public mg t course mar 2012
TRANSCRIPT
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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
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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
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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
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Tactics to brea' the vicious cycle
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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.
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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.
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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
(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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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 =
Stan Alone *uty Stan $y
?=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 =
Stan Alone *uty Stan $y
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
Stan Alone *uty Stan $y
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 2 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 1 #perator Failure A
Task ! Fitter Failure A
Task * +reaser Failure A
Task 2 #perator Failure
Task % Electrician Failure
Task 3 Fitter Failure C
Task ' #perator Failure C
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 ! Fitter Failure A
Task * +reaser Failure A
Task 2 #perator Failure Function 1
Task % Electrician Failure
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 ! Fitter Failure A
Task * +reaser Failure ATask 2 #perator Failure Function 1 #peration
Task % Electrician Failure
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
Scheduled)estoration
ScheduledDiscard
Scheduled)estoration
ScheduledDiscard
Scheduled)estoration
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
$otal 6/28 -.. -.7
Case StudyMore fre;uent but less servicingre;uire less PM "ill create better reliability:
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re;uire less PM "ill create better reliability:
*o"ntime analysis for this plantS t ti i PM h b BEF
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Secon stage 9 reuction in PM hours by BEF
*o"ntime analysis for this plantS t ti i PM h b BEF
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Secon stage 9 reuction in PM hours by BEF
Step GApproval an Implementation
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Approval an Implementation
5ain approval from nominated personnel( decide
&at else needs to be done to implement terecommendations( and complete tese activities.
The minimum stanars for issuing a PM to any person
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%ny resource tat is e?pected to complete an activity(must be given te tree 0eys.
Tools
an
mater
ials
S'
illsanTraining
Available Time
0host
The Three 1eys
Step ,iving Program
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,iving Program
=nsure tat te revised maintenance program is
completed on time( revie& all e
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source Winston ,eet -/.
CMMS
PMO$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 $evie&
Step ; unctional %nalysis @OptionalAStep 7 Conse
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Step -Tas' Collection
Page 16
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Step - Tas' Compilation
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5ater togeter in one place( all of te
maintenance tas0s @formal and informalA beingunderta0en on te asset being studied.
Page 16
Step -. Tas' Compilation.Sources of maintenance tas's
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ComputerisedMaintenanceManagementSystems.
OperatorRounds. ConditionMonitoringRounds.
ContractorSchedules.
LubricationRounds.
VendorMaintenanceManuals.
StandardOperatingProcedures
Memory andTradition
Page 16
0ather routine maintenance activities performeon the e;uipment.
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; p
Task Type Interval Trade
Task 1 Condition Monitoring )aily #perator
Task 2 Condition Monitoring )aily #perator
Task 3 Condition Monitoring ' Mont0s Fitter
Task ! Condition Monitoring ' Mont0s Fitter
Task % Failure Finding Annual ElectricianTask ' Time )irected eekly #perator
Task * Time )irected 0enever +reaser
ObHectives
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5ater in one place all te preventive or routine
maintenance activities tat are performed on tee
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Collect all te maintenance activities underta0en
by all site personnel. Decompose te maintenance activities into
separate tas0s if tey are Frolled upG.
/ist te maintenance tas0s in te one format on
te same document. =nsure tat te responsible trade and tas0
fre
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Many maintenance tas0s are F$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
Scheduled)estoration
ScheduledDiscard
FailureFindin
Page 1
There are at least three types of maintenanceactivities...
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=g. Cec0ing your car bra0e pads
'ondition
Monitorin
Condition Monitoring
Inspecting te condition of a component and leaving italone if it &ill survive to te ne?t inspection
Page 1
There are at least three types of maintenanceactivities...
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Scheduled)estoration
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
There are at least three types of maintenanceactivities...
