how to optimize strategic asset management planning with

How to Optimize Strategic Asset Management Planning with an

Integrated SystemNew Level of Operational Efficiency

21/06/2021

Claudio SpanóDuring the last 24 years, Mr. Spanó has been working with Reliability Engineering applied to Asset Management, Product Development and Maintenance. He started his career developing the subject in Mercedes-Benz and founded Compass in 1998 - then called ReliaSoft Brasil - to resell ReliaSoft software and provide reliability training and consulting for south American market.

Claudio is one of the strongest names on Reliability Engineering in Brazil, being responsible for several consulting projects, training most of the reliability professionals in Brazil and doing lectures about this subject in many organizations. He has also written and presented several papers in symposiums and congresses around the world, in countries such as United States, Germany, Holland, Singapore, Argentina, Chile, Colombia, Malaysia, Spain, South Africa, and India. He created and developed Orion system (asset management system supported by reliability engineering). He is part of the Asset Management & Maintenance Brazilian Association Board (ABRAMAN), and ABRAMAN asset management committee. This committee developed the Asset Management MBA, the criteria for qualification, certification for asset managers, and asset management seminars for continued education. He also participates in the Committee of the Asset Management Special Studies, ABNT / CEE-251, being responsible for the ISO 55000 standard series translation.

ReliaSoft Brasil CEO

Douglas Goncalves

More than 26 years of professional experience developed and consolidated in asset management, strategic business planning, strategic operational risk management, industrial maintenance management, reliability engineering, planning, programming, control of maintenance, engineering of maintenance, management projects and services.Coordinated and led the implementation of bigests projects for asset management and reliability engineering in Vale's pelletizing units.MBA - Asset Management - Fundação GorceixMBA - Project Management - Fundação Getúlio VargasAsset management especialist - CAMA - Certified Asset Management Assessor – WPIAMReliability engineering especilist - CRP - Certified Reliability Professional - ReliasoftCommittee member of the Asset Management Special Studies, ABNT / CEE- 251, being responsible for the ISO 55000 standard series.

Presenters Bio

Maintenance 4.0 – Industry 4.0!

Maintenance 4.0 – Industry 4.0!

INTEGRATION

Integration for Asset Management

SAP Ecosystem

Opening of notes and orders; RCM studies; Dynamic Criticality of Assets

Sending order and note data; Maintenance KPIS; Asset hierarchy

Sending order and note data; Maintenance KPIs; Asset hierarchy; Static criticality of assets; Spare Parts

Reliability Tools

RAM simulations; Failure Analysis

Asset Condition Analysis (Predictive and Sensitive Analysis)

Predictability of asset failure; Dynamic criticality

classification; Dynamic risk analysis; SPF, RCA, RGA analyzes

Asset condition analysis (predictive and sensitive analysis);

Process KPIs; Diagnostic Reports

Process variables; Process KPIs

DMS

Drawings (link) Projects; Docs

DocumentManagement System

Plant InformationManagement System

PIMS

Process KPIs; Maintenance KPIs; Production KPIs; Quality KPIs; Financial KPIs; Production data, plant shutdowns and losses; Hour meters.

MES Manufacturing Execution System

Integrated Asset Monitoring Center

Orion Modules

Condition-based maintenanceDegradation AnalysisReading Equipment DataPreventive MaintenancePredictive Maintenance

Reliability-based maintenanceLife Data Analysis - ReliabilityMTBF TrendFailure ForecastingSpare Parts ForecastReliability Centered MaintenanceFailure Reporting and Problem Resolution ProcessIntegration with ReliaSoft software

Maintenance risk managementFailure Mode & Effect Analysis - FMEAAsset Criticality Classification

Artificial Intelligence – AISpecialist detection and diagnosis system

Asset Management System• ISO 55001 Strategy Documentation• Organization Strategic Plan• Stakeholders Needs and Requirements• Asset Management Policy• Strategic Asset Management Plan - SAMP• Asset Management Objectives & Plans – AMPsAsset Management KPIsRisk Assessment and ManagementManagement of Change – MOCKaizen Quality Control CircleDesign Change RequestAction Plan and Tasks

Asset Performance & Health MonitoringAsset Performance KPIsTriggers & AlertsAssetBook

Analysis Modules Management Modules

What is Asset Management?

