presented by: abdul waheed – reliability engineer qurayyah sea water maintenance division may 3,...
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Equipment Reliability Initiatives and Challenges . Qurayyah Sea Water Maintenance Div. May 3, 2009. Presented by: Abdul Waheed – Reliability Engineer Qurayyah Sea Water Maintenance Division May 3, 2009. The Ultimate Goal – Reliability Excellence . Outline. - PowerPoint PPT PresentationTRANSCRIPT
“Safety is a Measure of Success”
Equipment Reliability Initiatives and Challenges
Qurayyah Sea Water Maintenance DivMay 3, 2009
Safety is a Measure of Success
The Ultimate Goal – Reliability Excellence
Key Elements of Reliability
Reliability is the probability that a piece of equipment will
perform its intended function over its intended period. It
directly correlates with ‘Quality of Maintenance’
Safety is a Measure of Success
Challenges
Way Forward
OutlineOur Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
• Deployment of Enhanced Business Processes
• Developed Forms for the use of Reliability Engineers
Rapid Improvement Teams
Our Strategy to Build Reliability
Expand Improvement Opportunities
Achieve and Sustain Best-In-Class Performance
STABALIZE
IMPROVE
SUSTAIN
Eliminate‘Bad Actors’
Capture Knowledge
Enhance Business Processes
Improve SAP Data Quality
Optimize Support Services
Deploy Predictive
Maint Tools
Max Systems & Resources
Utilization
Optimize Contract Services
Optimize Preventive
Maint
Continuous Awareness &
Team Building
Monitor Results
Journey Towards Maintenance & Reliability Excellence
Safety is a Measure of Success
Challenges
Way Forward
OutlineOur Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
• Deployment of Enhanced Business Processes
• Developed Forms for the use of Reliability Engineers
Rapid Improvement Teams
Safety is a Measure of Success
• Shipping Pumps G-7101 – G-7801• SO2 Gas Fan• Column Bottom Pumps
Current InitiativesElimination of ‘Bad Actors’ (Frequently Failing Equipment)
Safety is a Measure of Success
Shipping Pumps Trips 2008 – 2009 1st QRTData Source: SWED Trip Report & Operations Logbook (Period: Jan 2008 – March 2009)
1.5 MonthsCurrent MTBF:
60 MonthsDesired MTBF:
Mean Time Between Failure: (MTBF)
Safety is a Measure of Success
Shipping Pumps – Action Plan
Safety is a Measure of Success
Bad Actor- SO2 Gas Fan
Recommendations:• Short-term- Change Preventive Maintenance
interval from 12 to 3 Months.
• Long-term- Implement engineering design package (under development) to eliminate the process upset
Status: ETC: TBD
Safety is a Measure of Success
Bad Actor- Column Bottom Pumps
Root Cause:• Premature Failure of Pump Wear Rings and Anti-
Rotation pin due to inappropriate “Material” (Nitronic -60) causing “High Vibration”
Long Term Plan:• Inspect other nine (9) pumps module 20 – 28 and replace wear rings• Inform MS to contact the vendor for correct material wear rings and
stocking action
Short Term Plan:• Sent old wear rings to CSD Metallurgy Specialist for Analysis. –
Waiting for recommendations • Overhaul five (5) pumps module 15 – 19 and replace the wear rings
and anti rotation pins, fabricated from correct material
Safety is a Measure of Success
Reporting PM finding – Early detection of problems
Current InitiativesDeployment of Enhanced Business Processes
Maintenance Planner & Foreman
PM Supervisor PM Crew
Reports Deficiencies
Develops Monthly Report
Plan & Schedule
No Tracking & Feedback
Operations Foreman
Creates Notification
Old Process
Maintenance Planner & Foreman
PM Supervisor PM Crew
Reports Deficiencies
Create SAP Notification
Plan & Schedule
Reviewed by PM QA /QC
Operations Foreman
Approves SAP
Notification
New Process
Safety is a Measure of Success
Equipment Trips Reporting and Tracking
Current InitiativesDeployment of Enhanced Business Processes
Current Process
No E- Process, Trip Sheets are manually filled and Tracked.Plant Engineer Plant Foreman Operations Staff
SAP M2 Notification
Comments Comments
Root Cause Evaluation
Reliability Engineer’s Evaluation and Tracking
Maintenance
Findings
New E-Process
Safety is a Measure of Success
Maintenance Rework Tracking
Current InitiativesDeployment of Enhanced Business Processes
Reliability Engineer
Plant Foreman Operations Staff
Rework Notification
Comments Comments
Issues Finding & Recommendations
Report
Reliability Engineer Evaluates and Tracks through KPI
Maintenance
Findings
New E-Process
Current Process
No Business Process Exists. No Tracking or Reporting Mechanism available
Definition
Any maintenance work repeated due to same “failure mode” within three (3) months from last completion
Safety is a Measure of Success
Current InitiativesDeveloped Forms for the use of Reliability Engineers
Preventive Maintenance Deviation
To track the PM delays due to Operational requirement
Maintenance Rework To record the findings and corrective action taken for any maintenance rework
Bad Actor – Root Cause Analysis and
