Allied Reliability Phase II EMP Development Overview (March 2009)
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Equipment Maintenance Plan Development (The Allied Way)
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Allied Reliability Phase II EMP Development Overview (March 2009)
- 1. Asset Reliability Overview Allied Reliability Phased Approach to a Successful Reliability Initiative Presented by: What would you do Chris Colson with more free time? Copyright 2007 Allied Reliability, Inc.
- 2. Asset Reliability Overview Agenda • Who is Allied • Overview of Approach • Overview of Tools • Questions / Answers Copyright 2007 Allied Reliability, Inc.
- 3. Asset Reliability Overview Allied’s Reliability Success Formula Copyright 2007 Allied Reliability, Inc.
- 4. Asset Reliability Overview Impact of a Complete Reliability Initiative High +75% +27% • Significantly Improved • Improved Bottom Bottom Line Line Performance Business Process and Performance Culture Maturity • Lack of System • Practices and Systems Support Aligned Baseline -7% • Systems are not •Informal Complemented by Effective • Manual Planning Business Processes Processes • Significant Inefficiencies • Below Average Business Performance Low High Low Technology Maturity Source: Brynjolfsson (MIT), Wireman, Troyer, Allied Copyright 2007 Allied Reliability, Inc.
- 5. Asset Reliability Overview Copyright 2007 Allied Reliability, Inc.
- 6. Asset Reliability Overview Focused Improvement the Allied Reliability Transformational Analytics – “5-R” Improvement Process Way… Rationalize Ratify Recognize Develop Create and Identify Known PR Simulation Conduct Prioritized (Baseline) Educate Process Problem or Internal and and/or Reliability FMEA Blitz Improvement PR Plots Improvement Value Stream External Non Modeling Plan Team (PIT) Mapping Value-Add (VSM) And Wastes Eliminate ALL Manufacturing Wastes… Overproduction Transporting FMECA RCA Quality Inventory (All Defects) Motion RCM Sustain the Gains… Processing Waiting Train To New Audit/Monitor Document Process Continually New Process Resolve Realize Copyright 2007 Allied Reliability, Inc.
- 7. Asset Reliability Overview Allied Reliability – Overall AHA Workstream Asset Registry Module Asset Analysis Module Asset Integration Module Installed Asset Component Criticality Verification Analysis Technology Sourcing Strategy Asset RCM Equipment Definition Analysis Maintenance Phase Plans (EMP’s) (top 5-20%) 3 Technology Failure Asset Standards Mode Hierarchy OP1 & OP2 Analysis Copyright 2007 Allied Reliability, Inc.
- 8. Asset Reliability Overview Asset Registry Module Goals: Benefits: Asset Registry Module •Defines criteria for Asset selection •Increased planning efficiency due to •Identifies desired attributes by Asset type hierarchy structure •Uncovers Asset types requiring •Increased scheduling efficiency due Installed Failure Mode Analysis (FMA's) to hierarchy structure Component •Verify/identify installed Components •Hierarchy provides added granularity Verification •Creation of logical system to when criticality performed Asset structure •Components tracking through tagging and functional location •Improved cost tracking through Deliverables: Asset hierarchy structure •Accurate Asset count Definition •Increased MRO efficiency through •Complete hierarchy for Assets accurate Asset list •Component change control through tracking •Improved CMMS through addition •Multiple level cost tracking of hierarchy structure •Attribute data for Asset Asset repairs/replacement Hierarchy •Logical functional location •Hierarchy template for CMMS upload •Targeted seminars supporting reliability program •Site support for installed processes Copyright 2007 Allied Reliability, Inc.
- 9. Asset Reliability Overview Allied Reliability Phase 2 – Workflow Asset Analysis Module Goals: Benefits: Asset Analysis Module •Rank Assets using multiple criteria •Additional scheduling efficiency through •Refines planning and scheduling use of Asset ranking •Refine Maintenance, Repair and Operational •Input to critical spares through Asset Assets (MRO) Asset criticality Criticality •Categorize failure modes •Further CMMS improvement by Analysis addition of attribute & criticality •Improved MRO function through Deliverables: use of CMMS data •Ranked Asset list •Ability to prioritize failures and create •Defined failure modes for Asset types RCM “bad actors” list •Attribute template for CMMS upload Analysis •Targeted seminars supporting reliability (top 5-20%) program •Site support for installed processes Failure Mode Analysis Copyright 2007 Allied Reliability, Inc.