Asset Management Strategic ViewHigh Management Question:

Are we getting the best value

from our assets?

Visão Estratégica de um Sistema de Gestão de Ativos

Show me!

A Gestão de Ativos Suportada pela Engenharia da Confiabilidade leva o negócio a um novo patamar de Eficiência Operacional

-75% -20% -30% -20%

Até 75% de redução na

quantidade de planos de

manutenção

Até 20% de redução nos custos

anuais de manutenção

Até 30% de redução anual nos

custos de sobressalentes

Até 20% de redução nos custos

do premio do seguro

Eficiência Operacional• Otimização da Estratégias de Manutenção• Redução dos Custos de Manutenção• Redução dos Custos com Sobressalentes

• Otimização do Tempo de Reparo dos Ativos• Aumento da Disponibilidade• Gerenciamento do Risco Global do Negócio

A confiabilidade na gestão de ativos Não é uma Opção!“Quem não está aplicando, é um dinossauro.”

Billy BeaneGerente Geral do Oakland Athletics e Consultor do AZ AlkmaarBilly revolucionou o baseball ao usar estatística para montar times com eficiência acima da média e baixo orçamento.

Sob sua gestão, os Oakland Athletics chegaram aos playoffs da liga de beisebol 6x entre 2000 e 2008, sempre com um orçamento entre os cinco mais baixos dentre as trinta equipes.

Em 2009 foi eleito pela Sports Illustrated um dos 10 executivos do esporte mais importantes da década.

Hoje, não há um time que não tenha pelo menos um analista de números.

Sua história se tornou livro (Moneyball: The Art of Winning an Unfair Game) e filme (O homem que virou o jogo).

Case study - Business Oriented Maintenance Pelletizing Vale Brazil

BIGGEST PELLETIZING COMPLEX OF THE WORLD.

14 km² of area, 38% of green area;

2nd Largest railway yard in Latin America;

250 km of conveyor belts;

More than 12 thousand people;

Average energy consumption in 2019 - 1,541,075 MW;

Average natural gas consumption in 2019 – 396,000,000 Nm³;

Case study - Business Oriented Maintenance Pelletizing Vale Brazil

2015 / 2017- Consolidation of the center for monitoring Pelletizing assets.- Standardization of PCM processes.

2014- Implementation of the Asset Management concepts (ISO 55,000) for a physical asset management strategy supported by reliability engineering.- Implementation of the CMA- SAP Deployment.

2011- Implementation of the new management model focused on routine management.

2018- Implementation of Asset Performance Management -Orion;- Integration of CMA (maintenance, process and operation);

2019 / 2020- Operational Excellence- Integrated Risk Management- Intelligent Maintenance;- Robust Asset Management System (VPS & ISO 55,000);- Maturity in the processes of Change Management.

How was our journey…

RiskCulture

LeadershipReliability

CostPeople

Technologies

Asset Management


2013 - Implementation of the

Integrated Inspection Project.

ASSET MANAGEMENT SYSTEM

- To manage in a

sustainable and

optimized way the assets,

the performance, risks

and costs throughout

their life cycle in order to

achieve Vale's strategic

plan;

- To act in accordance

with the technical and

regulatory standards,

aligned with the best

practices in asset

management (VPS & ISO

55.000 / 01).

ASSET LIFE CYCLE MANAGEMENT

- Manage asset capacity

to ensure efficient and

effective performance

throughout its life cycle;

- To build and to

implement a strategic

asset management plan,

to enable the

organization to

proactively manage the

risks of asset incapacity;

ASSET MONITORING

- Otimize total cost;

- Ensure the fulfillment

of production volume

with sustainable results

of performance, quality,

environment and safety;

- Ensure integrated asset

management with a focus

on asset Efficiency, and

productive Process

Stability, providing rapid

responses to deviations.

ASSET MANAGEMENT AND RELIABILITY ENGINEERING

- Provide qualitative and

quantitative information to

evaluate the performance

of Pelletizing plants

equipment's;

- To manage the assets

through the technical

knowledge of their

performance (reliability)

throughout their entire life

cycle;;

- Support strategic and

sustainable reduction of

maintenance costs.

