Maximo: A Key Tool for Asset and Maintenance Management

Presented by Paul Backlund

Facility Manager - Canyon Ferry Dam and Power Plant

Reclamation’s Objectives• Have unity for an approach to asset Maintenance

and Management throughout Reclamation.• Clean up data from previous versions of Maximo.• Take advantage of new features to improve our

business processes• Set stage for asset management to sustain

Reclamation for the next 15 to 20 years• Develop a planned and scheduled approach to deal

with aging infrastructure and work force.• Implement an informed and measured approach that

promotes the cultural transition that meets demands

The Bureau of Reclamation’s Capital Asset and Maintenance Challenges

• Reclamation is a large complex organization• Careers at stake • Customers of Power and Water depend on

Reclamation systems• Significantly Aging infrastructure • Work force ready to retire (40% in 5 yrs)• Higher transparency with customers• Viability of Reclamation is dependent on having data

that supports our work and decisions

Reclamation’s approach to meeting viability in a reactive power and water

market.

• Senior Management’s goal for transparency in management

• Management of operational and maintenance risks associated with aging infrastructure

• Meet regulatory and customer demands• Provide training for the application and business

process improvement • Have data that demonstrates we manage assets in a

productive and financially responsible manner.

Reclamation Powerplant

Elephant Butte Dam

Accomplishments to Date

• Development of Standard Business practices and configuration of CARMA (Maximo) to meet those standards

• CARMA has been successfully implemented in total 113 generating units, at 39 sites, with 7,200 MW of generation. When fully implemented, 170 hydro units and 50 powerplants, representing 14,200 MW will be managed using Maximo, in addition to a number of water conveyance and delivery systems.

• The transition at Grand Coulee Dam has begun. Grand Coulee Dam is the largest generation facility in United States, with 27 units (6500 MW). Maximo will be deployed February, 2009.

Grand Coulee Dam

SCOPE of IMPLEMENTATION• Implementation is not a simple task in Reclamation, huge

responsibility with 58 power plant and 300+ dams and water conveyance structures

• Each site is unique, presenting its own challenges• Remote, large facilities, multiple locations with shared

work groups; – Northern California, Eastern Colorado

• Public safety through Safety of Dams Program• Power reliability and stability, safety, WECC requirements• Municipal and agriculture water delivery in CA, Nevada,

Arizona, and Colorado

CARMA Implementation Strategy• Unify the maintenance management system by

consolidating 18 independent installations of Maximo version 4

• Develop Standards to be used system wide and then create a standard configuration of Maximo

• Prototype a full implementation in CARMA to demonstrate the successful deployment

• Deploy the standards and application at the remaining Reclamation sites systematically. 14 major areas and multiple sites

• Employ contract support for the implementation as appropriate

IMPLEMENTATION CONSIDERATIONS• Understand current user needs and issues (4.1.1)• Carefully designed to insure data integrity and

continuity of operation• The need to support existing system is IMPORTANT• Ensure history and data are preserved in the

transition to the new system• Provide initial and follow up training and help the

users • As we progress through implementations use

flexible processes to improved application• Hone and improve business practices based on user

experience

MAXIMO CONFIGURATION to Support Business processes

• Standardize naming and numbering• Rebuild location and assets hierarchies to

improve flexibility in Maximo• Review and clean up Job Plans and PMs• Insure data integrity in new system• Expand use of Failure Codes and

Classifications• Minor configuration to support bankcard

transaction tracking• Standardize reports

Key Business Practices aimed at directional changes in asset

management

• Programs– Corrective Maintenance Program – Preventive Maintenance Program – Predictive Maintenance Program– Asset Modification and Improvement Program

Its not all work

CARMA Business Practices• Planning and Scheduling– Maintenance Planning– Maintenance Scheduling

• Purchasing and Inventory Control• Outage Management– Outage Planning and Scheduling

CARMA Business Practices

• MAXIMO Administration– MAXIMO System Administration – Location and Equipment Naming Conventions– Maintenance Reporting and Metrics– Management of Failure Codes and Classifications– Workflow of Work Order Processes

• Quality Assurance– Maintenance Quality Control– Calibration of Measuring and Test Equipment– Tool and Equipment Control

CARMA Business Practices

• Maintenance Training– Mandatory Training– Technical Training– MAXIMO Training Requirement Matrix

– Upfront– Go live – Follow up

REPORTS and REPORTS MANAGEMENT

• It’s all about Performance and Metrics

• PERFORMANCE REPORT monthly• System performance Reports• PROCESS REPORT• INFORMATIONAL REPORT• Querying Capabilities

Use of a Best in Class Commercial Software for Asset and Maintenance

Management System Asset management• Work order management• Work history• Cost tracking• Planning and scheduling of manpower and material

resources• Asset maintenance prioritization• Condition monitoring• Metrics and Performance Indicators (Reports and

Reports Management)

Materials and Inventory Support for Maintenance

• Recognized as key factor to Reclamation’s success in utilizing the new standards and application

• Management is working toward standardization of material support for maintenance in a single data base.

• The driver to develop this module and make it functional, in doing, so will ensure materials are captured against an asset.

Training Support

• Must invest in the appropriate, long-term training and support for use of Maximo

• Standardization of business practices, data, inventory and configuration requires Reclamation to develop and continually deliver standardized, appropriate training for management and staff

Summary

• In summary, our experience with implementation at Reclamation has had varying levels of success.

• Issues arising from implementing the new application and with adapting to the new business practices, requires committed leadership.

• We have found that, within Reclamation, we can help each other addressing issues as they arise

Points of Contact

Paul Backlund, Facility Manager, Canyon Ferry Dam and Powerplant

406-475-3923

pbacklund@gp.usbr.gov

Leona Paul, CARMA Project Manager

303 445-3392

lpaul@do.usbr.gov

Aging Infrastructure Who and Where?

QUESTIONS?