public mg t course mar 2012

7/23/2019 Public Mg t Course Mar 2012

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Asset Performance Management

Based on Planned MaintenanceOptimisation


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Who is OMCS International

Operations and Maintenance Consulting Services.

In business for 16 years. Developed te PMO!"""# $eliability %ssurance

metodology. Provide PM Optimisation metodology &orld'&ide.

Currently as sites in %ustralia( )e& *ealand( +olland(Sout %frica( Saudi %rabia( %rgentina( Pilippines(Malaysia( Indonesia( ,S%( ,-( Cile( ai&an( Bermudaand oters.

raining material &ritten in Cinese( $ussian( Spanis(

Baasa. /icensee net&or0 around te &orld.


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Who am I Steve Turner

1! years in te $%%2

3or0ed as a consultant &it4 5eneral Motors automotive supplier base Price 3aterouse ,r&ic0

OMCS International


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Course Outline

Day 1 Mainly teory and intro to case study and

soft&are Day ! to 7 Soft&are training and case study

using te soft&are

Days 6 to 8 3or0 on your o&n case study orassignment or elp someone else.


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About you ...

9our name

9our company

9our position &itin company

9our : biggest current maintenance

issues


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What has happene to most organisations ...

Reduction in employees and soft targetsta positions

Increased demand on production assets

Reduced maintenance budgets Increased fear of commercial catastrophes

Ever increasing focus on safety and theenvironment

Many failed improvement programs.


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Introuction


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!o" organisations get into trouble # the

vicious cycle of reactive maintenance

Page ;


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The $irth of inustrial Plant..a Common Scenario

Maintenance not involved in te design. Poor maintainability. /ac0 of condition monitoring considerations4

Inspection facilities. Sample points. 5auges and alarms.

Inade


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The $irth of inustrial Plant.. cont

e pro>ect runs over budget and te design

capability is reduced. ere is little margin bet&een &at te plant can

acieve and &at is e?pected of it.

e maintenance tradesmen arrive too late forade


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After Commissioning .

e pro>ect is anded over &itout a maintenance

program @and &itout dra&ingsA e tradesmen &rite one2

/ittle input from operations

)o consistent metod )o audit trail of rationale 5enerally ris0 averse ' over'servicing

Page 6


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The Infancy ays

ailures appen and useless tas0s are added.

Operations as no buy in for te maintenanceplan and tere is a reluctance to cooperate.

)ot all te PM Program is acieved and tis

becomes te culture of te organisation. emporary repairs creep in and get out of control

Consultants arrive andcut eads

Page 6


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Backlog grows

PM is missed

TemporaryRepairs

More repeatwork

More preventablefailures

Morale Declines

Resources takenby Breakdowns

Head / BudgetReduction

Standards Drop

The %icious Circle of &eactive Maintenance

Page ;


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Tactics to brea' the vicious cycle

Page


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As'ing for more manpo"er is not li'ely to be asuccessful solution

e ans&er lies in improving te effectiveness of

macines and people. is can be acieved troug ensuring tat every PM

tas0 is cost effective and adds value to te business2. e means to do tis is troug a PM Optimisation

based defect elimination and productivity improvementprogram.

3e call tis $eliability %ssurance.

Page


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otalime

(very asset has inherent capability

=?pected ailure

Planned Maintenance

,ne?pected ailure

%vailable ime InerentPerformance/evel

InerentCapability /oss

MaintenanceCapability /oss


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A typical e)ample

InerentCapa

bility


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PMO replaces useless PM "ith effective PM.. "hilstincreasing resources to o it.

=ffective PM

Before PMO %fter PMO

$esou

rces

toDo

PM

PM

)o

tDone

$eso

urces

toD

oPM

PM

)

otDone

,seless PM Missing PM

PMO l l PM ith ff ti


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PMO replaces useless PM "ith effectivePM.."hilst increasing effective resources...

$efore PMO

After PMO

$rea' *o"n Mce PM

+p Time

+p Time

(ffective &esource ,evel

(ffective &esource ,evel

An moreimportantly..increasinguptime

$rea' *o"n Mce PM


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!alving your o"ntimesource Winston ,eet -/.

To halve youro"ntime onlynee to get tohere.

Page


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The relationship bet"een the four elements source Winston ,eet -/.

CMMS

PMO$CM

Do&ntime

Data

Incident

Management


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The cornerstones of reliability assurance

CMMS

Do&ntimeDataManagement

PMO$CM

$eliabilityIncidentManagement

Wh t i li' l t b ith t


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What is li'ely to be "rong "ith your currentmaintenance program...

Some tas0s duplicate oter tas0s. Many tas0s &ill be intrusive and overaul based

&ereas tey sould be condition based. Some tas0s serve no purpose &atsoever. as0s done too often or too late. ere are preventable failures

tat need PM $outines

or defect elimination. ere is no audittrail of &y tas0sare done.

Page


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The minimum stanars for issuing a PM to any person

%ny resource tat is e?pected to complete an activity(must be given te tree 0eys.

Tools

an

materia

lsS'illsanTra

ining

Available Time

0host

The Three 1eys


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&eliability Centre Maintenance ..

$CM is a systematic approac to analysing te

maintenance re


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MaintenanceTasks

Functions

FailureModes

FunctionalFailures

Modifications

&CM is a top o"n process


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What is PM Optimisation2

PM Optimisation is a process &ic uses te

principles of $CM to rationalise e?istingmaintenance programs( failure istory and otertecnical documentation and eliminate defects.

It starts &it eiter te e?isting maintenance program for assets in use( or a maintenance program set up for similar e


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MaintenanceTasks

FailureModes

Modifications

PM Optimisation 3PMO4 starts "ith e)istingmaintenance tas's..

MaintenanceTasks

Failure History &Documentation

&CM 5 PM Optimisation are methos of analysis


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&CM 5 PM Optimisation are methos of analysisthat...

Determine effective maintenance actions and te

correct fre


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&CM ta'es a long time because....

It starts &it a blan0 seet of paper ignoring te

maintenance program in place. Spends too muc @:"EA of te analysis defining

functions.

It treats every li0elyfailure mode &enonly !"E of temcan be cost effectively

treated by PM.

PMO gets the same results in -67th of the time


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PMO gets the same results in -67thof the timebecause....

It starts &it your e?isting maintenance program(

failure istory and tecnical manuals. Completes functional analysis far more


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PMO Achieves the same results...

$CM

unctions

unctional ailures

$CM ' %ll ailureModes to berevie&ed

PMO

Current PM

ailure +istoryecnical Documentation

SamePM Program

PMO Pool of ailures

to be revie&ed

Preventableailure Modes


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Conventiona

lRCM

PMOptimisation

osts Time Benefits

Analysis Costs an Spee an $enefits

Source: Johnson 1996 (e!aunee "uclear #o!er #lant$


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Inherent Capability

Page ;

Some of our efinitions $eliability


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Some of our efinitionsMaintenance Categories..