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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 Type Interval Trade
Task 1 Condition Monitoring )aily #perator
Task 2 Condition Monitoring )aily #perator
Task 3 Condition Monitoring ' Mont0s Fitter
Task ! Condition Monitoring ' Mont0s Fitter
Task % Failure Finding Annual Electrician
Task ' Time )irected eekly #perator
Task * Time )irected 0enever +reaser
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 Interval Trade Failure
Task 1 )aily #perator Failure A
Task 2 )aily #perator Failure
Task 3 ' Mont0s Fitter Failure C
Task ! ' Mont0s Fitter Failure A
Task % Annual Electrician Failure
Task ' eekly #perator Failure C
Task * 0enever +reaser Failure A
*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 Interval Trade Failure
Task 1 )aily #perator Failure A
Task 2 )aily #perator Failure
Task 3 ' Mont0s Fitter Failure C
Task ! ' Mont0s Fitter Failure A
Task % Annual Electrician Failure Task ' eekly #perator Failure C
Task * 0enever +reaser Failure A
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
Task 1 #perator Failure A
Task ! Fitter Failure A
Task * +reaser Failure A
Task 2 #perator Failure
Task % Electrician Failure
Task 3 Fitter Failure C
Task ' #perator Failure C
Failure )
Task Trade Failure
Task 1 #perator Failure A
Task 2 #perator Failure
Task 3 Fitter Failure C
Task ! Fitter Failure A
Task % Electrician Failure
Task ' #perator Failure C
Task * +reaser Failure A
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 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
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
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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
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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 ! Fitter Failure A
Task * +reaser Failure ATask 2 #perator Failure Function 1
Task % Electrician Failure
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
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
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
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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
ConditionMonitoring ConditionMonitoring ConditionMonitoring ConditionMonitoring
Sc0eduledRestoration
Sc0eduled)iscard
Failure Finding
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Modification Modification or4o (M
Modification or4o (M
#perational/oss
a5ard Repair #nly
Why o "e bother splitting hien failures fromevient failures22
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idden Evident
ConditionMonitoring ConditionMonitoring ConditionMonitoring ConditionMonitoring
Sc0eduledRestoration
Sc0eduled)iscard
Failure Finding
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Modification Modification or4o (M
Modification or4o (M
#perational/oss
a5ard Repair #nly
Why o "e bother splitting haars from otherfailures.
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idden Evident
ConditionMonitoring ConditionMonitoring ConditionMonitoring ConditionMonitoring
Sc0eduledRestoration
Sc0eduled)iscard
Failure Finding
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Modification Modification or4o (M
Modification or4o (M
#perational/oss
a5ard Repair #nly
Why o "e bother splitting haars from otherfailures.
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idden Evident
ConditionMonitoring ConditionMonitoring ConditionMonitoring ConditionMonitoring
Sc0eduledRestoration
Sc0eduled)iscard
Failure Finding
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Modification Modification or4o (M
Modification or4o (M
#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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Stan Alone *uty Stan $y
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
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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
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Maintenance Policy *etermination
Page ;8
What variables shoul rive maintenance on anaeroplane...
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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
&un Assets to *rive the optimum maintenanceefficiency
7""" +rs
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(lapse Time
&emaining!ours
7""" +rs
1 9r
=?ample ive macines !7(""" ours total
production in te year 7(""" our overaul
&un Assets to *rive the optimum maintenanceefficiency
7""" +rs
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(lapse Time
&em
aining!ours
7""" +rs
1 9r
Tas' Selection
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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
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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.
Condition Monitoring
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
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Age
%ibration
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&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
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&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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&esistanceto 8ailure
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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&esistanceto 8ailure
P
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&esistanceto 8ailure
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...
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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
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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
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Can not be used for every failure2only failurestat give some &arning tat tere is a problem.
Page ;
On Conition Techni;ues
+uman Senses Sigt
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Sigt Sound ouc2.
Product uality Cec0s
Statistical Process Control2. ,sing specialist e
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person &it te trade
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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
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sould be consistently applied and relevant to te
type of tas0 re
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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..