RISK MANAGEMENT

- Eliminate risks

associated with the

health and safety of

people;

- Solidify risk

management in the first

line of defense;

- Prevent, mitigate and /

or contingent the risks of

assets associated with

the relationship with

stakeholders

(environmental, legal,

social, institutional, etc.),

licensing and insurance of

productive units;

Business Oriented Maintenance


OPERATIONAL PROCESSES MANAGEMENT

- Monitor and control the

main operational assets

- Identify and act on the

performance of critical

asset

- Identify and propose

improvements to

increase the control level

of the processes and

assets

- Identify and propose

improvements to

increase the control level

of the processes and

assets

- Monitor and evaluate

the productive process

performance

Apresentador

Notas de apresentação

We structure our work oriented to the concepts of the VPS, in order to interpret the life cycle of the assets adequately. We monitor critical assets in order to assess asset efficiency and the stability of production processes. We support all of our physical asset management strategy by reliability engineering tools and seek to mitigate asset and business risk.

MaintenanceData Hub


Reliability-based maintenanceLife Data Analysis – ReliabilityMTBF TrendFailure ForecastingSpare Parts Forecast

Reliability Centered MaintenanceFailure Reporting and Problem Resolution ProcessIntegration with ReliaSoft softwareMaintenance risk managementFailure Mode & Effect Analysis – FMEAAsset Criticality Classification



SAP Ecosystem

Reliability Tools

COI

Asset Management Ecosystem

Analysis Modules

Asset Management System• ISO 55001 Strategy Documentation• Organization Strategic Plan• Stakeholders Needs and Requirements• Asset Management Policy• Strategic Asset Management Plan - SAMP• Asset Management Objectives & Plans –

AMPsAsset Management KPIsRisk Assessment and ManagementManagement of Change – MOCKaizen Quality Control CircleDesign Change RequestAction Plan and Tasks

Asset Performance & Health MonitoringAsset Performance KPIsTriggers & AlertsAssetBook

Management Modules

Opening of notes and orders; RCM studies; Dynamic Criticality of Assets

Sending order and note data; Maintenance KPIs; Asset hierarchy; Static criticality of assets; Spare Parts

Sending order and note data; Maintenance KPIS; Asset hierarchy

RAM simulations; Failure Analysis

Asset Condition Analysis (Predictive and Sensitive Analysis)

Predictability of asset failure; Dynamic criticality

classification; Dynamic risk analysis; SPF, RCA, RGA analyzes

Asset condition analysis (predictive and sensitive analysis);

Process KPIs; Diagnostic Reports

Plant InformationManagement

System

Process variables; Process KPIs

Process KPIs; Maintenance KPIs; Production KPIs; Quality KPIs; Financial KPIs; Production data, plant shutdowns and

losses; Hour meters.

DMS

Drawings (link) Projects; Docs

Document Management System

Manufacturing Execution System

Vale Production System


Apresentador


In two thousand sixteen, we started defining the technical and management requirements for the implementation of a software for integration of our management and maintenance system.

RESULTOUTPUTPROCESSESINPUT

Planning (SAMP / AMP)

6.1 Actions to address risks and opportunities for theasset management system

6.2 Asset management objectives and planning to achievethem

6*

Operation8.1 Operational planning and control8.2 Management of change8.3 Outsourcing

8*

Internal and external market context

Business Context

Financial and human resources

Leadership

5.1 Leadership and commitment

5.2 Policy

5.3 Organizational roles, responsabilities and authorities.

5*

Context of the Organization

4.1 Understanding theorganization and its context

4.2 Understanding the needsand expectations ofstakeholders

4.3 Determining the scope of theasset management system4.4 Asset management system

4*

Analysis of capacity, productivity, assumptions, restrictions, relevant maintenance, opportunities and solutions, pellet demand and VALE's medium and long-term strategy

Maintenance strategy

Quantitativereliability studies

Legal requirements

HIRA

VPS – Vale Production System

Asset Management Master Plan

Profile and treatment of stops and losses

Failure analysis

Basic maintenance and operation guidelines

Operational risks

Support7.1 Resources7.2 Competence7.3 Awareness7.4 Communication7.5 Information requirements7.6 Documented information