Planned Maintenance

Preventive Maintenance Corrective Maintenance

Brea0do&n Maintenance =?pected ailure

=


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otalime


=?pected ailure

Planned Maintenance

,ne?pected ailure

%vailable ime InerentPerformance/evel




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A typical e)ample

InerentCapa

bility


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Some Interesting Concepts

Which people on site perform maintenance an


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Which people on site perform maintenance an"hich o not2

Page 1"

Skill Do Maintenance?

!itters

"lectricians

#peratorsontrol Room People

$nstrument Tec%s

"ngine Drivers

&uality ontrolondition Monitoring

'aboratory

Which people on site perform maintenance an


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Which people on site perform maintenance an"hich o not2

Page 1"

Skill Do Maintenance?

!itters

"lectricians

#perators

ontrol Room People

$nstrument Tec%s

"ngine Drivers

&uality ontrol

ondition Monitoring

'aboratory

!ours revie" per year


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!ours revie" per year 8oo inustry e)ample

)otes Before PMO is ours actually completed

Before PMO( te operators &ere doing a lot ofmaintenance informally.

The propose servicing plan for an e)cavator 9


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The propose servicing plan for an e)cavator Operators o more than traes:

+rs Service Hob Plan )ameimes

9ear/ab

+ours%nnual/abour

=very Sift Operator Inspections 8!" ".!7 1"

1 3ee0 Operator Clean 7! ! 1";

1 3ee0 Operator Inspections 7! ".! 1".;

otal !;.;

rades

Ops

The propose servicing plan for a process plant


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The propose servicing plan for a process plant9 Operators o more than traes:

Traes

Operators


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8ailure

Patterns

Page 1!

8inings 9 8ailures are essentially ranom an


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8inings 8ailures are essentially ranom anunpreictable Case Study

%M PM

is means tat tere are process anddesign issues tat sould be addressed.

A f t l ti


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A funamental ;uestion...

As e;uipment getsoler is it more li'ely

to fail22

Page 1!


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8ouners of &CM #


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5 pfailures coul be groupe into 7 patterns

Conitiona

lPro

bability

of8a

ilure

%ge

%4 Bat ub ;E

B4 3ear Out !E

4 Infant Mortality 6E

D4 %lmost $andom 8E

=4 $andom 1;E

C4 5radual 7E

Source4 ,nited %irlines 18

8ouners of &CM 9 They also foun a ominance


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%ge

yof infant mortality

Conitiona

lPro

bability

of8a

ilure

% ;E

B !E

6E

D 8E

= 1;E

C 7E

A & l t 8 il P tt


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e& failures are age related

Common in structures anddirect &ear components

May be prevented trougsceduled discard orrefurbisment

Age &elate 8ailure Patterns

%ge

Conitiona

lPro

bability

of8a

ilure

% ;E

B !E

C 7E

*ominantly &anom 8ailure Patterns


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6E

D 8E

= 1;E

Ma>ority of failures are random in nature

Common in ydraulics(

electronics( etc

Overaul based policy &ill not prevent failures

In practice, most ball

bearing failures appear

random

*ominantly &anom 8ailure Patterns

%ge

Conitiona

lPro

bability

of8a

ilure

Comparisons of Approaches to Maintenance


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p ppMoubray -

Old &ays

DC ad over ;""overaul components

,S Commercial %irlinesad around 6" crases

per million ta0e offs inte early 16"s

Most crases occurdue to e


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MostlyReactive

FixwhenBroken

Stages of Maintenance Evolution

MostlyOverhaul

RemoveBeforeFailure

MostlyConditionBased

FixOn Condition!

MostlyConditionBased with"efect#limination

ProactiveMaintenance

The "orl of maintenance is changing...

+ t i th C t f


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+nerstaning the Concepts of&eliability Centre Maintenance

3&CM4

What is &CM2


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What is &CM2

$CM stands for $eliability Centred Maintenance.

It is a metodology originated by )o&lan and+eap for developing maintenance programs foraircraft &ilst tey &ere in te design stage.

It starts &it a clean seet of paperand firstdefines a complete functionality assessment ofte e


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The seven ;uestions of &CM...

3at are te functions re


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()ploring the principles of &CM.

See te pump e?ample completed by te tutor.

&CM Principles A Practical ()ample>


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Stand %lone Duty Stand By

A $ C

System - System =

Consider : identical pumps &ose function isto pump !;" galmin troug a coolingsystem.

&CM Principles # A Practical ()ample>

?- The pumps have ifferent functions


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Stan Alone *uty Stan $y

A $ C

System - System =

?-...The pumps have ifferent functions...

?= They may fail in ifferent "ays


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Stops Stops Won@t Start

A $ C

System - System =


?=They may fail in ifferent "ays

? The failure moes can be ifferent


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A $ C

Bearing seiKed Impeller smased Coupling sears Po&er fails etc

Bearing seiKed

Impeller smased Coupling sears Po&er fails etc

Brinelling of bearing

Cannibalisation 5rease slumps S&itc fails Po&er fails

System - System =


Stops Stops Won@t Start

?..The failure moes can be ifferent...

?/ 5 B..What happens "hen failure occurs..oes


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Operational

,oss

&epair

Only

Conitional

Conse;uences


A $ C

EvidentEvident

each failure matter.

What if anything can be one to prevent each


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Operational

Conse;uences


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Operational

Conse;uences


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PM Optimisation

A to

The PM Optimisation process has nine steps


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The PM Optimisation process has nine steps.

Step 1 Task Compilation

Step 2 Failure Mode Analysis

Step 3 Rationalisation and Failure Mode Revie

Step ! Functional Analysis "#ptional$Step % Conse&uence Evaluation

Step ' Maintenance (olicy )etermination

Step * +rouping and RevieStep , Approval and -mplementation

Step . /iving (rogram

Step -. Tas' Compilation..S f


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ComputerisedMaintenanceManagementSystems.

OperatorRounds. ConditionMonitoringRounds.

ContractorSchedules.

LubricationRounds.

VendorMaintenanceManuals.

StandardOperatingProcedures

Memory andTradition

Sources of maintenance tas's

0ather routine maintenance activities performeth i t


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on the e;uipment.

Task Type Interval Trade

Task 1 Condition Monitoring )aily #perator


Task 3 Condition Monitoring ' Mont0s Fitter

Task ! Condition Monitoring ' Mont0s Fitter

Task % Failure Finding Annual ElectricianTask ' Time )irected eekly #perator

Task * Time )irected 0enever +reaser

Step = 8ailure Moe Analysis


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Step = 8ailure Moe Analysis

or eac tas0( determine &at failure mode@sA

eac tas0 is meant to prevent or detect.

0enerate a list of failure moes being aresseb i t


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by maintenance

Task Interval Trade Failure

Task 1 )aily #perator Failure A

Task 2 )aily #perator Failure

Task 3 ' Mont0s Fitter Failure CTask ! ' Mont0s Fitter Failure A

Task % Annual Electrician Failure

Task ' eekly #perator Failure C

Task * 0enever +reaser Failure A

Step . &ationalisation an 8ailure Moe& i


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&evie"

ind all tas0s tat serve to prevent eac individual

failure mode and group tem by asset and failuremode.

%dd to tat list &at dominant failures e?ist tatave not been generated troug Steps 1 and !.

