Amazon Quietly Enters

Reliability Centered Maintenance

Introduction

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Amazon Fulfillment recently incorporated Reliability Centered Maintenance into an overall Network Maintenance Solution

Amazon currently has over fifty Fulfillment Centers across the United States and counting…

These FC’s as we call them, are the way in which we fulfill customers orders otherwise known as the Customer Experience

Simply stated these Fulfillment Centers are where we stow inventory and ship items to our customers

Introduction

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In this overhead view we see an example of the MHE inside a typical FC

With over Fourteen miles of conveyor systems It’s very important that we maintain the equipment

properly

Introduction

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From the

Inbound/Receive

Material Handling

Equipment

Where product is

unloaded into the

facility and ready

for purchase

Introduction

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To Outbound

Ship Dock

Amazon customers rely on all of these

systems working correctly to continue

creating the positive Customer Experience. Where we ship

customer orders

Introduction

So, how do we keep all these complicated and high speed pieces of equipment functioning in our 24/7 environment?

These next steps will show the developments in that effort and tell the story of our journey.

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Introduction

• In July of 2013 we formed a Network Reliability Team

• This team met on a weekly basis and began discussing advanced maintenance strategies.

• Led by Regional Facilities Manager Rick Strickland this team began to establish goals and timelines. We looked at the latest industry practices and began comparing them to what RCM systems and technologies would best fit Amazon’s Business.

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Introduction

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2015 Guided by our

Facilities Mission/

Vision Promise and

Core Values

That speaks to the

heart of our mission

Introduction

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2015 Guided by our

Facilities Mission/

Vision Promise and

Core Values

Where Reliability is

our Mission the plan

Mission:

To Provide the Earth’s Most

Reliable Internet Fulfillment

Centers

Introduction

Examine the Current State vs Desired State

• Compare internally managed program vs a third party service provider

• Recent third party air audits were referenced

• No current program in Fulfillment to benchmark either internally or externally

• Discussions with other FC’s and their approach to facilities maintenance

• Determined to utilize internal resources and begin

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Introduction

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Maintenance Schedule

RCM Technology Training

RCM Implementation

Planning

EAM Integration

RCM Implementation

Identify the transition steps required to move from a Calendar based PM program that is

reliant upon a weekly 12 hour downtime window to a RCM / Predictive Maintenance program

that utilizes daily downtime opportunities

Calendar

Based PM

Program

2013 State

RCM

Program

Desired End State

Step 1 Step 2 Step 3 Step 4 Launch

Introduction

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Maintenance Schedule

RCM Technology Training

RCM Implementation

Planning

EAM Integration

RCM Implementation

The goal would be to follow these Transition steps and move from a Calendar based PM

program only, to a blend of Pm and PdM activities. RCM / Predictive Maintenance and PM

finds would be planned for daily 2 hour downtime opportunities

Calendar

Based PM

Program and

RCM

Current State

averaging

above 70%

proactive

Step 1 Step 2 Step 3 Step 4 Launch

Calendar

Based PM

Program and

RCM

Desired State

averaging

above 80%

proactive

PdM Technologies

Create Program – Beta site BNA3 Murfreesboro, TN

• Determine strategy from all existing PdM Technologies

• Thorough Examination, Deep Dive into:

• Infrared Thermography

• Vibration Analysis

• Airborne / Contact Ultrasound

• Oil Analysis and more…

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PdM Technologies

First Technology Start with Infrared Thermography

• Researched IR Imagers

• Fluke Model Ti 110 Chosen…

• Rep support from FLUKE was strong

• Train the entire Facilities Maintenance Team

• Technicians and Leadership

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PdM Technologies

Inspect the entire Fulfillment Center in a weekly cycle

• IR routes established per crews

• Balanced work load and increased familiarity with equipment.

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PdM Technologies

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Begin Thermal Imager inspections

Creating IR

Reports

PdM Technologies

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ADD a Second Technology ULTRASOUND

• Researched Ultrasound providers

• Chose UE Systems

• Site visit 1/11/2014

• Define FC application based on Technology capabilities

• Discovered that UE Systems can provide a two for one

approach. Airborne ultrasound for air audits and Contact

probe for mechanical condition monitoring

• Develop routes and determine Critical Path equipment

PdM Technologies

• Strong support from UE Systems

• Several training session held where

the entire facilities team received basic intro

• Advanced session planned for SME’s

• Chose the Ultraprobe 10,000

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PdM Technologies

• Designed imbedded job aids

• These documents are associated with every work order

• Provides instant support as needed

• Critical Path Map included

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PdM Technologies

• Air Audits include Template

• Common reporting format

• Detailed instructions

• Allows for instant YTD savings

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PdM Technologies

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From the UE work station we can do it all.

• EAM work orders

• UE Systems DMS application software

• Upload / Download / Analyze

• Track /Trend and reexamine as necessary

• Schedule required work

PdM Technologies

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Singulator CM

The Ultrasound data

collection for this critical

asset required the use of

remote access cables.

A great and safe option

PdM Technologies

ADD a Third Technology Strobe Light Inspections

• Easy to use

• Nova Probe BBX Monarch chosen

• Grainger purchase

• No training required

• Simple and effective v-belt and round belt inspections

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Summary

• All technologies now utilized on a daily basis at BNA3

• Beta testing successful - now a Network initiative

• BNA3 has experienced the best uptime in the network since implementation

• Currently shipped over 110, 000,000 units without a major unplanned downtime event or sev 1 callout

• The best uptime record at Amazon!

• Proactive labor rates averaging above 75percent

• All predicative work orders and supporting documentation in EAM

• Air Audit results – over $14,000 YTD

• Reduction in spare parts cost vs sister FC and YOY

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Summary

• Facilities Team has developed several Network RCM workshops

• Fulfillment Centers are attending per region; East, Midwest, Southwest and West

• Amazon Subject Matter Experts are now assisting RCM implementation at new sites

• RCM has become a commissioning tool at new builds

• As the program is implemented downtime avoidance is improving

• Air Audit cost savings YTD in network: $78,275 from six sites

• Developing best practices, standards and more…

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Summary

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Working together to continue providing you the best

Customer Experience possible.

Questions?

Summary

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