jasonballenne- - arms reliability · mastering sap pm 2013 equipment/%objectpart redesign%...

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Ins$tu$onalize Reliability Improvement

Jason Ballen$ne ARMS Reliability

Mastering SAP PM 2013

ABC Group …the typical RCM story

•  12 Global factory loca4ons

•  SAP since 2005, mostly legacy imports

•  RCM project ini4ated in 2007

!  Targets: o  10% Reduc4on in Maintenance Cost o  5% Availability improvement o  Reduc4on in safety incidents


ABC Group …the typical RCM story

•  8,000 ‘Cri4cal’ loca4ons iden4fied for RCM

•  7 Step Excel based process •  24 Month process

o  Es4mate > 20,000 Labour Hrs

•  Many thousands of tasks developed

ABC Group …the typical RCM story •  Some lingering ques4ons post the project….

o  Will the results actually be implemented?

o  Project contribu4on to KPI’s?

o  Could the project be turned into a process

"  “The work is not done yet”

o  How could it be made “easier” i.e. through alignment of SAP & RCM?


RCM & SAP-‐ Addi$onal Ques$ons to Answer

•  What results will (can) I get from RCM?

•  What do I need from SAP to do RCM effec4vely?

•  How do I efficiently update SAP with the results?

•  How do I turn a RCM project into a process?


Group Experience

1.  Who has used RCM to develop their opera4ons maintenance tac4cs?

2.  Are the results implemented? RCM=SAP

3.  Who has a living system?


In excess of 60% of RCM studies are never

implemented!

Source: Reliability Web Survey

RCM Defined •  What is the objec-ve of RCM Studies?

“Iden4fy appropriate maintenance tac4cs and other strategies to mi4gate the risk of asset failures”


RCM & SAP for Success

What can I expect from my RCM efforts?


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Pareto Predictions

Task Interval Optimisation


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Task Interval Optimisation


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Pareto Predictions


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Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Planned Spares (ZAR ,000) 398 419 424 428 417 443 423 414 421 422

Correc4ve Spares (ZAR ,000) 2,553 3,617 3,728 3,770 3,552 3,757 3,724 3,722 3,650 3,504

Labour (ZAR ,000) 253 284 285 292 279 288 291 290 288 282

Total Maintenance Cost (ZAR ,000) 3,204 4,320 4,437 4,489 4,248 4,488 4,438 4,426 4,359 4,207

ZAR 0

ZAR 500

ZAR 1,000

ZAR 1,500

ZAR 2,000

ZAR 2,500

ZAR 3,000

ZAR 3,500

ZAR 4,000

ZAR 4,500

ZAR 5,000

471 Dump Truck Maintenance Cost Profile

RCM Defined

•  …when is this project finally done?.....


RCM Defined

….RCM should be a process, not a project!

o  We make assump4ons (that’s what engineers do!) o  Changes in Assets (modifica4ons/ acquisi4ons) o  New inspec4on technologies and methods (Think P-‐F Curve) o  Skills development may impact failure characteris4cs & P-‐F o  Defect Elimina4on Programs (RCA) o  Opera4ng context changes (e.g. changes impac4ng equipment life) o  New failure modes come to the fore o  Consequence of failure (Down4me cost) changes over 4me… should we change our strategies?


RCM Defined

The argument is made….

RCM should be a process, not a project!



Elements of RCM & SAP Success


Define overall success:

» Jus4fied tac4cs. A transparent & well understood maintenance strategy!

» Defined alignment points for SAP & RCM » Plaporm for con4nuous improvement (Process vs. Project) » Educated people


SAP RCM & SAP for Success

RCM

Preventa4ve Maintenance

Hierarchy & Loca4ons

Maintainable Items

Failure modes

Consequence

Failure Characteris4cs

•  Plans, Items, Task Lists •  Resources (Labour & Spares)

Hierarchy & Func. Loca4ons

Object Parts

Symptoms & Cause Details (Catalogues)

Effect

Failure/ W.O. History

PM01 Details


Equipment/ Object Part

Redesign

Cooling Water Pump FMEA

Pump Provide cooling water to the process at xx rpm

No Cooling Water

Bracket Damaged

Bracket Corroded

Contain Cooling water

Cooling water leak

Pump Body worn through

Shaft Gland worn

No cooling

No cooling

No cooling Water leak


Cooling Water Pump FMEA

Pump Provide cooling water to the process at xx rpm

No Cooling Water Bracket Damaged

Bracket Corroded

Contain Cooling water

Cooling water leak Pump Body worn through

Shaft Gland worn

No cooling

No cooling



SAP Functional location/equipment

SAP Problem Code

SAP Object Part / Cause Code

SAP Effect

SAP Maintenance Plans

Maintenance Plan

Maintenance Plan

Maintenance Plan

Maintenance Plan

Maintenance Item Task List Task List Task List Task List Operation

Document

Task Alignment

RCM

Task Group Task

SAP Plan Item Task List Opera4on Docs

Maintenance Plan

Maintenance Plan

Maintenance Plan

Maintenance Item

Maintenance Items •  Mul4ple Maintenance Items per single Maintenance Plan •  Split on (??)

o  Maintenance Interval o  Volume of work o  Resource o  Equipment


Map your Process! &

Include points of RCM & SAP alignment!


Take an Enterprise Approach

•  Taking an enterprise approach o  improves efficiency o  supports consistent implementa4on o  supports con4nuous improvement

The Right Focus •  The best organisa4ons focus on ins4tu4onalising

o  Role Defini4on o  Competencies o  Processes o  Standards o  Quick Reference Guides (QRG’s) o  Support o  Measurement


• Triggers for review "  Calendar

"  Changes in Consequence ▫  The “New Reality”

"  Pareto

"  CI Process (Defect Elimina4on)

! COMBINATION OF ABOVE


Process Map

Ins$tu$onalising •  Successful Implementa4on is the key

o  Ins4tu4onalising creates the path and supports the processes

Key Points

1.  RCM should be a CI process, not just a project!

2.  Map your process

3.  Ensure SAP & RCM alignment 1.  Ensures sustainable use 2.  Data can become informa4on and advance your tac4cs

(think analy4cs!)


Conclusion

SAP & RCM can help you con=nually improve your maintenance strategies!

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Ques$ons


Produced by: Supported by:

Jason Ballen$ne ARMS Reliability

[email protected]

jasonballenne- - arms reliability · mastering sap pm 2013 equipment/%objectpart redesign%...

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