Fault Tree Maintenance

A presentation by Werardt Systems P Ltd

By: Satish Nandesatish@werardt.com

Werardt started its Operations over 20 years ago, Developing Customized

Management Solutions & implementing its own software Products to the

Industry …

Thus acquiring expertise in a wide range of Domain areas and then sharing

it with its clients. In the process it’s focus is on enhancing and optimizing

Business Operations.

Werardt has a team of around 40 people for Development,

Implementation & Support

ABOUT WERARDT

SOME OF OUR CLIENTS …

PLANT ENGINEERING & MAINTENANCE

Primary Goal

To see that Production is NOT affected

due to Machine

Stoppages!

To use Best Practices so

that Asset Life is Enhanced

Daily Operations

To Ensure faster

Response time in attending to

Stoppages

Resource Utilization

To ensure Optimum

utilization of Manpower,

Spares & Contract

Resources

To Stop Fire-fighting, Do the right

things – at the right time – in

the right manner!

To achieve a higher level of

planning to ensure the

Primary Goal

Costs Incurred

To achieve something

tangible, you have-to spend something … judiciously!

To see that Operations

Add Value to the Asset Life

& Performance

PLANT ENGINEERING & MAINTENANCE

Primary Goal

To see that Production is NOT affected

due to Machine

Stoppages!

To use Best Practices so

that Asset Life is Enhanced

Daily Operations

To Ensure faster

Response time in attending to

Stoppages

Resource Utilization

Includes the use of

Manpower, Spares & Contract

Resources

To Stop Fire-fighting, Do the right

things – at the right time – in

the right manner!

To achieve a higher level of

planning to ensure the

Primary Goal

Costs Incurred

To achieve something

tangible, you have-to spend something … judiciously!

To see that Operations

Add Value to the Asset Life &

Performance

KEY ASSET OPERATIONS DATA

• The Technical Asset Register consisting of all Equipment

Equipment Breakup Subsystems LRU’s (Last Repairable Units)

• The Fault-Tree or Failure Modes & Causes

• Machine Specific Spares & Repairable Spares lists

• All Information documents in one place

• A paper-less Department Log Book

• Chronological records of Work done so as to get Equipment History

• Authentic Data of – Breakdowns, PM, Miscellaneous Jobs, Repair of Spares,

Opportunity or Proactive Jobs, Service Jobs, Refurbishing of Equipment,

Planned Jobs, AMC Management, etc.

• Resources utilized – be they Manpower or Spares

APPLYING BEST PRACTICES

• Ensure Data centric decision making

• Reduce the Response time for Attending any work

• Ensure the availability of Spares when required

• Maintain Inventory levels based on the Consumption pattern of Spares

• Continuous Improvement programs based on Problem Analysis

• Ensuring value-add in Contract Management activities

• Move from Unplanned-Procurement to Planned-Procurement

• Share Knowledge across Locations!

HOW DOES FTM

ACHIEVE THIS?

FTM HELPS YOU TO FOCUS ON YOUR PROBLEMS

Section wise Pareto (Dn.time OR Freq) Equipment wise Pareto (Dn.time OR Freq)

Dept. wise Distribution MTBF v/s MTTR

10

EQUIPMENT LIFE & RELIABILITY

PROPER Systems & Best Practices will Increase

Equipment ROI

IMPROPER practices will Reduce

Equipment ROI

Useful Life

Extend Life of Asset

Bath Tub Curve

Asset Register

Workflow Management

Resource Utilization

Your Factory Setup

Central Knowledge

Base

Enhanced Reliability

Enhanced Asset ROI

Reduced Cost

Happy Stakeholders

FTM IN SHORT

Asset Management

Spares

Failure Modes &

Causes

Resource or Manpower

Vendors

Breakdown Maintenance

Preventive Maintenance

Document Management

System

The TPM Module

Manpower Utilization

Repairs Management

AMC Schedule Monitoring

Miscellaneous Jobs & Tasks

Inventory Management

Spares Consumption

Utility Equip Monitoring

Reports Notifications &

Alerts

FTM MODULES

FTM PROVIDES NUMEROUS READY-TO-USE REPORTS

One excellent feature of the system is to adapt to the needs of

the culture of the organization. This starts with using the same

terminologies being used in the plant such as,

• Equipment or Equipment or Tag No.

• Section or Workshop or Line or Channel or Cell

• Region or Building or Unit or Plant or Division

• Job Request or Work Order or Work Request

• …

So on and so forth

During Startup FTM can be configured to use your Terminologies!!!

FTM IS MULTI-LINGUAL & MULTI-TERMINOLOGY

The Offline Mode of Entry

In an Offline mode of data entry, the maintenance users do the Job

entries on their own. Then, based on the availability of time, these

Jobs will be entered in FTM say, at the end of the Shift or Day or

Week or even at the end of the Month.

The Online Mode of Entry

In an Online mode of data entry, the Stores users will Log onto FTM

and send a request to Maintenance for attending a Job.

On the Maintenance users Pending Jobs screen a Pop-up screen will

tell him that a new job has arrived which he then can see in his

Pending jobs list.

WORKFLOW MANAGEMENT IN FTM

• B/D Breakdown Jobs

• PRTL Partial Breakdowns

• OPRT Opportunity Maintenance Jobs

• SERV Service Jobs

• MISC Miscellaneous Jobs

• PM Preventive Maintenance Jobs

• ABPM Activity Based PM

• REPRS Repairs of Spares

• CB Instrument Calibration

• R/M Reconditioning & Modifications

• … and others

Jobs Directly Affecting Business (Downtime Jobs)

Jobs Not Directly Affecting Business (Zero Downtime Jobs)

VARIOUS TYPES OF WORK RECORDED IN FTM

B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

Factory

Prod. Divn-1

Prod. Divn-2

Prod. Divn-3

Section-1 Section-2

Machine-1 Machine-2

Attached Documents

Specific Spares

Instruments & Gauges

4 Level Machine Breakup

YOUR PLANT & WORK MANAGEMENT

Man PowerSpares

Internal External

Consumable Repairable

B/D

PRTL

OPRT

SERV

PM / ABPM

REPRS

MISC (User Defined)

CB

Fault Nature

Fault Code

Cause

Cause 1

Cause 2

The Fault Tree

Machine Specific

Knowledge

WORK & RESOURCE MANAGEMENT

Phase-I Foundation Phase

This is the phase, where we will setup systems and

procedures and a data collection framework for

Maintenance to operate in,

Phase-II Sustenance Phase

This is the phase where we would wish to make use of the

data, analyze it and take right action so as to control

costs, optimize resources and increase throughput

Phase-III Achieving Excellence

This is the phase where we would want to align towards

world class management techniques such as TPM, LEAN,

Reliability, 6 Sigma, etc. to achieve a higher Plant ROI

A PHASE WISE SUCCESSFUL APPROACH

FTM Application Framework

Plant-2

Plant-1

Plant-3

Plant-4

Plant-5

FTM MULTI-LOCATION ARCHITECTURE

Centrally Located FTMApplication Framework

A Common Collaborative Management Dashboard

Multi-Location Maintenance Operations

MULTI-LOCATION SOLUTION FRAMEWORK

FTM Implementation ApproachA Successful Approach

The FTM Success

Approach

THANK YOU