Post on 06-Aug-2019
transcript
Boxer Environmental1908 Creekwater Blvd., Port Oranage, FL 32128
Asset Management Building a Successful World Class Maintenance Organization
How do we measure success?
People – The Who
Processes – The What
Platforms – The Tools
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Components of a Maintenance OrganizationComponents of a Maintenance OrganizationPeople - Who– Qualifications and Job descriptions
– Internal Communications
– Training
– Utilization
– Accountability
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Components of a Maintenance OrganizationComponents of a Maintenance OrganizationProcesses - What– A balanced Maintenance Strategy
– Work Flow to execute the strategyWork Identification
Planning
Scheduling
Packaging
Execution
Close Out
– Continuous Improvement Methods
– Metrics
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Components of a Maintenance OrganizationComponents of a Maintenance OrganizationPlatforms - Tools– CMMS
– PdM TechnologiesVibration
Oil Analysis
Thermal
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Four Maintenance StrategiesFour Maintenance Strategies
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Which to use depends on:• The equipment to be maintained
• The operational context
• The maintenance resources available
• Health & Safety compliance
• General Practicalities
• Cost
4 Strategies4 Strategies
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
• All FOUR maintenance strategies are required to make an effective maintenance plan
• All FOUR maintenance strategies have advantages when implemented correctly
• All FOUR maintenance strategies have disadvantages when implemented incorrectly
• The appropriate strategy can only be chosen when the reasons for equipment failures are fully understood
Maintenance Strategies - Key PointsMaintenance Strategies - Key Points
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Assess condition of organization and determine stage of development of the reliability program in– Work Flow– Technology– Organization– People
Some Advanced strategies may be in place without having the basics in place. Costing more money than they should.
Develop a StrategyDevelop a Strategy
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
AUDIT
EXECUTE
SCHEDULE
PLAN
WORK ORDERSMaintenance Work In ProgressMaintenance Work In Progress
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
1. Consistent Top Management support for the program2. Develop and implement a Strategy 3. Standardize Work Flow Process4. Organized to support the Work Flow Process5. CMMS System that supports the Work Flow and Organization
Total Productive MaintenanceReliability Centered Maintenance
Reliability Based Maintenance
Predictive
Preventive
Reactive
World Class Programs (Relative % time/activity)
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Advanced StrategiesAdvanced StrategiesSERP – System Equipment Reliability Prioritization -Method to rank all of a plant’s equipment.
Streamlined RCM – Streamlined Reliability Centered Maintenance – Process to determine the appropriate Failure Defense Plan.
Failure Defense Plan – Plan for each piece of equipment detailing the Maintenance Strategy (the big 4), frequency, resources, etc. to protect the equipment’s reliability.
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
SERP (System Equipment Reliability Prioritization)SERP (System Equipment Reliability Prioritization)A 3-tiered approach involving the ranking of– System Criticality, taking into consideration:
Process Throughput, Operational Cost, Product Quality, Safety Considerations and Regulatory Compliance
– Asset Criticality, involving:Operational Criticality Ranking
– Maintenance Priority IndexAsset Failure Probability Factors
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Streamlined RCM ProcessStreamlined RCM ProcessA process to examine current maintenance requirements and validate them for probability, applicability and reasonability using operational and technological experience
–– PProbableEstablish The Need for MaintenanceEstablish The Need for Maintenance
–– AApplicableTask is Beneficial in Restoring or Maintaining Task is Beneficial in Restoring or Maintaining Inherent ReliabilityInherent Reliability
–– RReasonableEnsure Task is JustifiedEnsure Task is Justified
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Failure Defense PlanFailure Defense PlanSystematic Review of all Maintenance Strategies for all criticalequipment and adjusting strategies based upon actual equipment failure history, ACR and MPI.Strategy adjustment includes:– Changing shutdown inspections to Condition Based running inspection
– Extending frequency of inspections
– Adding/deleting procedures as required
For plant with many PMs, expect a 20-30% reduction in PMs
For a plant with no PMs, this is a method to document them.
The Right Maintenance on the Right Equipment at the Right Time by the Right People at the Right Cost.
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Industrial Example: Fossil PowerIndustrial Example: Fossil PowerMaintenance Practices Mix
Prior to Program ImplementationMaintenance Practices Mix
After Program Implementation
PdM - PredictivePM - PreventiveRTF - Run-to-FailurePAM -Proactive
PdM46%
PM35%
PAM3%
RTF16%RTF
42%
PdM12%
PM45%
PAM1%
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Fossil Power Industry – Program SavingsFossil Power Industry – Program SavingsAverage Program Savings: $2.0M (ROI = 4.73:1)
ProductionCapacity
(Availability)65%
Parts Reduction(Inventory)
10%
EFORReduction
10%
Other5%
InsuranceReduction
1% LaborReduction9% (OT)
Savings by Classification
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Fossil Power Industry - InvestmentFossil Power Industry - InvestmentAverage Program Investment: $423K
Labor62%
Technology26%
Consulting& Training
12%
Total Investment Mix
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Steps to Reaching World ClassSteps to Reaching World Class
PM
RM
PDM
RM
PAM
PM
PDM
PM
RM
Adequate BestBetter
Elements In Place
•Maintain Status Quo
Elements In Place
• Management Support
• Right Personnel
• Work Flow Process
•Planning
• CMMS
• KPIs
•Accountability
Elements In Place
• All of “Better”
• Equipment Priority -SERP
• Failure Defense Plans on >30% of equipment
• Predictive Programs
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Adequate
CMPM
Transformation - Adequate to BetterTransformation - Adequate to Better
Better
CMPM
PDM
CMMS
PdM concepts in place
PM starts to drive actions
Planning function staffed
Scheduling function staffed
Boxer Environmental1768 1768 ArashArash CircleCirclePort Orange, FL 32128Port Orange, FL 32128
Transformation - Better to BestTransformation - Better to Best
Better
CMPM
PDM
Best - LCP
CM
PM
PDM
PAM
CMMS
FDP has been done using SERP, FMEA, SRCM
Optimized Maintenance Program
KPIs identified and communicated
CBA in place
Planning function staffed
Scheduling function staffed