- 10. Asset Reliability Overview Allied Reliability Phase 2 – Workflow Asset Integration Module Goals: Benefits: Asset Integration Module •Apply failure modes to Assets •Engineered equipment •Select Asset coverage model maintenance plans (EMP’s) •Facilitate condition monitoring •Further planning efficiency gains sourcing strategy through EMP’s •Identify PdM/PM gaps •Additional CMMS gains through Technology •Create condition monitoring creation of PdM & PM tasks Sourcing operational procedures •Consistent measures and Strategy reporting across technologies Equipment •Identify PM’s required to address Deliverables: Asset failure modes Maintenance •Equipment Maintenance Plan for in Plans scope Assets Phase (EMP’s) •Coaching/Mentoring template 3 development for PM’s that address Technology targeted failure modes Standards •Documented and maintainable OP1 & OP2 equipment maintenance plan •Condition monitoring (CM) operational standards •Recommended condition monitoring sourcing strategy •Targeted seminars supporting reliability program •Site support for installed processes Copyright 2007 Allied Reliability, Inc.
- 11. Asset Reliability Overview Processes and Tools • Based on the collection of Best Practices • Built by “Users” • Integration Theme • Enforces Discipline to Standards • Drives Transparency Copyright 2007 Allied Reliability, Inc.
- 12. Asset Reliability Overview Walkdown Tool Copyright 2007 Allied Reliability, Inc.
- 13. Asset Reliability Overview Walkdown Tool – Component Mapping Copyright 2007 Allied Reliability, Inc.
- 14. Asset Reliability Overview Walkdown Tool-Attribute Entry Copyright 2007 Allied Reliability, Inc.
- 15. Asset Reliability Overview Criticality Tool Copyright 2007 Allied Reliability, Inc.
- 16. Asset Reliability Overview Criticality Tool- Category Management Copyright 2007 Allied Reliability, Inc.
- 17. Asset Reliability Overview Criticality Tool-Ranking Copyright 2007 Allied Reliability, Inc.
- 18. Asset Reliability Overview Asset Health Matrix (AHM) Tool Copyright 2007 Allied Reliability, Inc.
- 19. Asset Reliability Overview AHM-Component Management Copyright 2007 Allied Reliability, Inc.
- 20. Asset Reliability Overview AHM-Failure Mode Management Copyright 2007 Allied Reliability, Inc.
- 21. Asset Reliability Overview AHM- CBM Technology Coverage Copyright 2007 Allied Reliability, Inc.
- 22. Asset Reliability Overview AHM-Coverage Model Copyright 2007 Allied Reliability, Inc.
- 23. Asset Reliability Overview RCM Blitz Tool Copyright 2007 Allied Reliability, Inc.
- 24. Asset Reliability Overview RCM Blitz Copyright 2007 Allied Reliability, Inc.
- 25. Asset Reliability Overview RCM Blitz - FMECA Copyright 2007 Allied Reliability, Inc.
- 26. Asset Reliability Overview PM Evaluation Tool Copyright 2007 Allied Reliability, Inc.
- 27. Asset Reliability Overview PME Tool •A PM classification sort is applied. •A PM recommendation sort is applied. •Comments are added to clarify recommendations and classifications. Copyright 2007 Allied Reliability, Inc.
- 28. Asset Reliability Overview PME Tool – Sample Summary Output PME Classification Total Number % Administration & Safety 4342 64.39% Asset Care 491 7.28% Inspection 1405 20.84% Quantitative PM 464 6.88% Regulatory 3 0.04% Time Based Replacement 38 0.56% PME Recommendation (Without Safety tasks) Total Number % No Changes 653 27.20% No Value Added (Delete) 313 13.04% Re-Engineer 883 36.78% Replace with PdM or NDT 552 22.99% Copyright 2007 Allied Reliability, Inc.
- 29. Asset Reliability Overview Developing Effective Work Procedures Tool Copyright 2007 Allied Reliability, Inc.
- 30. Asset Reliability Overview What is required in a procedure? Copyright 2007 Allied Reliability, Inc.
- 31. Asset Reliability Overview Driving consistency in procedures Copyright 2007 Allied Reliability, Inc.
- 32. Asset Reliability Overview DEWP Tool Copyright 2007 Allied Reliability, Inc.
- 33. Asset Reliability Overview Questions? Copyright 2007 Allied Reliability, Inc.