Consoliate into +ni;ue 8ailure Moes


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Consoliate into +ni;ue 8ailure Moes

Task Trade Cause

Task 1 #perator Failure A

Task ! Fitter Failure A

Task * +reaser Failure ATask 2 #perator Failure

Task % Electrician Failure

Task 3 Fitter Failure C

Task ' #perator Failure C

A other ominant 8ailure Moes


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Task Trade Cause



Task * +reaser Failure A

Task 2 #perator Failure




Failure )

Step /. 8unctional Analysis 3Optional4


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p y 3 p 4

%ssess &at functions &ould be lost if te failure

&ere to occur.

,ist ,ost 8unctions to the 8ailure Moes 6 Causes


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Task Trade Cause Function

Task 1 #perator Failure A Function 1



Task 2 #perator Failure Function 1


Task 3 Fitter Failure C Function 2Task ' #perator Failure C

Failure ) Function 1

Step BConse;uence (valuation


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Conse;uence (valuation

%ssess &eter eac failure mode is idden or

evident and &at &ould be te failureconse


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;

Task Trade Cause Function Effect

Task 1 #perator Failure A Function 1 #peration


Task * +reaser Failure ATask 2 #perator Failure Function 1 #peration


Task 3 Fitter Failure C Function 2 iddenTask ' #perator Failure C

Failure ) Function 1 #peration

Step 7.Maintenance Policy *etermination


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Maintenance Policy *etermination

Maintenance Policy Determination

,sing te $CM decision logic define &at( if any(maintenance can be done to prevent eac failureand &at sould be done if a suitable preventivetas0 can not be found.

&CM Tas' Selection Se;uence


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Hidden %ident

'onditionMonitorin 'onditionMonitorin 'onditionMonitorin 'onditionMonitorin

Scheduled)estoration

ScheduledDiscard

FailureFindin


ScheduledDiscard


ScheduledDiscard


ScheduledDiscard

Modification Modificationor "o #M

Modificationor "o #M

*+erational,oss

Ha-ard )e+air *nly

;

*etermine the Maintenance Policy


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y

Cause Function Effect Policy Interval

Failure A Function 1 #peration -nspect Daily

Failure Function 1 #peration 4o (M

Failure C Function 2 3idden Test Annually

Failure ) Function 1 #peration -nspect Weekly

Step D.0rouping an &evie"


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0rouping an &evie"

5roup maintenance tas0s into li0e trades and

intervals( and revie& te analysis outcomes toestablis an efficient( yet effective( means ofensuring tat te maintenance policy aligns &itbot business and production ob>ectives.

Case StudyOutcome PMO Analysis....Part of a Processing Plant


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#nly () * ofpreviousmaintenance waseffective+ ,early one

fift% of t%e

maintenance was awaste oftime+

Part of a Processing Plant

Analysis of Mechanical Changes

Delete

1E

=?tend Interval

:"E

)e& as0

1:E

$educe Interval

!7E

,se %s Is

1:E

*o"ntime analysis for this plant Case Study


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$a%le of Overall "owntime for PM on &nit

Sum of 'ours Proposed Pro(ram Previous Pro(ram

)nterval $otal *a% "+time

Per

,ear $otal *a% "+time

Per

,ear $otal

-

Monthly

./0 1 ./0 2 -

Monthly 3/14 - 0 1- 02

$wo

5eeks -/-3 1 -/-3 -2 36 1 7 -2 -.7

5eekly

1/6- 1 - 3- 1.89rand

$otal 6/28 -.. -.7

Case StudyMore fre;uent but less servicingre;uire less PM "ill create better reliability:


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re;uire less PM "ill create better reliability:

*o"ntime analysis for this plantS t ti i PM h b BEF


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Secon stage 9 reuction in PM hours by BEF

*o"ntime analysis for this plantS t ti i PM h b BEF


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Secon stage 9 reuction in PM hours by BEF

Step GApproval an Implementation


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Approval an Implementation

5ain approval from nominated personnel( decide

&at else needs to be done to implement terecommendations( and complete tese activities.



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Tools

an

mater

ials

S'

illsanTraining

Available Time

0host

The Three 1eys

Step ,iving Program


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,iving Program

=nsure tat te revised maintenance program is

completed on time( revie& all e


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source Winston ,eet -/.

CMMS

PMO$CM

Do&ntimeData

IncidentManagement

(lements of a successful ,iving Program


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CMMS

Do&ntime

DataManagement

PMO$CM

$eliability

IncidentManagement

$oth types of failures shoul proceethrough the follo"ing process


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through the follo"ing process

()pecte sealer failures eliminate throughreesign


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reesign

'

1""

!""

:""

;""

7""

6""

,ost Minutes of ProuctionCause by Sealer 8ailures

-nitial (M c0anges and sealer modifications

introduced after orks0ops

SealerFailures

minsmth

Preventable failures eliminate by e)ecuting theright PM Program


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PMO implementedere

right PM Program


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PM OptimisationA to

The PM Optimisation process has nine steps.


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Step 1 as0 CompilationStep ! ailure Mode %nalysisStep : $ationalisation and ailure Mode $evie&

Step ; unctional %nalysis @OptionalAStep 7 Conse


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Step -Tas' Collection

Page 16


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Step - Tas' Compilation


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5ater togeter in one place( all of te

maintenance tas0s @formal and informalA beingunderta0en on te asset being studied.

Page 16

Step -. Tas' Compilation.Sources of maintenance tas's


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ComputerisedMaintenanceManagementSystems.

OperatorRounds. ConditionMonitoringRounds.

ContractorSchedules.

LubricationRounds.

VendorMaintenanceManuals.

StandardOperatingProcedures

Memory andTradition

Page 16

0ather routine maintenance activities performeon the e;uipment.


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; p






Task % Failure Finding Annual ElectricianTask ' Time )irected eekly #perator


ObHectives


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5ater in one place all te preventive or routine

maintenance activities tat are performed on tee


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Collect all te maintenance activities underta0en

by all site personnel. Decompose te maintenance activities into

separate tas0s if tey are Frolled upG.

/ist te maintenance tas0s in te one format on

te same document. =nsure tat te responsible trade and tas0

fre


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Many maintenance tas0s are F$olled ,pG ... t&o or

more independent tas0s are &ritten into one. It is often useful to FdecomposeG tese into te

elements specifically directed at failure modes.

It is common for tas0s to be &ritten in a vague

manner tat leaves te tradesman or operator tocomplete a number of actions largely at isdiscretion. 3ere tis is te case( te single line tas0 sould be

e?panded.

Page 18

()ample of a vague tas' being ecompose


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Page 1

Task asWritten

Tasks as performed

Do a PM on

the Fan

Change the gearbo oil

Chec! the coupling "or #ear by "eeling

the etent o" rotational di""erential

mo$ement.

%rease "an sha"t bearings.

Chec! all bearings "or signs o" #ear.

Clean and inspect the "an blades "or

crac!s.

&nspect all bolts and "asteners "or

security.

()ample of Multiple tas's &olle into One


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Page 1

Tas' Types 3Optional4


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/isting te tas0 type elps &it understanding te

focus of te maintenance and &eterdecomposition is re


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Maintenance tas0s are bro0en into tree groups

Condition Monitoring

+ard ime

ailure inding

Modification is not amaintenance tas0.