Recommendations
To track frequently failing equipment – coordination for Root Cause Analysis and recommendations tracking
PM Deviation
Rework
Bad Actor Tracking
Safety is a Measure of Success
Challenges
Way Forward
OutlineOur Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
• Deployment of Enhanced Business Processes
• Developed Forms for the use of Reliability Engineers
Rapid Improvement Teams
Safety is a Measure of Success
• Firefighting – Reactive Maintenance Culture – Low Schedule Compliance
• Historical data for ‘Failure Analysis’ is not available • Lack of Quality Assurance • Incomplete Equipment SAP Database and Bill of Materials • Equipment without PM program • Lack of Condition Monitoring Tools and Skills• No defined Maintenance Strategy to transform from PM to PdM• Non availability of Standard Job Plans • No Reliability KPIs deployed
Challenges
Safety is a Measure of Success
Challenges
Way Forward
OutlineOur Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
• Deployment of Enhanced Business Processes
• Developed Forms for the use of Reliability Engineers
Rapid Improvement Teams
Safety is a Measure of Success
• Deploy new business process and Reliability Tracking Forms
• Conduct SAP awareness sessions
• Develop a ‘Best Practice’ • KPIs and Monitoring• Involve Crafts in RCA• Audit SAP M2 Notifications
Repaid Improvement Teams
Enhance Equipment Trip Tracking and Monitoring
Scope Champion :
Abdul WaheedReliability Engineer
Safety is a Measure of Success
• Arrange training workshops• Develop template for
quality history input• Develop ‘Quick Reference’
pocket books for crafts• Facilitate SAP authorization
for Quality data
Repaid Improvement Teams
Improve the ‘Quality’ of Equipment Repair History and Knowledge Sharing
Scope Champion :
Salah Al-Shihri Maintenance Foreman
Safety is a Measure of Success
• Facilitate the Schedule Compliance Improvement
• Measure the current manpower utilization and improve the process
• Deploy a system for Crafts daily assignment through work ticket.
• Identify the causes for Material delays
Repaid Improvement Teams
Improve the Planning & Scheduling Process and Manpower Utilization
Scope Champion :
Khalid Al-Shehri Reliability Engineer
Safety is a Measure of Success
• Establish an action plan to improve the SAP Equipment data quality
• Link Bill of Materials and e-copy of equipment manuals / URL of smart drawings
• Assign appropriate PM for the new equipment through PM Coordinator.
Repaid Improvement Teams
Improve the SAP Equipment Data Quality and Bill of Materials
Scope Champion :
Mohammad Al-Garrash Reliability Engineer
Safety is a Measure of Success
• Develop PM QA scope• Tour Plant and identify
deficiencies from Maintenance Perspective
• Track and Monitor the deficiencies reported by PM Crew
• Balance PM workload for next year
Repaid Improvement Teams
Lead the PM Quality Team
Scope Champion :
Mohammad Al-FadhalMaintenance Foreman
Safety is a Measure of Success
• Develop guidelines for stepping jobs to Contractor
• Deploy KPI to track and monitor the emergency mobilization
• Monitor repeated work on ‘Short Form Contract’ and peruse for a Long Form Contract
Repaid Improvement Teams
Contracts Optimization and Effective Utilization
Scope Champion :
Hani S Nogaidan Contracts Engineer
Safety is a Measure of Success
Challenges
Way Forward
OutlineOur Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
• Deployment of Enhanced Business Processes
• Developed Forms for the use of Reliability Engineers
Rapid Improvement Teams
Safety is a Measure of Success
• Continue on Quarterly Reward and Recognition for Maintenance Crafts in taking the “Proactive Maintenance approach”
• Involve Maintenance Crafts in improvement projects• Continue capitalizing on PM findings to develop appropriate
Maintenance Strategies• Strengthen the PM QA process • Conduct PM optimization using PMO 2000 in 2011.• Deploy Predictive Maintenance Tools (IR Camera – Ultra sound)• Deploy Wireless technology for Vibration Monitoring• Purchase hand held vibration monitors • Strengthen the OCM Program
Way Forward
Safety is a Measure of Success
Scattered knowledge
Inconsistent actions
What Maintenance Work?
At What time?
Current Reality
Safety is a Measure of Success
The Right Workat
The Right Time
consistent action
Information System provides easy access to a Common Knowledge Repository
actionableknowledge
Consistent organized way to capture and use Knowledge & Information
business process and practices
Future Outlook
Safety is a Measure of Success
“We are what we repeatedly do. Excellence then, is not an act, but a habit.”
~ Aristotle, 4th century BC Greek philosopher
Thank You
Safety is a Measure of Success
QSMD PM Workload
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500.0 HR
1,000.0 HR
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2,000.0 HR
2,500.0 HR
3,000.0 HR
3,500.0 HR
4,000.0 HR
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QSMD