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Deploying Criticality Analysis in Multi-Plant Reliability Improvement Programs Michel Cote & Serge Mathieu Prosygma Reliability and Maintenance Professional Services 1
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Deploying Criticality Analysis in Multi-Plant Reliability Improvement
Programs
Michel Cote & Serge MathieuProsygma
Reliability and Maintenance Professional Services
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What is Criticality ?
Work Prioritization
To better prioritize work
out of the maintenance
backlog
To ensure that reliability
improvements are made based on risk
rather than perception
Reliability Improvement
Initiatives
A tool used to evaluate how equipment failures impact organizational
performance in order to systematically rank plant assets for the purpose of :
To support MRO initiatives
to identify critical spares
Material Classification
PM /PdM Development
To prioritize activities
dedicated to PM / PdM development
or optimization
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Impact on safety(0 to 4)
Impact on environment
(0 to 4)0 to 256=x
Impact on quality(0 to 4)
Impact on cost or production
(0 to 4)xx
Cross-functional analysis and input from Operations and Maintenance, and as
required, input from Engineering, Material Management, Environment and
Health and Safety representatives
Weigh the impact of a failure on each asset across all 4 criteria
The Process
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Impact on Safety
Potential to cause death or permanent injuries
Potential to cause non-permanent bodily injuries
Potential to cause significant inconvenience to personnel
Potential to cause minor inconvenience to personnel
Will have no significant impact on personnel
0
1
2
3
4
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Deploying Criticality Analysis in a Multi-Plant Reliability Program
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• Quebec (4)• Ontario (2)
• Wisconsin (1)• Pennsylvania (2)• North Carolina (1)• New York (2)• Oregon (1)• Arizona (1)• Tennessee (1)
Mills located in the United States
Mills located in Canada
One of the Major Tissue Producers in North America
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The Objective• For all of the 15 mills, associate a criticality ranking to each
asset in the CMMS.
The Challenge• Have the criticality ranking done for all of the 15 mills within
a schedule of 8 to 12 weeks. • A total of 45,000 assets, ranging from 600 to 16,000 per mill.
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Criticality RankingThe criticality ranking is calculated by multiplying each of the scores (from 0 to 4) obtained for each of the 4 criteria.The total is then converted into one of the following 4 criticality rankings, namely A,B,C or D.
Evaluation Score Criticality Ranking0 ≤ Criticality ≤ 96 Extreme = A
97 ≤ Criticality ≤ 145 High = B146 ≤ Criticality ≤ 193 Moderate = C194 ≤ Criticality ≤ 256 Low = D
Safety Environment Quality Economical Total =PE-002 Pump xyz 4 4 4 1 64 APE-005 Pump ABC 4 4 4 2 128 BVE-100 Blower YYZ 4 4 4 3 192 CAG-201 Agitator DBC 0 1 4 4 0 ACL-403 Air Conditionning 4 4 4 4 256 D
Criticality EvaluationEquipment Number
DescriptionCriticality Ranking
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Lessons Learned
• Prevent mill personnel from taking shortcuts –this is an objective and quantitative process
• Avoid entering rankings one by one - work with IT to import the criticality rankings in the CMMS
• Take the time to explain the advantages of a criticality ranking system
• Make sure equipment hierarchy is adequate before you start
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Keys to Success• There is a wide variety of criticality tools and methods out there,
Keep it simple!
• Make sure to adapt the matrix with the operational context of each facility
• It is OK to use the copy/paste method for identical or very similar equipment in a facility
• Make sure you arrive prepared and organized