'onditionMonitorin


ScheduledDiscard

FailureFindin

Page 1

There are at least three types of maintenanceactivities...


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=g. Cec0ing your car bra0e pads

'ondition

Monitorin


Inspecting te condition of a component and leaving italone if it &ill survive to te ne?t inspection

Page 1



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ScheduledDiscard

=g replacing te oil in your car

+ard ime( @OveraulA

Sceduled $estoration( or Sceduled Discard

$estoring or replacing a component at a specific

interval regardless of its condition

Page 1



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=g esting fire alarms.

FailureFindin

ailure inding

or idden failures ' testing to see if tey are still&or0ing2. Is terefore not a preventive tas0. $arely done to prevent evident failures

Page !"

0ather routine maintenance activities performeon the e;uipment.


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Task % Failure Finding Annual Electrician

Task ' Time )irected eekly #perator


St =


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Step =8ailure Moe Analysis 38MA4

Page !6

8ailure Moe Analysis # ObHective


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or eac tas0( determine &at failure mode@sA

eac tas0 is meant to prevent or detect.

Page !6

0enerate a list of failure moes currentlyaresse by maintenance...


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Page !6




Task 3 ' Mont0s Fitter Failure C

Task ! ' Mont0s Fitter Failure A

Task % Annual Electrician Failure

Task ' eekly #perator Failure C


*efinition of 8ailure Moes


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ailure modes are defined as te general reasons

&y e


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% single maintenance tas0 could cover a large

number of failure modes.. /ist only tose tat are li0ely. 3en &riting failure modes( it is not necessary to

define te root cause of eac failure in precise

detail. =?cessive detail can lead to a slo& process &it a ig

proportion of repetitive results.

Page !6

Ma'ing the tas' efficient


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Page !8

8ailure Moes &elating to Protective *evices


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e testing is often a simple( ceap and effective

tas0. /ittle may be gained from an Fin deptGanalysis of te maintenance.

In some cases in dept analysis is >ustified. e testing of protective devices is te primary reason

for sutting do&n plant( e tests are dangerous( or e tests temselves are li0ely to cause failures(

overstress te macinery or leave te system in an

unprotected state

Page !8

8ailure Moes &elating to !aars


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or failure modes tat are li0ely to ave safety(

commercial or environmental conse


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Task 3 ' Mont0s Fitter Failure C

Task ! ' Mont0s Fitter Failure A

Task % Annual Electrician Failure Task ' eekly #perator Failure C


8ailure moes associate "ith human error..


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ailure modes associated &it uman error are

not listed unless te follo&ing circumstancese?ist4 tere is a reasonable cance tat tey can occur( and e conse


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Step .&ationalisation an 8MA &evie"

ObHective


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e ob>ective of tis step is to create a single list

of uni


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Sort te ailure Mode %nalysis @M%A by

component and failure mode. Create a single list of uni


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+aving multiple tas0s aimed at one failure mode

does not usually add value4 =ac of te responsible maintenance groups mayassume tat te oter as done teir tas02neiterdoes eiter.

If one tas0 is "E effective ten te oter tas0sbecome lo& value maintenance activities.2..In succircumstances( te resources &ould be far betterdeployed &ere te incremental returns are iger.

Page :1

The one 8ailure # one tas' policy


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e oter important aspect is tis4

In te living program &en failures are investigated( it isuseful to ave accountabilities for managing eacfailure mode clearly and uni


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Before %fter Task Trade Cause








Failure )

Task Trade Failure








Sort an a missing 8ailure Moes


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Sources of missing failuremodes come from ailure istory @recorded or

memoryA $evie& of tecnical

documentation loo0ing foridden failures or failures

tat ave not appened butcould and &ould lead to aaKard.

%fterTask Trade Cause



Task * +reaser Failure ATask 2 #perator Failure




Failure )

Step /


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Step /8unctional Analysis 3Optional4

Page ::

ObHectives


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Define te re


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Maintenance cannot alter teinerent


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Age

Achievable

Performance

What theasset

can o

Page :;

Maintenance can only achieve the inherent levelsof performance


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Age

Achievable


135/396

Age

Achievable

What theasset

can o


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Age

Achievable

What theasset

can o


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Age

Achievable

What theasset

can o


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%ll e


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!opper

"rusher

Stoc#pile

Stoc#pile

$% tonnes

!r

-.tonnes

/Hr

Possible

Conveyor

What is the primary function of the conveyor2


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6. tonnes / Hr

Operators re


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... =ven toug an item as been

purcased for a specific purpose( it asoter functions designed in. eimportance of eac function may be

different to different companies.

Page :7

Typical Seconary 8unctions

=nvironment


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=nvironment

Safety Support

Containment

Contamination

Control

%ppearance

Protection

=conomy =fficiency

Page :8

8unctions # Containment

% function of a pipe in a gas plant may be to


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% function of a pipe in a gas plant may be to

transport te gas from one area to anoter. Its function is also to contain te gas inside te pipe ' ienot lea0.

e function of a diamond sorting macine may

be to sort diamonds from &ortless roc0s. Its function is also to contain te diamonds &itin te

macine ' ie not ave tem all over te floor.

8unctions # Appearance

e function of a fire main is to transport &ater to


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e function of a fire main is to transport &ater to

te fire ydrant. Its function is also to be painted red to indicate it is partof a fire system.

e function of a large fuel storage tan0 at an

airport may be to store fuel. Its function may also be to appear in armony &it te

environment.

8unctions # Support

e function of a conveyor may be to transport


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e function of a conveyor may be to transportore over ! miles at a rate of 7" tonnes per our. It may also be re


146/396

e function of car fuel system is to store fuel. It may also be re


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Sometimes it is di:cult to %e precisea%out re;uired performancet (et %o((ed down/

Performance may be stated in te follo&ingcategories4 Output rate Product


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Hopper

Crusher

Stockpile

Stockpile

6. tonnes / HrConveyor

Plant personnel re


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6. tonnes / Hr

Operators re


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Task Trade Cause Function

Task 1 #perator Failure A Function 1


Task * +reaser Failure ATask 2 #perator Failure Function 1


Task 3 Fitter Failure C Function 2Task ' #perator Failure C

Failure ) Function 1

Step B


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Conse;uence (valuation

Page :

ObHectives


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e ob>ectives of tis step are to assess tefollo&ing4 3eter a failure mode is idden or evident( and 3at &ould be te conse


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idden Evident

ConditionMonitoring ConditionMonitoring ConditionMonitoring ConditionMonitoring

Sc0eduledRestoration

Sc0eduled)iscard

Failure Finding


Sc0eduled)iscard


Sc0eduled)iscard


Sc0eduled)iscard

Modification Modification or4o (M

Modification or4o (M

#perational/oss

a5ard Repair #nly

8ailure (ffects an Conse;uences

e failure effects and conse


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e failure effects and conse


155/396

Operational/oss

+idden =vident

+aKard $epair Only

as0 SelectionPage ;1

!ien 8ailure Moes

Some failures ave no impact unless some oter

idden Evident


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Some failures ave no impact unless some oterfailure occurs2 tis is often te case &ere tefailure is protected in some &ay.

