Allied Reliability Phase II EMP Development Overview (March 2009)
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Transcript of Allied Reliability Phase II EMP Development Overview (March 2009)
Asset Reliability OverviewAsset Reliability OverviewAsset Reliability OverviewAsset Reliability Overview
Allied ReliabilityPhased Approach to a Successful Reliability Initiative
Copyright 2007 Allied Reliability, Inc.
Presented by:
Chris ColsonWhat would you do
with more free time?
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Agenda
• Who is Allied
• Overview of Approach
Copyright 2007 Allied Reliability, Inc.
• Overview of Tools
• Questions / Answers
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Allied’s Reliability Success Formula
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Impact of a Complete Reliability Initiative
Bu
sin
ess
Pro
cess
an
d
Cu
ltu
re M
atu
rity
+27%• Improved Bottom
Line Performance
• Lack of System
Support
High
+75%• Significantly Improved
Bottom Line
Performance
• Practices and Systems
Aligned
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Technology Maturity
Bu
sin
ess
Pro
cess
an
d
Cu
ltu
re M
atu
rity
Source: Brynjolfsson (MIT), Wireman, Troyer, Allied
LowLow
Aligned
Baseline •Informal
• Manual Planning
Processes
• Below Average
Business Performance
-7%• Systems are not
Complemented by Effective
Business Processes
• Significant Inefficiencies
High
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Eliminate ALL Manufacturing Wastes…
RatifyDevelop
PrioritizedImprovement
Plan
Identify
Internal and
External Non
Value-Add
And Wastes
Create andEducate Process
ImprovementTeam (PIT)
Conduct FMEA Blitz
Known
Problem or
Value Stream
Mapping
(VSM)
Recognize
Transformational Analytics – “5-R” Improvement Process
Focused Improvement the Allied Reliability Way…
(Baseline)PR Plots
Rationalize
PR Simulation
and/or Reliability
Modeling
OverproductionOverproductionTransportingTransporting
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Realize
Train To NewProcess
Audit/MonitorContinually
Sustain the Gains…
DocumentNew Process
Quality
(All Defects)
WaitingWaiting
MotionMotionInventoryInventory
Resolve
RCA
RCM
FMECA
ProcessingProcessing
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Allied Reliability – Overall AHA Workstream
Asset Registry Module Asset Analysis Module Asset Integration Module
Installed
Component
Verification
Equipment
Maintenance
Plans (EMP’s) Phase
Asset
Definition
Asset
Criticality
AnalysisTechnology
Sourcing
Strategy
RCM
Analysis
(top 5-20%)
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Plans (EMP’s) Phase
3
Asset
Hierarchy
Failure
Mode
Analysis
Technology
Standards
OP1 & OP2
(top 5-20%)
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Asset Registry Module
Goals:•Defines criteria for Asset selection
•Identifies desired attributes by Asset type
•Uncovers Asset types requiring
Failure Mode Analysis (FMA's)
•Verify/identify installed Components
•Creation of logical system to
Asset structure
Deliverables:•Accurate Asset count
•Complete hierarchy for Assets
Benefits:•Increased planning efficiency due to
hierarchy structure
•Increased scheduling efficiency due
to hierarchy structure
•Hierarchy provides added granularity
when criticality performed
•Components tracking through tagging
and functional location
•Improved cost tracking through
hierarchy structure
•Increased MRO efficiency through
accurate Asset list
Asset Registry Module
Installed
Component
Verification
Asset
Definition
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•Complete hierarchy for Assets
•Component change control through tracking
•Multiple level cost tracking
•Attribute data for Asset
repairs/replacement
•Logical functional location
•Hierarchy template for CMMS upload
•Targeted seminars supporting
reliability program
•Site support for installed processes
accurate Asset list
•Improved CMMS through addition
of hierarchy structure
Asset
Hierarchy
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Allied Reliability Phase 2 – Workflow
Asset Analysis Module
Goals:•Rank Assets using multiple criteria
•Refines planning and scheduling
•Refine Maintenance, Repair and Operational
Assets (MRO)
•Categorize failure modes
Deliverables:•Ranked Asset list
•Defined failure modes for Asset types
•Attribute template for CMMS upload
•Targeted seminars supporting reliability
program
Benefits:•Additional scheduling efficiency through
use of Asset ranking
•Input to critical spares through
Asset criticality
•Further CMMS improvement by
addition of attribute & criticality
•Improved MRO function through
use of CMMS data
•Ability to prioritize failures and create
“bad actors” list
Asset Analysis Module
Asset
Criticality
Analysis
RCM
Analysis
(top 5-20%)
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program
•Site support for installed processes
Failure
Mode
Analysis
(top 5-20%)
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Allied Reliability Phase 2 – Workflow
Asset Integration Module
Goals:•Apply failure modes to Assets
•Select Asset coverage model
•Facilitate condition monitoring
sourcing strategy
•Identify PdM/PM gaps
•Create condition monitoring
operational procedures
Deliverables:•Equipment Maintenance Plan for in
scope Assets
Benefits:•Engineered equipment
maintenance plans (EMP’s)
•Further planning efficiency gains
through EMP’s
•Additional CMMS gains through
creation of PdM & PM tasks
•Consistent measures and
reporting across technologies
•Identify PM’s required to address
Asset failure modes
Asset Integration Module
Equipment
Maintenance
Plans Phase
Technology
Sourcing
Strategy
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scope Assets
•Coaching/Mentoring template
development for PM’s that address
targeted failure modes
•Documented and maintainable
equipment maintenance plan
•Condition monitoring (CM)
operational standards
•Recommended condition monitoring
sourcing strategy
•Targeted seminars supporting
reliability program
•Site support for installed processes
Plans
(EMP’s)Phase
3
Technology
Standards
OP1 & OP2
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Processes and Tools
• Based on the collection of Best Practices
• Built by “Users”
• Integration Theme
• Enforces Discipline to Standards
• Drives Transparency
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• Drives Transparency
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Walkdown Tool
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Walkdown Tool – Component Mapping
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Walkdown Tool-Attribute Entry
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Criticality Tool
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Criticality Tool- Category Management
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Criticality Tool-Ranking
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Asset Health Matrix (AHM) Tool
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AHM-Component Management
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AHM-Failure Mode Management
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AHM- CBM Technology Coverage
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AHM-Coverage Model
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RCM Blitz Tool
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RCM Blitz
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RCM Blitz - FMECA
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PM Evaluation Tool
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PME Tool
•A PM recommendation sort
is applied.
•A PM classification sort is
applied.
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is applied.
•Comments are added to
clarify recommendations
and classifications.
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PME Tool – Sample Summary Output
PME Classification Total Number %
Administration & Safety 4342 64.39%
Asset Care 491 7.28%
Inspection 1405 20.84%
Quantitative PM 464 6.88%
Regulatory 3 0.04%
Time Based Replacement 38 0.56%
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PME Recommendation (Without Safety tasks) Total Number %
No Changes 653 27.20%
No Value Added (Delete) 313 13.04%
Re-Engineer 883 36.78%
Replace with PdM or NDT 552 22.99%
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Developing Effective Work Procedures Tool
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What is required in a procedure?
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Driving consistency in procedures
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DEWP Tool
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Questions?
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Questions?