Scheduled)estoration
ScheduledTas' Selection
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Discard
F+ardtimeG
Page 7"
(ngine servicing # spar' plug failure history.
Solution Interval of spar0 plug replacementSpar' Plug ,ife
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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
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Sensor
Battery
?larm
!o" o you test the follo"ing items222
=mergency paracute
lare cartridge
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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
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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
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=vent Based Servicing
Page 6"
(vent#$ase
Performed only &en a specific event occurs.@ard landing( etcA
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Page 6"
(vent $ase tas's or Special Servicing
=vent Based tas0s are used to inspect e
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potentially aKardous event.
Page 6"
(vent $ase tas's or Special Servicing
ypical events include4 Inspection of an aircraft undercarriage after a eavy
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landing. urbine inspection after overspeed. ilter cange after a dust storm.
Page 6"
(vent $aseOil storage tan' that can fail "hen heavy rain falls.
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8loating &oof
Water *rain %alves
Crue Oil Storage Tan'
*rain to Oily Water Pit
(vent $aseOil storage tan' that can fail "hen heavy rain falls.
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8loating &oof
Water *rain %alves
Crue Oil Storage Tan'
*rain to Oily Water Pit
(vent $aseOil storage tan' that can fail "hen heavy rain falls.
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8loating &oof
Water *rain %alves
Crue Oil Storage Tan'
*rain to Oily Water Pit
(vent $aseOil storage tan' that can fail "hen heavy rain falls.
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!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
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Independent Inspection
Inepenent Inspections
Performed &ere design cange is not feasiblefor safety( environment or ig cost
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conse
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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
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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"
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Page 67
Step D 0rouping an &evie"
5roup maintenance tas0s into li0e trades andintervals( and revie& te analysis outcomes to
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establis an efficient( yet effective( means ofensuring tat te maintenance policy aligns &itbot business and production ob>ectives.
Page 67
The minimum stanars for issuing a PM to any person
The Three 1eys
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%ny resource tat is e?pected to complete an activity(must be given te tree 0eys.
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.
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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
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Page 68
Step G Approval an Implementation
5ain approval from nominated personnel( decide&at else needs to be done to implement te
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recommendations( and complete tese activities.
Page 68
Step ,iving Program
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Page 6
Step ,iving Program
=nsure tat te revised maintenance program iscompleted on time( revie& all e
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of tat e
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CMMS
Do&ntime
DataManagement
PMO$CM
$eliability
IncidentManagement
The relationship bet"een the four elements source Winston ,eet -/.
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CMMS
PMO$CM
Do&ntimeData IncidentManagement
,iving Program
=nsure tat te revised maintenance program iscompleted on time( revie& all e
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of tat e
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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
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Macine not re
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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
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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
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Corrective Maintenance Brea0do&n Maintenance
=?pected ailure =
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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
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Condition
Monitoring
Condition
Monitoring
Condition
Monitoring
Condition
Monitoring
Sc0eduledRestoration
Sc0eduled)iscard
Failure Finding
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Sc0eduledRestoration
Sc0eduled)iscard
Modification Modification or4o (M
Modification or4o (M
#perational/oss
a5ard Repair #nly
e fre
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$esistanceto ailure
Potentialailure
unctional ailure
%ge
P' Interval@montsA
Cec0 at 1 montly intervals
8i)e time replacement fre;uency .