Often( failures of protective systems are 0no&n asidden failures.

e conse


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Metal*etector

O DearSome metal in tesystem and no ligt.

The *ecision ,ogic *iagram.


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#perational/oss

idden %ident

a5ard Repair #nly

as0 SelectionPage ;;

Safety Conse;uencesHa-ard


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... &en te failure creates an intolerableris0 to personnel safety.

Page ;;

(nvironmental Conse;uencesHa-ard


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... &en te failureleads to a breac of any0no&n environmental

standard orregulation.

Page ;;

*isastrous CommercialConse;uences Ha-ard


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... &en te failure leads to a significant lossof mar0et sare or customer dissatisfaction

Oops

Page ;;

The Decision o!ic Dia!ram"#


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#perational/oss

idden Evident

a5ard Repair #nly

Task Selection

Operational Conse;uences *+erational,oss


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... &en te failure affectsproductionoutput(


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#perational/oss

idden Evident

a5ard )e+air *nly

Task SelectionPage ;;

Cost Conse;uences )e+air *nly


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... &en te only conse


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... supported bydecision logic.

2 distinguisesbet&een iddenand evident failures

2 tas0 selection is made from avariety of options

ConitionMonitoring

ConitionMonitoring

ConitionMonitoring

ConitionMonitoring

Scheule&estoration

Scheule*iscar

8ailure 8ining

Scheule&estoration

Scheule*iscar

Scheule&estoration

Scheule*iscar

Scheule&estoration

Scheule*iscar

Moification Moification or


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*+erational,oss

idden %ident

Ha-ard )e+air *nly

as0 Selection

Why o "e bother splitting hien failures fromevient failures22


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idden Evident



Sc0eduled)iscard

Failure Finding


Sc0eduled)iscard


Sc0eduled)iscard


Sc0eduled)iscard



#perational/oss

a5ard Repair #nly

Why o "e bother splitting hien failures fromevient failures22


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idden Evident



Sc0eduled)iscard

Failure Finding


Sc0eduled)iscard


Sc0eduled)iscard


Sc0eduled)iscard



#perational/oss

a5ard Repair #nly

Why o "e bother splitting haars from otherfailures.


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idden Evident



Sc0eduled)iscard

Failure Finding


Sc0eduled)iscard


Sc0eduled)iscard


Sc0eduled)iscard



#perational/oss

a5ard Repair #nly

Why o "e bother splitting haars from otherfailures.


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idden Evident



Sc0eduled)iscard

Failure Finding


Sc0eduled)iscard


Sc0eduled)iscard


Sc0eduled)iscard



#perational/oss

a5ard Repair #nly

!ien 8ailures


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Page ;1

8ailure Conse;uences


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ailure Conse


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A $ C

(%I*(


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circumstances( and

It is idden for ever unless one of t&o tingsappen4 Some oter failure occurs( or

% failure finding tas0 is performed. ere must be at least t&o failures before te

conse


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protective devices &ic are not fail safe.

+idden functions often ave many failure modesNsome of &ic are idden and some of &ic are

evident.

Some protective devices are completely fail safeand terefore te functions are not idden...Be&are of tis claim

Page ;1

!ien 8unctions


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Metal*etector

)ormal Operation)o metal in te system

!ien 8unctions


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Metal*etector

BingoSome metal in tesystem and te

ligt comes on

!ien 8ailure


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Metal*etector

O DearSome metal in tesystem and no ligt.

!ien 8unctions


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Metal*etector

Design Cange/igt normally on

ailures are no& evident..

System is fail safe.

An e)ample of ma'ing failures evient.


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Some ospitals no& run stand'bygenerators continually puttingpo&er into te grid. is costsmoney but tey do not e?periencetotal loss of po&er &en te gridfails.

!ien failures are often foun "ith the follo"ingevices.

=mergency stops

S f t l

ire alarms

S 0 d t t


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Safety valves

Standby pumps Interloc0s

Bunds

)on return valves

urbine overspeed s&itc

Smo0e detectors

Metal detectors Circuit brea0ers

Standby generator

Safety So&ers

irst aid 0its

=mergency paracutes

=mergency bra0e

Page ;:

Care must be ta'en "hen assessing "hetherfailures are hien...


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8ilter &emoves benene 8romMineral Water ,ight comes on to inicate

8ilter $y#pass

It is normal for benene to e)ist in the "ater.The light is actually a conition monitoring

evice.

8ilter

Which of these functions are hien222

unctions


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o provide a local indication of lube oiltemperature @normally :7';7 deg CA

o sound an alarm in te control room &en telube oil reaces ; deg C

o sut te macine do&n &en te lube oilreaces 7" deg C.

Which of these functions are hien222


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o provide a local indication of lube oiltemperature @normally :7';7 deg CA =vident

o sound an alarm in te control room &en te

lube oil reaces ; deg C +idden but could be evaluated as a condition

monitoring device

o sut te macine do&n &en

te lube oil reaces 7" deg C. +idden

A failure is hien "hen...

It can not be detected by site personnel underl i t d


186/396

normal circumstances( and

It is idden for ever unless one of t&o tingsappen. =iter4 Some oter failure occurs

% failure finding tas0 is performed. ere must be at least t&o failures before te

conse


187/396

Maintenance Policy *etermination

Page ;8

What variables shoul rive maintenance on anaeroplane...


188/396

J

What variables shoul rive maintenance on anaeroplane...


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/andings

=ngine +ours

lying +ours

=lapsed ime

5 /imit e?cursions

Plan your maintenance intelligently

With meter base servicings maintenance mustcontrol the asset use

irst create an annual utilisation plan &ic is4 + ill b d i t


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+o& many ours &ill be used in te year +o& many macines &ill be use +o& many ours per macine @divide ours by

macinesA

Create te servicing plan Drive te asset use into te plan

&un Assets to *rive the optimum maintenanceefficiency

s 7""" +rs


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(lapse Time

&em

aining!ou

rs7""" +rs

1 9r

=?ample ive macines !7(""" ours total

production in te year 7(""" our overaul


7""" +rs


192/396

(lapse Time

&emaining!ours

7""" +rs

1 9r

=?ample ive macines !7(""" ours total

production in te year 7(""" our overaul


7""" +rs


193/396

(lapse Time

&em

aining!ours

7""" +rs

1 9r

Tas' Selection


194/396

Terminologysome organisations use five typesof maintenance activities...

On'Condition @Condition MonitoringA


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+ardtime @Sceduled $estoration DiscardA

ailure inding

=vent Based

Independent Inspection

Page ;1

There may be a

ailure evident tooperating cre&J

9es)o

&CM *ecision *iagram


196/396

There may be a

number of tas's thatcan be use foreach failure moe.

Only one tas' shoul

be selecte for eachfailure moe.

+idden =vident9es)o

ailure inding

or

or

or

9es

9es

9es

+aKard

When the choice is

mae move on tothe ne)t failuremoe.


