Creating a robust asset management strategy to optimise asset performance and improve asset reliability

Transcription

1 N o v e m b e r, Creating a robust asset management strategy to optimise asset performance and improve asset reliability Nick Tompkins Technical Manager Asset Management November,

2 Asset Management Objective: The objective of asset management is to achieve the best possible match of physical assets with the requirements and goals of the business that uses the assets. Therefore addressing the costs in terms of: reduced demand for new assets by adoption of 'non-asset' solutions; maximising the service life of existing assets; lowering the overall cost of owning assets through the use of life-cycle costing techniques; and ensuring a sharper focus on results by establishing clear accountability and responsibility for assets. Asset Management November,

3 Understanding the current Asset Management Standards GFMAM (The Global Forum on Maintenance and Asset Management) 10 member organisations including the AMCouncil The Asset Management Landscape IAM (Institute of Asset Management) Asset Management An anatomy 39 Subjects in 6 Key Areas o Strategy and Planning o Asset Management Decision Making o Lifecycle Delivery o Asset Information o Organisation & People o Risk & Review PAS55 ISO55000, ISO55001, ISO55002 IAM Certificate Endorsed Assessment JA1011 (RCM) Asset Management November,

4 Asset Management Resources Asset Management November,

5 Total Life Cycle Management Asset Management November,

6 Life Cycle Cost Analysis Asset Management November,

7 Asset Management Process Asset Management November,

8 Reliability Growth Model Cost & Risk Optimisation Assessment Optimised Maintenance Strategy Structured Work Management System Disciplined Defect Elimination Program Effective Data Capture and Performance Management Systems Complementary Workforce Development Program Derived from the DuPont Operational Excellence Model Structured Documentation and Control System Asset Management November,

9 Key success factors Buy-in Skills Support Process mapping Procedures RACI Process People KPI s Systems CMMS Document control Tech Library Asset Management software Tactics Maintenance Operation Optimisation Renewals Asset Management November,

10 Where do we focus? What your Assets require What you can afford We cannot solve our problems with the same thinking we used when we created them - Albert Einstein Asset Management November,

11 Industry Benchmarks Continuing to do what you have always done will not provide the outcomes you are looking for Best performers keep getting better Poor performers are falling further behind Asset Management November,

12 Investment in Asset Management Asset Management November,

13 Business capabilities and technology drivers 65% of best in class organisations have cross functional teams to improve risk and asset performance 76% of best in class organisations use historical and real time data coupled with asset lifecycle plans as actionable intelligence Asset Management November,

14 Aberdeen Group Research Research Papers delivered in 2012 by Aberdeen Group 1. Asset Management, Building the Business Case 2. Operation Risk Management Asset Management November,

15 Aberdeen Group Research % of Energy Leaders apply Risk Management techniques to Asset Management / Maintenance Energy Leaders have 4.3% unscheduled asset downtime Asset Management November,

16 Total Cost or impact to the business Asset Management November,

17 P-F Interval to determine task frequency P : is the earliest possible detection point of potential failure (Inspection method dependent) Potential Failure Curve P- Sensitive Cond. Monitoring P Basic Cond. Monitoring Asset Condition P Rudimentary Inspection F Functional Failure Acceptable Limit Set Point Asset/Component Destruction Time P-F Interval Recommended Frequency Asset Management November,

18 Maintenance frequency optimisation Asset Management November,

19 Risk Based Component Analysis Increased Risk Cost Reduction 0-10% 3,231,580 10%-20% 20%-30% 30%-40% 50%+ Grand Total 1,429,326 1,244, ,015 24,648 6,058,895 Asset Management November,

20 Asset Condition Assessment Methodology Mechanical, Electrical and Structural condition assessment Review existing major work lists including proposals for upgrades or refurbishments Review work order history focussing on completion of Preventative Maintenance Determine last repair/replace dates Review condition monitoring / test reports Determine Asset expected life based on operating context Determine remnant life based on production forecasts Visual inspections where required to determine obvious signs of structural distress Thickness / Crack testing (structural and pipeline) Corrosion analysis Estimate repair / replace capital estimate and timeline Determine upgrades where required Assign risk ratings to each asset / structure / equipment Asset Management November,

21 Renewal strategies Asset Management November,

22 Risk with component extension What risk are we exposed to by extending component lives?? Condition Monitoring Strategies Unaffected by component extensions as condition determines replacement Ensure PF interval exceeds planning horizon Critical Spares Analysis to reduce risk Fixed Time Replacement Strategies Glasser Graphs give good indication of optimum replacement interval Quantifies decision in terms of Operate to Failure Strategies No impact Asset Management November,

23 Condition monitoring Technique or technology determines the P-F interval (period of time between detection and failure sometimes known as Remaining Useful Life RUL) P-F Interval must exceed the planning horizon (time to plan the corrective) If not, the failure will happen in an unscheduled fashion Having parts on hand will reduce the planning horizon HOWEVER holding parts is expensive Critical Spares Analysis assesses the COST of holding versus the RISK of failure An optimum holding reduces the overall RISK to the business Asset Management November,

24 Fixed time replacement Fixed time replacements are warranted when the cost or consequence of failure overrides the cost of prediction, however The hazard rate must be increasing (risk), and The cost of doing the activity in an unscheduled fashion far exceeds that of doing it in a scheduled fashion. Glasser s graphs can be used to determine the optimum replacement interval and the RISK cost to the business of extending component lives Asset Management November,

25 Risk based spares analysis Asset Management November,

26 Risk based spares analysis Asset Management November,

27 Optimising Shutdowns Task Shutdown Activity 1 Shutdown Activity 52 Shutdown Activity 13 Shutdown Activity 20 Shutdown Activity 21 Shutdown Activity 15 Shutdown Activity 44 Shutdown Activity 45 Shutdown Activity 18 Shutdown Activity 48 Shutdown Activity 50 Shutdown Activity 4 Shutdown Activity 49 Shutdown Activity 51 Shutdown Activity 19 Shutdown Activity 28 Shutdown Activity 29 Shutdown Activity 37 Shutdown Activity 38 Shutdown Activity 43 Shutdown Activity 22 Shutdown Activity 23 Shutdown Activity 24 Shutdown Activity 25 Shutdown Activity 26 Shutdown Activity 27 Shutdown Activity 2 Shutdown Activity 3 Shutdown Activity 39 Forecast Date 1/04/ /03/ /03/2014 1/12/ /03/ /11/2013 1/12/ /03/ /03/2014 1/05/2014 2/05/2014 1/03/2014 1/03/ /03/2014 1/02/ /03/ /01/2014 1/02/ /01/ /12/ /02/ /02/ /12/2013 1/02/2014 1/03/2014 2/04/2014 1/02/ /02/ /03/2014 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-13 Mar-13 Apr-14 May-14 Cost Task 122, , ,600 76,200 76,200 40,000 33,800 33,800 32,600 22,150 22,150 19,580 17,500 17,500 9,200 9,000 9,000 8,160 8,160 6,945 6,600 6,600 6,600 6,600 6,600 6,600 6,375 6,375 5,820 Access time Asset Management November,

28 3 Take-away points 1. Current benchmarking in Asset Management indicates that the best in class are investing money in Asset Management. 2. It is imperative to apply risk management techniques to Asset Management / Maintenance. 3. A successful Asset Management Strategy is one that takes the whole organisation into consideration and is driven by senior management / corporate level. Having a small team in charge of and accountable for Asset Management won t work. Asset Management November,

29 Questions? Asset Management November,