Asset Criticality Ranking A Best Practice Overview

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Norma Stevens
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1 Asset Criticality Ranking A Best Practice Overview Asset Reliability Systems & Technology Strategy & Process Asset Criticality Ranking Overview What is Asset Criticality Ranking (ACR)? A tool used to evaluate how asset failures impact organizational performance Provides reliability leaders a detailed profile of characteristics that makes each asset critical Provides focus to ensure that reliability improvements are made based on calculated risk rather than perception: Safety and Environmental Impact Operational Throughput Maintenance Costs Utilization Rate Allows for the systematic ranking of assets for prioritization of all efforts 22 1

2 Asset Criticality Ranking Overview Benefits to ACR Primary mechanism needed to prioritize improvement activities when time and resource availability are limited This prioritization should be applied to Continuous Improvement efforts PM Optimization (PM and PdM Development) Bill of Material Development (to include Critical Spare Parts) Capital Investments This prioritization should also be applied to Daily Management of the CMMS Workflow Process Planning Scheduling Material Procurement 33 Asset Criticality Ranking Overview Critical Success s The ACR process is made up of two phases The first phase is the initial analysis which requires crossfunctional input from Operations, Maintenance, Engineering, Quality, and EH&S This cross functional analysis is required to ensure an accurate criticality ranking as well as gain buy in and overcome perceptions of criticality The second phase is evergreen, meaning that the criticality ranking process must be maintained and reevaluated throughout the asset s lifecycle (approximately every months or as triggered) This is done to determine when risk has been mitigated and the significance of each asset has changed 44 2

applied to Daily Management of the CMMS Workflow Process Planning Scheduling Material Procurement 33 Asset Criticality Ranking Overview Critical Success s The ACR process is made up of two phases The

3 Asset Criticality Ranking Overview ACR Strategy Development 1. Determine the Components for ACR Asset Business Impact / Asset Reliability Impact 2. Determine the s for each Component Operational Throughput / Utilization / Quality / Detection Risk / etc. 3. Determine the and Scoring for each 4. Determine the Weighting for each 5. Determine the Scoring Calculation for each Component 6. Determine the Scoring Calculation for ACR Utilize Range Scaling if needed 7. Determine ACR Score groupings for bulk analysis Classification / Percentile / Quartile 55 ACR Framework Breakdown Asset Criticality Ranking Component Component Score 1 A B C D E F G H I Component Score = A * B * C * D * E Component Score = F * G * H * I ACR Score = Component Score + Component Score 66 3

Determine the Scoring Calculation for each Component 6. Determine the Scoring Calculation for ACR Utilize Range Scaling if needed 7.

4 Asset Business Impact Score 77 Asset Reliability Impact Score 88 4

5 ACR Weighting s Weighting allows for specific factors to be weighted heavier than others 99 ACR Tool

6 ACR Classification Classifying (or Grouping) your Assets based on ACR is a primary mechanism used for prioritization Beyond basic Classification as shown above, your Assets can be sorted by ACR Percentile and ACR Quartile 111 ACR Execution Process Map

basic Classification as shown above, your Assets can be sorted

7 Applying Asset Criticality Ranking to the CMMS Work Order Priority & Work Order Criticality Work Order Priority combined with Asset Criticality Ranking allows for a quick and efficient distribution of Work Orders using WO Criticality. WO Priority + ACR = WO Criticality 1313 Applying Asset Criticality Ranking to the CMMS ACR for Planning Utilize ACR to rank your Assets, driving priority for Work Orders that require PLANNING in the CMMS

8 Applying Asset Criticality Ranking to the CMMS ACR for Scheduling Also utilize ACR to prioritize Work Orders for SCHEDULING in the CMMS Applying Asset Criticality Ranking to the CMMS ACR for PM Optimization Input your developed PM s and associated Job Plans from your ACR based PM Optimization effort into the CMMS

1515 Applying Asset Criticality Ranking to the CMMS ACR for PM Optimization Input

9 Prioritizing Improvement Efforts Applying ACR to your Asset Health Plan 1717 Prioritizing Improvement Efforts Applying ACR to your Reliability Strategy ACR Quartile PMO FMEA Operator Care Run to Failure Critical Spares 1 X X X X 2 X X X 3 X X 4 X X ACR Quartile Motor Analysis Oil Analysis Thermal Analysis Ultrasonic Analysis Vibration Analysis 1 X X X X X 2 X X X 3 X X

Care Run to Failure Critical Spares 1 X X X X 2 X X X 3 X X 4 X X ACR Quartile Motor Analysis

10 Prioritizing Improvement Efforts Applying ACR to your PdM Strategy Point (P) Potential Failure begins Optimized Condition Early Signals detected by PdM P F Curve Audible Noise Condition Life is better at the top of the curve! Hot Surface Point (F) Functional Failure occurs Time P F Interval 1919 Achievable Benefits using Asset Criticality Ranking EAM Strategy Benefits Eliminate wasted maintenance labor hours on tasks of low relative importance Prevent critical tasks being lost in the maintenance backlog Improve level of satisfaction with the operations team Improve the confidence in the organization with the effectiveness of the maintenance delivery functions Work orders are now executed based on the asset s effect on the overall operation Provide a prioritized list of assets for capital replacement and redesign

Hot Surface Point (F) Functional Failure occurs Time P F Interval 1919 Achievable Benefits using Asset Criticality Ranking EAM Strategy Benefits Eliminate wasted maintenance labor hours on tasks of

Increase Equipment Uptime Through Robust Enterprise Asset Management. For the Upstream, Midstream & Downstream Sectors of the Oil & Gas Industry

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