Sc0eduled Restoration

Sc0eduled )iscard

Page ;1

(ach tas' "hich is selecte must be practicalan effective.


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Practical means4

Fte tas0 tecnicallyfeasible based on tefailure caracteristicsof te item.G

Effective means4

Fte tas0 &ort doingbased on te failureconse


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FOn Conditionas0sG

On Conition Maintenance # Conition Monitoring


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Age

%ibration


200/396

Age

%ibration


201/396

&e 8ace8I0LAM

Thin' you@re Mel 0ibson

8all over

Collapse

*rin'ing

P8 Curve

indicates that a functional failure is in the process ofoccurrin!#

Chuner

Slurre Speech

Tell the boss the truthTell the Mrs the truth

!appy 8ace

More $eer

Pots of $eer

P i t h

+nerstaning the P#8 Curve


202/396

&esistanceto 8ailure

Potential 8ailure

8unctional

8ailure

Age

Point "here "e can

fin out if it is failing

Point "here it has faile

Page ;

P 8 Interval

P#8 Curve


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Potential 8ailure

8unctional 8ailure

Age

P#8 Interval

Interval bet"een the occurrence ofa potential failure an its ecay

into functional failure

Page ;

Th f f O C iti t '

On Conition Tas' 8re;uency


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P


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Potential

8ailure

8unctional 8ailure

Age

P#8 Interval3months4

Chec' at - monthly intervals

must be less than the P#8 Interval.

Page ;

ailure evident tooperating cre&J

On Conition tas's are applicable if...


206/396

it is possible to efine a clearpotential failure conition

the P#8 interval is fairlyconsistent

it is practical to monitor the itemat intervals less than the P#8interval #

ie the P#8 interval is long enoughto be of some use

Conition Monitoring2

Scheule &estoration2

Scheule *iscar2

or

or

or

9es

9es

9es

!ien (vient

Moification2

!aar

Page 7"

On Conition Tas's

,sually not intrusive and some can be done &ente plant is operating


207/396

te plant is operating

,sually ceap to apply

Ma?imises te life of te asset

Can be applied independently of &at te failure

pattern is Can be assessed &itout a large ban0 of failure

istory

Page ;

On Conition Tas's

%re not al&ays cost effective and

Can not be used for every failure only failures


208/396

Can not be used for every failure2only failurestat give some &arning tat tere is a problem.

Page ;

On Conition Techni;ues

+uman Senses Sigt


209/396

Sigt Sound ouc2.

Product uality Cec0s

Statistical Process Control2. ,sing specialist e


210/396

person &it te trade


211/396

tree elements4 e instruction( e acceptable limits( and 3at to do if an unacceptable condition is found.

+ard time tas0s contain only te instruction.

Tas' "riting stanars.cont

e use of te &ords cec0( inspect and e?aminesould be consistently applied and relevant to te


212/396

sould be consistently applied and relevant to te

type of tas0 re


213/396

y p

are as follo&s4 Qisually inspect te saft for signs of corrosion. 3it a spanner( cec0 tat te bolts are tigt. 3it a termograpic camera( e?amine te control

board for signs of eat 2..


ScheduledTas' Selection


214/396

Discard

F+ardtimeG

Page 7"

(ngine servicing # spar' plug failure history.

Solution Interval of spar0 plug replacementSpar' Plug ,ife


215/396

Safe /ife

Solution2 Interval of spar0 plug replacement

needs to be tree monts.Spar' Plug ,ife

Sample sie EE spar' plugs

"

7

1"

17

!"

!7

:"

:7

" ".7 1 1.7 ! !.7 : :.7 ;

Months Since Installe

=BE years

Page 77

Testing protective evices shoul test the "holesystem if practical...

+o& sould a smo0e detector be testedJ


225/396

Sensor

Battery

?larm

!o" o you test the follo"ing items222

=mergency paracute

lare cartridge


226/396

g

Building fire sprin0ler

Car airbag

+ouseold fuse

igter aircraft e>ector seat

Page 78

8rench police lose e)plosives on Het

Monday( December 6( !""; P%$IS R Police at Paris top airport lost trac0 of a passengers


227/396

bag in &ic plastic e?plosives &ere placed to testbomb'sniffing dogs( police said Saturday. 3arned tatte bag may ave gotten on any of nearly " fligtsfrom Carles de 5aulle( autorities searced planes

upon arrival in /os %ngeles and )e& 9or0.

Tas' Selection.Other types of tas's


228/396

=vent Based Servicing

Page 6"

(vent#$ase

Performed only &en a specific event occurs.@ard landing( etcA


229/396

Page 6"

(vent $ase tas's or Special Servicing

=vent Based tas0s are used to inspect e


230/396

potentially aKardous event.

Page 6"

(vent $ase tas's or Special Servicing

ypical events include4 Inspection of an aircraft undercarriage after a eavy


231/396

landing. urbine inspection after overspeed. ilter cange after a dust storm.

Page 6"

(vent $aseOil storage tan' that can fail "hen heavy rain falls.


232/396

8loating &oof

Water *rain %alves

Crue Oil Storage Tan'

*rain to Oily Water Pit



233/396

8loating &oof

Water *rain %alves





234/396

8loating &oof

Water *rain %alves





235/396

!eavy or consistent rain.....

=vent rigger

as0

Chec' roof "ater rains are clear anensure that "ater rains freely from theroof section

Tas' Selection.Other types of tas's


236/396

Independent Inspection

Inepenent Inspections

Performed &ere design cange is not feasiblefor safety( environment or ig cost


237/396

conse


238/396

Modification

or "o #M

or tese failures &e consider one of te follo&ingoptions sould be4

$e'design( or )o sceduled maintenance

Page 7

Tas' selection summary

ere are tree main types of programmed maintenanceactivity4


239/396

Condition Monitoring @predictive maintenanceA Interval determined by P interval.

+ard ime $eplacement or $efurbisment @preventivemaintenanceA Interval determined by safe or economic life.

ailure inding Interval determined by MBs and acceptable ris0 of multiple

failure.

ere is no point in doing tas0s tat acieve noting.

Note that event based servicing and independent inspections are not

programmed maintenance activities

Step D0rouping an &evie"


240/396

Page 67

Step D 0rouping an &evie"

5roup maintenance tas0s into li0e trades andintervals( and revie& te analysis outcomes to


241/396

establis an efficient( yet effective( means ofensuring tat te maintenance policy aligns &itbot business and production ob>ectives.

Page 67


The Three 1eys


242/396


Toolsan

mat

erials

S'ills

anTraining

Available Time

0host

Step D.An e)ample of a maintenance plan on a three "ee' cycle

e letters T% troug to TQ represent maintenancescedules comprising many tas0s.


243/396

Sc

eduleInter

val

Off /ine

3ee0 : 6 1! 17 1 !1 !; !8 :" :: :6 : ;! ;7 ; 71 7;

: % % % % % % % % % % % % % % % % % %

: B B B B B B B B B B B B B B B B B B

: C C C C C C C C C C C C C C C C C C: U U U U U U U U U U U U U U U U U U

6 D = D = D = D = D = D = D = D = D =

6 5 5 5 5 5 5 5 5 5

1 H - / M M H - / M H - / M

!; @!8A ) )1 O O1 P ) )1 O O1 P

:6 @!8A $ S $ S

7! @7;A , Q

+ours 1; 1: 1! 1; 1: 1! 1: 1: 1: 1: 11 11 1: 1; 1: 1: 11 1!