e fre
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Safe /ife
d
Maintenance Options for (vient 8ailure Moes
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$ate of Deterioration
1ailurePattern
$andom
%ge$elated
Sudden 5radual
i?ed ime $eplacement only
d
Maintenance Options for (vient 8ailure Moes
Condition Based $eplacement only
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$ate of Deterioration
1ailurePattern
$ando
m
%ge$elated
Sudden 5radual
Condition Based $eplacement only
d
Maintenance Options for (vient 8ailure Moes
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$ate of Deterioration
1ailurePattern
$ando
m
%ge$elated
Sudden 5radual
Bot i?ed ime $eplacement andCondition Based $eplacement
d
Maintenance Options for (vient 8ailure Moes
ailure &ill al&ays result in a
brea0do&n
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$ate of Deterioration
1ailurePattern
$ando
m
%ge$elated
Sudden 5radual
brea0do&n
(very asset has inherent capability
Planned Maintenance Inerent
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otalime
=?pected ailure
Planned Maintenance
,ne?pected ailure
%vailable imeInerentPerformance/evel
InerentCapability /oss
MaintenanceCapability /oss
A typical e)ample
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InerentC
apability
Some funamental conceptsThe Inherent Performance ,evel
Inherent Performance evel
Inherent Capa%ility oss
O==
Management
$eliability
IncidentManagement
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Inherent Performance evel
Inerent Capability /oss includes4
Off line Preventive Maintenance as0s(
Off line Corrective Maintenance( and
=
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Maintenance Capability /oss includes4
=
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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
Inherent Capa%ility oss
The general approach.e)ample
O==
Management
$eliability
IncidentManagement
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&aintenance Capa%ility oss
%ctual performance /evel
Esta%lish actualand inherent
performance
-Set up !eneric
data collection
system
.
The general approach cont.
O==
Management
$eliability
IncidentManagement
&aintenance Capa%ility oss
Inherent Capa%ility oss
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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"
&aintenance Capa%ility oss
Inherent Capa%ility oss
The general approach cont.
O==
Management
$eliability
IncidentManagement
VParetoV Cart of /osses
RBEEEEE
R7EEEEE
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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 !"""
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 !"""
The general approach cont.
O==
Management
$eliability
IncidentManagement
VParetoV Cart of /osses
RBEEEEE
R7EEEEE
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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"
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 !"""
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"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
$eliability
IncidentManagement
*o"ntime Costs of !ea 8ailures
All Moomba 8iel Compressors
W""(""".""
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Archive Data
3)evise inherent
Performance
4
Find *e$ 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
#xample 3@ More fre;uent shutdowns
$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
$otal 6/28 -.. -.7
More fre;uent but
less servicing re;uire less PM # more reliability:
#xample 3@ More fre;uent shutdowns
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*o"ntime analysis for this plantSecon stage 9 reuction in PM hours by BEF
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*o"ntime analysis for this plantSecon stage 9 reuction in PM hours by BEF
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The process of Incient Management
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Incient Management is a simple
seven step process
2 )evie$ )esults
3# Archive
O==
Management
$eliabilityIncident
Management
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.# 6ri!inate
/# Analysis 7 )ecommendations
2# )evie$ )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
O==
Management
$eliabilityIncident
Management
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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.
Why &eliability Assurance
can be ifficult .
Data collection strategy is too generic and lac0sdefinition.
3at problems are being loo0ed at and for &atreasons
O==
Management
$eliabilityIncident
Management
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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.
Why &eliability Assurance
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.
Why &eliability Assurance
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
O==
Management
$eliabilityIncident
Management
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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.
Why &eliability Assurance
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
O==
Management
$eliabilityIncident
Management
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anoter problem not part of tis presentation.
Integrating the / elements of
&eliability Assurance
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y
CMMS
Do&ntimeData
Management
PMO$CM
$eliabilityIncident
Management
Conclusion
Our *efinition of
&eliability Assurance
% 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
O==
Management
$eliabilityIncident
Management
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serves first to increase te level of performance tote inerent level by te application of preventiveand predictive maintenance( and
ten( by data collection and problem solving(increase te inerent performance level trougte introduction of modifications to te macine
design and te operating conditions or metods.
An important realisation about the four ;uarants of
&eliability Assurance
e realisation tat all oftese Systems are distinctlydifferent yet need to beintegrated is very important.
CMMS PMO$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.
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Management
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