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Leveraging CMMS Work History To Improve Reliability

Leveraging CMMS Work History To Improve Reliability. Using The Past To Improve Our Future. Presented by Jim Oldach – Genesis Solutions. A Wise Person Once Said…. Actually it was a wise fortune cookie factory worker that wrote….. “A risk foreseen is half avoided”.

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Leveraging CMMS Work History To Improve Reliability

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  1. Leveraging CMMS Work History To Improve Reliability Using The Past To Improve Our Future Presented by Jim Oldach – Genesis Solutions

  2. A Wise Person Once Said…. Actually it was a wise fortune cookie factory worker that wrote….. “A risk foreseen is half avoided”

  3. What’s our job as Maintenance and Reliability Professionals? • Reduce overall asset operational risk using the resources provided to us. • Therefore, a proper measurement of our job performance would be Total Risk Reduced / Total Resources Invested To improve…..we can either reduce more risk, or reduce resource investment…..or better yet, do both!!! Risk Investment

  4. Pareto Was Right! The majority of our risk (80%) lies within a very small population of our assets (20%?). Water Treatment 4.1% Oil Rig 2.4% Airport 6% What percentage of your asset population consumes 80% of your resources?

  5. Identifying Where Our Risk Is The issue • Risk = Consequence x Probability • 2 Basic Options For Identifying Risk • Proactively – What could happen Probabilistic Risk Analysis – to anticipate where risk is highest and to implement actions that will minimize, prevent or mitigate that risk. • Criticality Ranking • RCM Analysis • FMEA Analysis • PRA Analysis • etc.

  6. Identifying Where Our Risk Is • Risk = Consequence x Probability • 2 Basic Options For Identifying Risk • Reactively – What has happened Historical Data Analysis – to use historical information to understand where it’s been demonstrated that risk is highest, and to implement actions that will minimize, prevent or mitigate that risk.

  7. Focus Here: Historical Data Analysis • Assumptions: • Equipment records have the basic information required to analyze work history. • Work orders are being written against the right level of the equipment hierarchy. • Work order documentation is complete and accurate. • Opportunities: • Improve MEL Equipment Record and supporting information (i.e. Mfg, Model, BOM, Failure Codes, Critical Spares, etc.) • Minimize equipment failures / reactive maintenance • Optimize the predictive and preventive maintenance programs • Improve labor resourcing • Improve training • Improve spare parts management • Conduct asset level failure analysis • Measure performance across operating units

  8. Improving MEL Equipment Records Equipment records and supporting information (BOMs, Failure Codes, Critical Spares Lists) are needed in preparation for, or as a result of work being performed on an asset..so why not focus resources on improving those asset records that are worked on the most? The large majority of historical maintenance spend (80%) is against a very limited number of assets….. typically between 5% to 10% of the total asset population. Airport

  9. Minimize Failures / Reactive Maintenance Assets with a high level of PM that have a corresponding high level of reactive maintenance , should be reviewed for PM effectiveness. Note the absence or low level of proactive activities on some of the most reactive intensive assets. Airport

  10. Optimize PM/PdM Programs Assets that have a high percentage of PM inspection activities, should be reviewed for PM reduction thru identification of low value tasks or replacement with more effective and less costly PdM inspection tasks. Airport

  11. Optimize PM/PdM Programs PMO Analysis By Asset Type Wastewater Treatment Facility

  12. Improve Labor Resourcing Why ET1 use so low in summer and so high in winter? Is this an opportunity for resource load leveling? Wastewater Treatment Facility

  13. Improve Labor Resourcing Are there enough craft to support work demand? What’s ET backlog look like? Are ELEC craft performing too much PM? Are MECH craft performing too little PM? Airport

  14. Improve Labor Training Since craft is spending a high percentage of their time here, perhaps training should include OEM or other training on these asset types. Research and Development Facility

  15. Improve Spare Parts Management Use this knowledge to reduce material intensive failures as well as improving logistics for the most often used spare parts. Airport – 80% of material costs ($1.5M) were consumed by only 1.1 % of total assets (349 assets)

  16. Conduct Asset Level Failure Analysis Failure code analysis can focus actions down to the failure mode level on the most critical or maintenance intensive assets. Again, develop failure codes where they will be used. Pharmaceutical

  17. Measure Performance Across Units Note how this unit is looking good regarding its proactive approach to maintenance.

  18. Measure Performance Across Units Is there an opportunity to reduce Proactive Hours and still maintain low Reactive Hours?

  19. Questions?

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