Step GApproval an Implementation


244/396

Page 68

Step G Approval an Implementation

5ain approval from nominated personnel( decide&at else needs to be done to implement te


245/396

recommendations( and complete tese activities.

Page 68

Step ,iving Program


246/396

Page 6

Step ,iving Program

=nsure tat te revised maintenance program iscompleted on time( revie& all e


247/396

of tat e


248/396

CMMS

Do&ntime

DataManagement

PMO$CM

$eliability

IncidentManagement

The relationship bet"een the four elements source Winston ,eet -/.


249/396

CMMS

PMO$CM

Do&ntimeData IncidentManagement

,iving Program

=nsure tat te revised maintenance program iscompleted on time( revie& all e


250/396

of tat e


251/396

Some of our efinitions()amples of high level loss categories

,tilisation losses include te follo&ing4 +aving upgrades or modification.

M i t i d f d ti

O==

Management

$eliability

IncidentManagement


252/396

Macine not re


253/396

Tas' selection summary forevient failure moes.

ere are tree types of maintenance strategiesfor evident failure modes4

C diti M it i @ di ti i t A

O==

Management

$eliability

IncidentManagement


254/396

Condition Monitoring @predictive maintenanceA Interval determined by P interval.

+ard ime $eplacement or $efurbisment @preventivemaintenanceA

Interval determined by safe or economic life. $un to failure

3ere failures are random and unpredictable( or Cost of PM is greater tan te cost of failure.

Some of our efinitionsMaintenance Categories..

Planned Maintenance Preventive Maintenance

C ti M i t

O==

Management

$eliability

IncidentManagement


255/396

Corrective Maintenance Brea0do&n Maintenance

=?pected ailure =


256/396

Bac0log gro&s

PM is missed

Band'aidMaintenance

More repeat &or0

More preventable

failuresMorale Declines

$esources ta0enby Brea0do&ns

+ead Budget$eduction

Standards Drop

The SA( LA -E-- stanar for tas' selection .

idden Evident


257/396

Condition

Monitoring

Condition

Monitoring

Condition

Monitoring

Condition

Monitoring


Sc0eduled)iscard

Failure Finding


Sc0eduled)iscard


Sc0eduled)iscard


Sc0eduled)iscard



#perational/oss

a5ard Repair #nly

e fre


258/396

$esistanceto ailure

Potentialailure

unctional ailure

%ge

P' Interval@montsA

Cec0 at 1 montly intervals

8i)e time replacement fre;uency .

e fre


259/396

Safe /ife

d

Maintenance Options for (vient 8ailure Moes


260/396

$ate of Deterioration

1ailurePattern

$andom

%ge$elated

Sudden 5radual

i?ed ime $eplacement only

d


Condition Based $eplacement only


261/396


1ailurePattern

$ando

m

%ge$elated

Sudden 5radual

Condition Based $eplacement only

d



262/396


1ailurePattern

$ando

m

%ge$elated

Sudden 5radual

Bot i?ed ime $eplacement andCondition Based $eplacement

d


ailure &ill al&ays result in a

brea0do&n


263/396


1ailurePattern

$ando

m

%ge$elated

Sudden 5radual

brea0do&n


Planned Maintenance Inerent


264/396

otalime

=?pected ailure

Planned Maintenance

,ne?pected ailure

%vailable imeInerentPerformance/evel



A typical e)ample


265/396

InerentC

apability

Some funamental conceptsThe Inherent Performance ,evel

Inherent Performance evel

Inherent Capa%ility oss

O==

Management

$eliability

IncidentManagement


266/396

Inherent Performance evel

Inerent Capability /oss includes4

Off line Preventive Maintenance as0s(

Off line Corrective Maintenance( and

=


267/396

Maintenance Capability /oss includes4

=


268/396

Starts system

Esta%lish actual

and inherent

performance

Determine

defects and

'uantify

Develop and

implement

improvement plan

8inish

Are there

any morepro%lems tosolve(

! ! y

Track success of

plan and revise

plan if necessary

Archive data

*

+

Develop and

implement ne,t

improvement plan

)evise inherentperformance

&aintenance Capa%ility oss


The general approach.e)ample

O==

Management

$eliability

IncidentManagement


269/396


%ctual performance /evel

Esta%lish actualand inherent

performance

-Set up !eneric

data collection

system

.

The general approach cont.

O==

Management

$eliability

IncidentManagement




270/396

Determinedefects and

'uantify

/

VParetoV Cart of /osses

R#

R-EEEEE

R=EEEEE

REEEEE

R/EEEEE

RBEEEEE

R7EEEEE

Problem

1

Problem

!

Problem

:

Problem

;

Problem

7

Problem

6

Problem

8

Problem

Problem

Problem

1"




O==

Management

$eliability

IncidentManagement


RBEEEEE

R7EEEEE


271/396

Develop and

implement

improvement plan

0

)evise data

!atherin! system

1

R#

R-EEEEE

R=EEEEE

RAEEEEE

R/EEEEE

Problem

1

Problem

!

Problem

:

Problem

;

Problem

7

Problem

6

Problem

8

Problem

Problem

D

Problem

1"

Task Responsibility Timing

as0 1 Production Operator By :" %ug !"""

as0 ! Planning By 1" Sep !"""

as0 : $eliability Officer By :" %ug !"""

as0 ; Instrument Supervisor By 1" Oct !"""

as0 7 Production Supervisor By 1" )ov !"""








O==

Management

$eliability

IncidentManagement


RBEEEEE

R7EEEEE


272/396

Track success ofplan and revise plan if

necessary

2

R#

R-EEEEE

R=EEEEE

RAEEEEE

R/EEEEE

Problem

1

Problem

!

Problem

:

Problem

;

Problem

7

Problem

6

Problem

8

Problem

Problem

D

Problem

1"













*o"ntime Costs of !ea 8ailures

All Moomba 8iel Compressors

W".""

W1""(""".""

W!""(""".""

W:""(""".""

W;""(""".""

W7""(""".""

W6""(""".""

W8""(""".""

W""(""".""

1 ! : ; 1 ! : ; 1 "" ! ""

Once the problem is solve

5

O==

Management

$eliability

IncidentManagement

*o"ntime Costs of !ea 8ailures

All Moomba 8iel Compressors

W""(""".""


273/396

Archive Data

3)evise inherent

Performance

4

Find *e$ Pro%lem to

Solve

5

W".""

W1""(""".""

W!""(""".""

W:""(""".""

W;""(""".""

W7""(""".""

W6""(""".""

W8""(""".""

