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Downtime Reduction Ideas for a Symposium Presentation and Training

This presentation focuses on real examples and strategies for reducing downtime in industrial plants. It covers maintainability issues, improvement opportunities, specific repair case studies, and statistical approaches for analyzing repair times.

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Downtime Reduction Ideas for a Symposium Presentation and Training

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  1. Downtime ReductionIdeas for a Symposium Presentation and Training

  2. Message Hi Readers I am putting together slides for a Conference presentation and also for training on Downtime reduction, I am currently working in Angola. Here are some example slides but I am looking for real examples. These are only sample slides and is not intended to be a complete presentation

  3. Seeking • Any photos of bad maintainability issues, labelling, access, design, lifting • Any photos showing improvements • Any examples where a specific repair took far longer than they should and what were the causes and any good corrective actions • Any examples of a Maintainability Study of a specific repair (see RCA approach) • A list of repair times or downtimes and the causes (see Statistical approach)

  4. Definitions • Maintainability Review – a formal review of a plant or system or equipment may be as part of a new project or of an existing project. Review may identify candidates for a Maintainability Study • Maintainability Study (RCA approach) – a formal review of a maintenance job with a view to reduce the total time required, best when done as a team • Maintainability Study (Statistical approach) Uses a combination of statistics and RCA approaches

  5. Maintainability Study (e.g. Team based approach)

  6. Job Elements Locate Fault Handover & Access Test & Hand-over Repair Dismantle Assemble

  7. Maintainability Study (RCA Approach) • Specify a target for the repair • Start a sequence of event chart with what you know Normal Operation Downtime 12hours Equipment Failure Activity Activity 1 Determine Job Activities

  8. Maintainability Study (RCA Approach) • Complete all the job steps by gathering info, interviewing people (waiting time can be put as a job step) • Estimate the time required for each job step

  9. Sequence of Event Chart • Gather facts about each step (don’t look for corrective actions at this stage – collect all data first) • Remember we want a no blame culture • Identify factors that prevented the job step been done quicker

  10. Sequence of Event Chart • List causal factors • Brainstorm for good corrective actions • etc

  11. Maintainability Study (Statistical Approach)

  12. Comments • This is just one example of a statistical approach

  13. Improving Availability • Assume Plant Manager wants 3% extra Availability • Increase MTBF • Reduce MTTR • Improve both • Lets assume we feel Downtime provides the easiest path to improve Availability • Knowing the MTBF and the Plant Manager’s target availability, we can calculate a new target MTTR using Avail = mtbf / (mtbf + mttr)

  14. Maintainability Study (Statistical Data Set) • Assume availability needs to be increased and MTTR is considered to offer the best opportunity • Determine current MTTR (actual) • Determine new MTTR (the target) • Plot the new line on the probability plot • Read of the target for each past repair • Read of the target for the new repair time • Conduct Maintainability Study

  15. Past Performance Mean & Median Repair Time

  16. Past Performance and Target Performance • Target line set to achieve a greater reduction for larger repair times and smaller reduction for shorter repair times • Job A took 356hrs now, target now 215 hrs • Job B took etc etc • For simplicity not all repair times shown

  17. Statistical Analysis – More Detailed Analysis Required Some times more work is required Here Probability plot indicates multiple populations, i.e. 3

  18. RAM Study with Improved Downtime/Repair Times We can see effect on throughput, costs, availability from downtime improvements

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