7*

Performanceevaluation

9.1 Monitoring measurement, analysis and evaluation

9.2 Internal audit

9.3 Management review

9*

Improviment10.1 Nonconformity andcorrective action10.2 Preventive action

10.3 Continual improvement

10*

High productivity

Safety and discipline operational

Long-term performance vision

Integrated risk management

Cost sustainable reduction (fixed and variable)

Operational excellence

Environment preserving

Physical availability maximization

Sustainability and reputation


Apresentador



OUTPUTPROCESSESINPUT RESULT

Asset hierarchy Criticality rating Asset information Maintenance orders Preventive maintenance

plans Inspection plans Standards

Strategic assetmanagement plan

(SAMP)Goals Target

Asset management plan (AMP)

MoC – Management ofchange) ROIProcesses

management

LDA - Life Data Analysis

RGA - Reliability Growth

SPF - Spare Parts Forecast

FTA - Fault Tree Analysis

RBD - Reliability block diagram

RAM - Reliability, maintainability and

availability

Risk analysis

RCM - Reliability centered maintenance

RCA - Root Cause Analysis - Ishikawa - 5 Why - Analysis of cause and effect

VPS / ISO 55000 - Asset Management Requirements

Quantitative reliability methods

Qualitative methods of reliability

Asset Management Strategy

Definition of the optimal maintenance time

Definition of the optimal inspection time

Prioritization of expenses (physical or variable)

Spare parts optimization ($ / risk)

Total Cost of Ownership (TCO)

Optimal review interval ($ / hour) - Optimal

replacement interval ($ / hour)

Future failure predictability

Failure prediction based on degradation data

Elimination of recurrent and potential failures

RAM Model - Evaluation of new projects and scenarios

Scenario analysis - Support in decision making

Asset Management

Analysis managementAsset book

Asset management indicators integrated with the Strategic Plan

Improved asset reliability(eliminate losses).

Increased asset availability

Elimination, mitigation, minimization or control of risks

Development of new projects supported by reliability

Benchmarking and KnowledgeManagement

Reduction of costs and expenses (fixed and or variable)

Well-organized and structured routine management processes

Asset health monitoring

Production losses

Condition monitoring (assethealth)

Risk monitoring (Business, units, processes and assets)

Performance indicators (triggers)

Requisitos legais e normas

World ore and pellets market

Business KPIS


Apresentador







ANALYSIS MODULES

LIFE DATA ANALYSIS

Apresentador







ANALYSIS MODULES

SPARE PARTS FORECAST

Apresentador







ANALYSIS MODULES

RELIABILITY GROWTH ANALYSIS

Apresentador







ANALYSIS MODULES

FAILURE FORECASTING

Apresentador



RAM Analysis - Reliability, Maintainability and Availability


Apresentador








RAM - Reliability, maintainability and

availability

Risk analysis






RAM - Reliability, maintainability and availability

Risk analysis

Métodos quatitativos de confiabilidadeLoss of DF indicator

OUTPUTPROCESSESINPUT RESULT

Asset

Asset hierarchy

Criticality rating

Asset information

Maintenance orders

Preventive maintenance plans

Inspection plans

Standards

Production losses

Risk

Requisitos

World ore

)

ROI PerformancePerformance indicators(triggers)

RCM - Reliability

RCM - Reliability centered maintenance

RCA - Root Cause Analysis

- Ishikawa - 5 Why - Analysis of cause and effect

Qualitative methods of reliability

Total Cost

ture

Asset Management Strategy

Definition of the optimal maintenance time

Definition of the optimal inspection time

Prioritization of expenses (physical or variable)

Increased asset availability

Improved asset reliability(eliminate losses).

Elimination, mitigation, minimization or control of risks

Development of new projects supported by reliability

Reduction of costs and expenses (fixed and or variable)

Elimination of recurrent and potential failures

Future failure forecast

Quantitative reliability methods

MoC – Management ofchange)


THANKS

Claudio Spanóe-mail:Contacts

Douglas Gonçalves R. do Nascimentoe-mail: [email protected]: +55 27 98112 9090 / +55 27 99224 3235

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