1 ! : ; 1 ! : ; 1 "" ! ""

Strategic Collection of

,ost Performance *ata

s

Set up !eneric

data collection

system

)evise data

!atherin! system

O==

Management

$eliability

IncidentManagement


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Starts syste

Esta%lish actual

and inherent

performance

Determine

defects and

'uantify

Develop and

implement

improvement plan

8inish

Are there

any morepro%lems tosolve(

Track success of

plan and revise

plan if necessary

Archive data

*

+

Develop and

implement ne,t

improvement plan

)evise inherentperformance

The concept of Maintenance 8ree Operating

Perio 3M8OP4

=very asset as inerent failure caracteristics. =very asset as a fi?ed preventive maintenance

program based on eiter te P Interval or teS f = i lif f


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program based on eiter te P Interval or teSafe or =conomic life of te component.

ese are determined by4 te &ay te e


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=?amples e MOP for your car may be 1"(""" 0ms &ic may be drivenby spar0 plug life.

e MOP of a belt driven fan may be t&o years &ic may bedriven by fan belt life.

Page 66

*uring grouping an revie" the M8OP is

revie"e against the business nees.

Ignoring te MOP &ill result in une?pectedfailures and unnecessary reactive maintenance.

If te analysis so&s tat une?pected failures cost


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If te analysis so&s tat une?pected failures costmore tan te PM( ten tere is no sense inignoring tat fact.

If tere is a conflict bet&een te operatingstrategy and te maintenance strategy ten tereare only t&o options4 Cange te operating strategy( or

Modify te e


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Purcase longer life parts and consumables. ,se different condition monitoring tecni


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Safe /ife

initially at fourmont interval.

Discard Interval

replacement to : monts2.ten trial better spar0plugs.

p p p g

"

7

1"

17

!"

!7

:"

:7

" ".7 1 1.7 ! !.7 : :.7 ;

Months Since Installe


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%ibration Analysis

Measure coupling "ear

Intrusive igfre


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Age

!; Monts

ro& a&ay valve every !;monts

' Disassemble andinspect for pin &ear

%alve Pin Wears

Improved Strategy

#nly () * ofprevious

Conflicting M8OP

This plant "as being shuto"n every t"o "ee's.

#xample 3@ More fre;uent shutdowns


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ypreviousmaintenance waseffective+ ,early one

fift% of t%emaintenance was a

waste oftime+

Analysis of Mechanical Changes

Delete

1E

=?tend Interval

:"E

)e& as0

1:E

$educe Interval

!7E

,se %s Is

1:E

PMO etermine the

follo"ing scheules "ere re;uire


$a%le of Overall "owntime for PM on &nit

Sum of 'ours Proposed Pro(ram Previous Pro(ram


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e MOP &as one &ee0 not t&o.

)nterval $otal *a% "+time

Per

,ear $otal *a% "+time

Per

,ear $otal

-

Monthly ./0 1 ./0 2 -

Monthly 3/14 - 0 1- 02$wo

5eeks -/-3 1 -/-3 -2 36 1 7 -2 -.7

5eekly 1/6- 1 - 3- 1.8

9rand

$otal 6/28 -.. -.7

More fre;uent but

less servicing re;uire less PM # more reliability:



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*o"ntime analysis for this plantSecon stage 9 reuction in PM hours by BEF


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*o"ntime analysis for this plantSecon stage 9 reuction in PM hours by BEF


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The process of Incient Management


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Incient Management is a simple

seven step process

2 )evie$ )esults

3# Archive

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.# 6ri!inate

/# Analysis 7 )ecommendations

2# )evie$ )esults

0# Approve

1# Implement

-# Allocate Analysis )esponsi%ility

$oth types of failures shoul proceethrough the follo"ing process


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Where most programs stall


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Why &eliability Assurance

can be ifficult .

ere is no PMO or $CM or is not documented. ere is no'one in te organisation tat is

responsible for administering te system. e system is fragmented and cumbersome

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p g y e system is fragmented and cumbersome.

$eports get lost and nobody is 0eeping trac0 oftings.

5etting information is time consuming2. )otintegrated &it CMMS( O== or PMO system.

oo many incidents are being investigated atonce.

)o'one trac0s &eter te improvements &or0edor not2 tey are not integrated &it O== system.


can be ifficult .

Data collection strategy is too generic and lac0sdefinition.

3at problems are being loo0ed at and for &atreasons

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reasons.

e systems are poorly set up. It is too ard toget data in and get data out.

oo muc data is being collected. ere is more tan one system collecting te

same data. is

rustrates te people &o collect te data( and /eads to arguments about te data rater tan a focus

on solutions.


can be ifficult .

e people tat collect te data are not involvedin using it to solve problems.

is results in poor data


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e data is collected at te &rong level and cannot be interrogated according to te necessaryparameters. or e?ample in a manufacturing plant( data may be

collected against te line and so investigationscomparing performance of different products can not beeasily done.


can be ifficult .

e data codes are entered &en te failureappens not &en te problem is fi?ed.

%t tis point( te operators are guessing. If t bl b l d b t i i

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If te problem as been solved by a tecnician(ten te data relating to te problem detail souldbe entered by te tecnician. Often tis data is not entered or entered incorrectly by

te operator.


can be ifficult .

People believe tat te CMMS can do more tanit is capable.

ey mostly dont use te functionality it as but tis isanoter problem not part of tis presentation

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anoter problem not part of tis presentation.

Integrating the / elements of

&eliability Assurance


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y

CMMS

Do&ntimeData

Management

PMO$CM

$eliabilityIncident

Management

Conclusion

Our *efinition of


% process tat determines te inerent reliabilityand performance of an asset in its operational

conte?t( and ser es first to increase te le el of performance to

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serves first to increase te level of performance tote inerent level by te application of preventiveand predictive maintenance( and

ten( by data collection and problem solving(increase te inerent performance level trougte introduction of modifications to te macine

design and te operating conditions or metods.

An important realisation about the four ;uarants of


e realisation tat all oftese Systems are distinctlydifferent yet need to beintegrated is very important.

CMMS PMO$CM


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e purcase and use of aCMMS alone &ill leave alarge void in an $%infrastructure.

o our 0no&ledge(no CMMS as suitable data relationsips for tere


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you are not effectively using your data.

Setting up ata collection systems


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Some tips about setting up ata

collection systems in prouction lines

,se codes and avoid te need for operators to&rite tings.

ry not to ave te operators record every failureunless tere are less tan 1" per sift

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unless tere are less tan 1" per sift. If tis is te case( ensure te person &o diagnosed

fi?ed te problem attributes te codes and te

comments. is must be done after te rectification not &en te

problem is detected.

Some tips about setting up ata

collection systems in prouction lines

Involve te operators in te design of te seets Put a lot of tougt into te database tat te data

goes into. Only use spreadseets as a sort termtrial use a database &en you bed do&n your

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trial use a database &en you bed do&n yourneeds.

Set up te form so tat te data entry is easy.

Do not collect redundant data. Spend time training and coacing te operators.

Be tere at sift cange &en te system goes live get out of bed early and stay late if you ave to.

Send te graps to te operators &ee0ly andinvolve tem in te problem solving.

Some tips about setting up ata collection systems in

prouction lines continue

Dont get ung up on tecnology.%utomatic data collection systems are good tools but

tey are not te only metod of data collection yousould use.

O==

Management

$eliabilityIncident

Management

public mg t course mar 2012

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