AUDIT

    EXECUTE

    SCHEDULE

    PLAN

    WORK ORDERSMaintenance Work In ProgressMaintenance Work In Progress

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

    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)

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

    Advanced StrategiesAdvanced StrategiesSERP System Equipment Reliability Prioritization -Method to rank all of a plants 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 equipments reliability.

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

    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

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

    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

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

    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.

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

    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%

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

    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

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

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

    Labor62%

    Technology26%

    Consulting& Training

    12%

    Total Investment Mix

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

    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

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

    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

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

    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