The Leading Reward of Maintenance Management

Transcription

1 Halting the Cycle of Break & Fix: The Leading Reward of Maintenance Management Eric Hancock Practice Leader for Operations & Asset Management Jacobs Engineering Group Inc.

2 Best Maintenance Strategies t What is your current maintenance philosophy? h How useful is your CMMS? How do you improve reliability?

3 Reactive Maintenance Failure Based Preventive Maintenance Time Based Inspections/Lubrication Predictive Maintenance & Condition Monitoring Condition Based Vibration Analysis Infrared Thermograph Motor Circuitry Analysis Oil Analysis

4 Reactive Maintenance Pros: Cons: Cheap and easy to institute. Makes sense on some equipment. No exact time-line to failure. May cause collateral damage. Cannot be used on everything.

5 Preventive Maintenance Pros: Cons: Ensures certain maintenance activities are done and tracks their completion. Helps meet warranty requirements. Can be excessive and unnecessary. Can be labor intensive. Can introduce more problems than it prevents.

6 Pros: Cons: Predictive Maintenance (PdM) Can be used to modify PM frequency. Allows the detection of faults in the early stages of failure. Increased equipment up-time. Extended equipment life cycle. Can be costly to institute (in-house or outsourced). Learning curve. Quantifying i ROI.

7 Asset Management Basics What do I own? Where is it? What is its condition? What is its useful u life? What is its value? Is it adequate for my needs?

8 Computerized Maintenance Management System A software/hardware solution to streamline maintenance operations. The foundation for an Asset Management Program. Maximo

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10 A CMMS should Contain asset registry/hierarchy. Include a defined naming convention. Record and maintain work history. Include work tasks and frequencies. Maintain i maintenance inventory. Accommodate all methods of work accomplishment.

11 A CMMS should Effectively interface and communicate with related systems. Provide feedback information for analysis (reports, KPI s). Reduce costs through effective maintenance planning and informed decisions. f Result in maximizing asset life cycles while minimizing total cost of ownership.

12 Collection System Assets Gravity Pipe Material, shape, diameter, liner, gasket material Force Main Air relief valves Collection System Access Manhole, manhole cover, vault Pump Station Dry well, ejector, electrical system, emergency power supply, flow meter, HVAC system, pipe system, pressure monitoring system, pump, p, structure, wet well

13 Data Capture Type of defect, type of repair, location of repair (GIS info), type of blockage, photos. Materials used, equipment used, man- hours, contractor. PACP data, rim/invert/grade elevation. Sample of defective material. Use checkboxes and pick list whenever possible to capture data.

14 A Successful CMMS Program Supported by management. Must be viewed as a tool to help with work. Must be simple to use. Data collection needs clearly communicated. Data collection/retrieval must be easy. Must have value to organization. Properly trained staff. May be staged.

15 Reliability Reliability - the ability of an item to perform a required function under a stated set of conditions for a specific time period. Moving from reactive maintenance to proactive maintenance is a best management practice. Change in philosophy - integration of skill sets. Root cause analysis - finding the real cause of the problem and dealing with it rather than simply continuing to deal with the symptoms.

16 Improving Reliability Maintenance Management is a business process. CMMS software is the technology used to automate and support that process. CMMS will expose those flaws even quicker. Use methodologies like Reliability Centered Use methodologies like Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM), or PM Optimization to ensure that your maintenance management is based on a disciplined decision process.

17 What is RCM and Why Do It? Reliability Centered Maintenance (RCM): Generally, a systematic and logical method for developing a PM culture that will: Maximize plant reliability and Help mitigate the effects of any failures that do occur. RCM should be performed in order to improve personnel efficiency, i root out hidden faults, and preserve plant and public safety. Neal Bloom, RCM Implementation Made Simple.

18 RCM in the Water Industry Application of Reliability Centered Maintenance in the Water Industry Published February 2006, by the American Water Works Association (AWWA) Research Foundation. Report provides guidance and recommendations for implementing a RCM program Relates that one of participants in the pilot study realized a reduction of percent in maintenance cost

19 Conclusions Evaluate current maintenance strategy proactive. Maintenance management is a business process. Best in Class - ensure that your maintenance management is based on a disciplined decision process such as RCM. CMMS is a tool and should be carefully selected to fit your business process. Involve those doing the work in the process. Adequate training. Staged approach.

20 Questions?