Reliability Asset Management

10/14/2016

Reliability Asset Management

Maintenance Efficiency: Impact on the Big Picture Operational Efficiency Expense Throughput Inventory

Equipment Reliability

LEAN Principles

Uptime

Overall Equipment Effectiveness OEE

MTBF MTTR

Maintenance Efficiency Productivity

Support Systems

LEAN Principles

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Reliability Financial Report

Digging into the Benchmark MAINT $

STORES $

(%RAV)

(% RAV)

Top 1st

1.2 %

Middle 1st

QUARTILE

% VIB

% IR MECH

% IR ELEC

% OIL ANAL

% OTHER NDT

% ON PM

% ON BOM

0.3 %

85.7 %

73.6 %

100.0 %

42.9 %

42.2 %

25.0 %

66.0 %

2.7 %

0.9 %

75.6 %

62.8 %

91.9 %

38.6 %

35.5 %

26.0 %

63.0 %

Top 2nd

3.7 %

1.3 %

64.9 %

54.3 %

87.4 %

32.6 %

30.9 %

27.0 %

58.0 %

Middle 2nd

5.1 %

2.0 %

52.7 %

44.3 %

81.9 %

26.7 %

25.3 %

30.0 %

55.0 %

Top 3rd

6.5 %

3.0 %

44.7 %

36.9 %

76.4 %

22.3 %

20.5 %

31.0 %

49.0 %

Middle 3rd

8.1 %

4.6 %

30.0 %

25.4 %

69.1 %

17.6 %

15.6 %

34.0 %

45.0 %

Top 4th

9.9 %

6.0 %

22.1 %

16.7 %

63.1 %

12.9 %

11.7 %

36.0 %

40.0 %

Middle 4th

13.2 %

8.1 %

10.3 %

4.0 %

57.0 %

6.8 %

7.5 %

38.0 %

36.0 %

Bottom 4th

17.3 %

12.3 %

3.3 %

0.0 %

47.6 %

1.6 %

3.6 %

40.0 %

30.0 %

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C MMS

KPI A S SET ST RATEGY & P R OCEDURES

BOM

ISO 14224 ACR RCM

Taxonomy

Data Integrity

FM EA P M O

KPI

A S SET MASTER D A TA

TRAINING

A S SET C R ITICALITY

RELIA BILITY JOURNEY KPI

S T ART

!

C ON D ITION M ON IT ORING

OD R NDT

S c heduling P l anning

PM

U l t rasound

L u b rication

I n f rared Oi l A n alysis

M o t or t e sting

PM

V i bration W ORK E X E CUTION

A l ignment & B a lancing

A n alysis P recision M a intenance

F o llow up

REACTIVE

W o rk Identification

KPI M R O Optimization S T OR E P rocess P a rameters

W OR K M A NAGEMENT

M R O & SU PPLY C HAIN M A N AGEMENT

C o n dition I n dicators

A S SET H E ALT H

KPI CMMS

Parts Catalog

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E x ecutive S p onsorship

H u m an M a n agement C a p ital

Op e rational E x cellence V i sion

I S O 55000

WELCOME TO

APM TOWN

I n c id ents SST

A v a i lab ility

M a i n tena nce C o s ts

P r o fit $

KPI

BAD ACTOR

D E F ECT E L IMINATION

RCA W E I BULL

MT BF

C ON TINUOUS I M PR OVEMENT M E ASUREMENT & C ONTROL

Core vs Support • Is the Reliability Organization a core or support function?

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How your company views failure and where would you like it to be? Schools of Thought Normal Accident Theory

- Accidents in complex and tightly coupled systems are inevitable (Perrow 1981) with the risk of an accident increasing as complexity increases or coupling becomes tighter. - There is a trade-off between safety and other operational outcomes such as quality or productivity.

Institution Theory - For legitimacy, compliance as signal of commitment, e.g. certification - Increase sales and reputation but would not alter production processes or the production system’s reliability

High Reliability Theory - Accidents are preventable. Organizations are described as “mindful”. - HRT suggests that high reliability benefits all operational performance outcomes, not just safety – can prevent accidents and failures, quality defects, late deliveries, etc.

High Reliability Organization (HRO) • Main principle: “mindfulness”

• Understanding of unexpected events and emerging threats and respond to them as soon as they appear • Capable of tracking even the smallest of failures and ultimately learn from them for future application

• Characteristics of HRO 1. 2. 3.

4. 5.

Preoccupation with failure – reporting of errors, learn from near-misses, articulate mistakes to be avoided Reluctance to simplify Sensitivity to operations – interaction with frontlines, promote situational awareness Commitment to resilience – capabilities in place to detect, contain and bounce back to original state or better in times of error Deference to expertise – encourage expertise (group) vs groups (singular)

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Reliability Management • Best view in the context of Asset Management • ISO 55000:2014 defines: • Asset Management as: “the coordinated activity of an organization to realise value from assets” ; and • An asset as an “item, thing or entity that has potential or actual value to an organization”

• If integrated with the Operational Management System, safety and operational efficiency are optimized.

Asset Management

The first ISO standard for Asset Management

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Asset Management Process

Asset Health Indices can also be referred to as: • Equipment Health Rating(HER) • Asset Condition Assessment (ACA) • Asset Condition Index (ACI)

Essentially, an Asset Health Index can be defined as: • A way of measuring the overall health of a asset • A list of data parameters for an asset that feed into a calculated health rating • A way of comparing different asserts and asset classes in a consistent manner • An output of Big Data and asset analytics • An input, or building block, to a broader asset management process

Reliability Frameworks

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Reliability Framework • What Reliability Management framework is suitable for your operation?

Institute of Asset Management

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Novelis Reliability Pyramid

Consisted of 14 Reliability Elements

Chevron’s Surface Equipment Reliability Improvement Process (SERIP)

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Shell’s Operation Excellence

Marshall Institute’s 8-Phase Reliability Improvement Model

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Reliasoft’s Asset Performance Management

RasGas Integrated Asset Management Model

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Integrity = Reliability • The Integrity of the System • The Integrity of the structure • The Integrity of the brand • The Integrity of the data • The Integrity of the person

• The Reliability of the system • The Reliability of the structure • The Reliability of the brand • The Reliability of the data • The Reliability of the person

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A Journey to Shape Reliability Excellence at Bristol Myers-Squibb

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CRE Capabilities    



    

Facilitation of Uptime Elements as basis for Asset Management Plan Asset Health Index PM Optimization and Work Management Reliability Engineering Training with International Certifications o SMRP Certified Maintenance & Reliability Professional (CMRP) o AMP Certified Reliability Leader (CRL) o ASQ Certified Reliability Engineer (CRE) Condition Based Maintenance Training with International Certification o VI USA Vibration Analyst Cat. 1 & 2 o ICML Machinery Lubrication Technician I & Machinery Lubricant Analyst II o Infrared Institute Certified Thermographer Level 1 & 2 o UE Systems Airborne Ultrasound Level 1 Engineering and Reliability Management Training Maintenance & Reliability Basic Skills Training Customized In-House Training Consultancy Services Technical Books

Thank you! Erwin Bernal, MLT I, MLA II Sales Operations Manager CRE Philippines 2f 718 Bldg. Shaw Blvd. Mandaluyong City Philippines 1552 Tel: +63 2 718 3480 loc. 402 Mobile: +63 917 500 8306 Email: [email protected] www.crephils.com

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