Leveraging CMMS Work Leveraging CMMS Work History To Improve ReliabilityHistory To Improve Reliability

Using The Past To Improve Our Future

Presented by

Jim Oldach – Genesis Solutions

A Wise Person Once A Wise Person Once Said….Said….Actually it was a wise fortune cookie factory worker that wrote…..

“A risk foreseen is half avoided”

What’s our job as Maintenance What’s our job as Maintenance and Reliability Professionals?and Reliability Professionals?Reduce overall asset operational risk using

the resources provided to us.Therefore, a proper measurement of our job

performance would be Total Risk Reduced / Total Resources Invested

Investment

Risk

To improve…..we can either reduce more risk, or reduce resource investment…..or better yet, do both!!!

Pareto Was Right!Pareto Was Right!The majority of our risk (80%) lies within a very small population of our assets (20%?).

Water Treatment

4.1%Oil Rig2.4%

Airport6%

What percentage of your asset population consumes 80% of your resources?

Identifying Where Our Risk IsIdentifying Where Our Risk IsRisk = Consequence x Probability2 Basic Options For Identifying Risk

◦ Proactively – What could happenProbabilistic Risk Analysis – to anticipate where risk is

highest and to implement actions that will minimize, prevent or mitigate that risk.

◦ Criticality Ranking◦ RCM Analysis◦ FMEA Analysis◦ PRA Analysis◦ etc.

The issue

Identifying Where Our Risk IsIdentifying Where Our Risk IsRisk = Consequence x Probability2 Basic Options For Identifying Risk

◦ Reactively – What has happenedHistorical Data Analysis – to use historical information to understand where it’s been demonstrated that risk is highest, and to implement actions that will minimize, prevent or mitigate that risk.

Focus Here: Historical Data Focus Here: Historical Data AnalysisAnalysis

Assumptions:◦ Equipment records have the basic information required

to analyze work history.◦ Work orders are being written against the right level of

the equipment hierarchy.◦ Work order documentation is complete and accurate.

Opportunities:◦ Improve MEL Equipment Record and supporting

information (i.e. Mfg, Model, BOM, Failure Codes, Critical Spares, etc.)

◦ Minimize equipment failures / reactive maintenance◦ Optimize the predictive and preventive maintenance

programs◦ Improve labor resourcing◦ Improve training◦ Improve spare parts management◦ Conduct asset level failure analysis◦ Measure performance across operating units

Improving MEL Equipment Improving MEL Equipment RecordsRecords

The large majority of historical maintenance spend (80%) is against a very limited number of assets….. typically between 5% to 10% of the total asset population.

Equipment records and supporting information (BOMs, Failure Codes, Critical Spares Lists) are needed in preparation

for, or as a result of work being performed on an asset..so why not focus resources on

improving those asset records that are worked on the most?

Airport

Minimize Failures / Reactive Minimize Failures / Reactive MaintenanceMaintenance

Note the absence or low level of proactive activities on some of the most reactive intensive assets.

Assets with a high level of PM that have a corresponding high level of reactive maintenance , should be reviewed for PM effectiveness.

Airport

Optimize PM/PdM ProgramsOptimize PM/PdM Programs

Assets that have a high percentage of PM inspection activities, should be reviewed for PM reduction thru identification of low value tasks or replacement with more effective and less costly PdM inspection tasks.

Airport

Optimize PM/PdM Programs Optimize PM/PdM Programs

PMO Analysis By Asset Type

Wastewater Treatment Facility

Improve Labor ResourcingImprove Labor Resourcing

Why ET1 use so low in summer and so high in winter? Is this an opportunity for resource load leveling?

Wastewater Treatment Facility

Improve Labor ResourcingImprove Labor Resourcing

Are there enough craft to support work demand? What’s ET backlog look like?

Are ELEC craft performing too much PM? Are MECH craft performing too little PM?

Airport

Improve Labor TrainingImprove Labor Training

Since craft is spending a high percentage of their time here, perhaps training should include OEM or other training on these asset types.Research and Development Facility

Improve Spare Parts Improve Spare Parts ManagementManagement

Airport – 80% of material costs ($1.5M) were consumed by only 1.1 % of total assets (349 assets)

Use this knowledge to reduce material intensive failures as well as improving logistics for the most often used spare parts.

Conduct Asset Level Failure Conduct Asset Level Failure AnalysisAnalysis

Failure code analysis can focus actions down to the failure mode level on the most critical or maintenance intensive assets. Again, develop failure codes where they will be used.

Pharmaceutical

Measure Performance Across Measure Performance Across UnitsUnits

Note how this unit is looking good regarding its proactive approach to maintenance.

SITE Proact Hrs/Loc SITE React Hrs/Loc SITE Total Maint Hrs/LocATLANTIS 3.04 NAKIKA 2.35 ATLANTIS 5.60POMPANO 3.45 ATLANTIS 2.56 POMPANO 6.02

MARLIN 3.92 POMPANO 2.57 MARLIN 6.88MAD DOG 4.03 HOLSTEIN 2.94 HOLSTEIN 7.32

THUNDER HORSE 4.36 MARLIN 2.95 THUNDER HORSE 7.57HOLSTEIN 4.38 THUNDER HORSE 3.21 MAD DOG 10.32HORN MT 6.29 HORN MT 5.13 NAKIKA 10.32

NAKIKA 7.97 MAD DOG 6.29 HORN MT 11.42

Measure Performance Across Measure Performance Across UnitsUnits

Is there an opportunity to reduce Proactive Hours and still maintain low Reactive Hours?

Questions?Questions?