show me the value! - a cbm strategy development story
TRANSCRIPT
Organized by:
Show me the Value!
Felix M Laboy, CMRP, CRL
Jesus M Laboy, MBA, CMRP
What is Condition Based Maintenance?
• Condition Based Maintenance (CBM) is a maintenance strategy that uses the actual condition of the asset to indicate what maintenance needs to be done.
• CBM dictates that maintenance should only be performed when certain indicators show signs of decreasing performance or upcoming failure.
Welcome to the 90’s
Dramatization: 1990
Situation: Meeting Room
• We need less failures
• What can we do?
Dramatization: 2015
Situation: Meeting Room
• We need to increase availability and decrease our maintenance costs!
• We need to do MORE with LESS.
• What can we do?
Objectives
Strategy
Value
• Asset Management Policy
• EHS Policy
• Quality Policy
• Mission / Vision
Objective
• High Quality Products
• Low Production / Maintenance Cost
• On Time Delivery
• Zero Loss Time
Strategy
• Reliability Centered Maintenance
• Total Productive Maintenance (TPM)
• Lean Manufacturing
• Risk Management
Objectives“Got it:
• Objective 1: increase equipment availability
• Solution: Buy more systems. A redundant system, is a reliable system!
• Objective 2: reduce maintenance cost
• Solution: Predictive Maintenance!”
Increase Availability
+ =
Reduce Maintenance Cost
=
Equipment
+Training
+Calibration
Pray to the Reliability Gods
W. Edwards Deming
To Achieve Success
Focus on Improving
the System Not On
Individual
Performance
Felix Laboy
іMi Santo,
No Seas Abusador!
Proactive Workflow ModelAsset Catalog
Criticality Analysis
Failure Modes Analysis
Equipment Maintenance Plans (EMP)
PM/PdMInspections
Results of PdM
Preventive & Predictive Work 80%
of Total Work
MOC Procedures Planning MOC Procedures
Scheduling
Daily Coordination
Work Performed
Requested Work 20% of Total Work
Job Plan Improvement
Equipment Reliability
Improvements
MOC Procedures
Failures Breakdowns
Ass
et H
ealt
h A
ssu
ran
ce
Failure Modes Analysis
Failure Codes Creation
Work Order History Analyis
Root Cause Analysis
Strategy Adjustment
F.R.A.C.A.SKaizen Loop
Pro
acti
ve W
ork
flo
w M
od
el
Source: AlliedReliabilityGroup
Method / Process
• Proactive Workflow Model
– Focused on failure elimination
– Reduces maintenance costs and increases availability
– Implementing CBM is a tool necessary to realize the company's value objectives
– No need to justify CBM technologies if the right process is used!
Real World Results: Utilities
Real World Results: Packaging Line
0
50
100
150
200
250
300
350
400
450
Actual New
70% Reduction in
Scheduled Maintenance
Downtime Hours
Eliminate: No added value
10% Reassign to operators
26%
Replace with PdM11%
Redesign22%
No change31%