Post on 11-Jan-2016
description
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?