Workshop A Quality Costs Support Maintenance
Preventive, Predictive and Proactive MaintenanceSteven Cooke,
MChE, FAICSenior Quality Management EngineerADGAS
24 November 25 November 2013Abu Dhabi, United Arab Emirates
Plant Maintenance and HSE Middle East 6th Annual MeetingMoving From
Preventive To Predictive Maintenance To Enhance Efficiency
Maintenance Activities are the only controllable factor in risk
reduction for the facility and thus the personnel.
The Cost of Maintenance activities can be compared to an
amortized cost of risk to demonstrate the cost/ benefit of
predictive maintenance activities with respect to risk
reduction.
Preventive To Predictive MaintenanceLate 1960sLate
1970s2000sMaintenance
StrategyBreakdownPreventiveReliability-BasedMaintenance
EnvironmentScheduled OverhaulStandby capacityMaximum Capacity
DemandSkill RequiredSkilled CraftsmenTrained Technicians,
Time-based activityPredictive TechnologiesFailure ManagementOperate
to Failure,Frequent RebuildsScheduled OverhaulsRegardless of Actual
Need, Large CrewsRoot Cause Analysis of failureIdentification Using
Condition Monitoring ToolsReliabilityHighly Over-designed. Wearout
Types FailuresDual Standby UnitsHigh Spare InventoryCondition
Monitoring facilitating a Predictive/proactive ApproachDesign
ConceptOver-DesignedHighly RobustSlow developmentUnsophisticated
ControlBuilt In ObsolescenceStandby capabilityDesign for maximum
availability while operating at capacity. Higher Precision, Less
robust components, operating in much more demanding Applications.
Highly Sophisticated Control SystemsEnvironment
ConcernsNoneEmergingAn increasingly Important Aspect of Concerns.
Zero Emission targets, Hazards, Extended Oil LifeMaintenance
Management System EvolutionPreventive To Predictive
Maintenance3Reliability Strategy DevelopmentPreventive To
Predictive Maintenance
Preventive To Predictive Maintenance Whats wrong with Preventive
Maintenance?It is the role of Maintenance to maximize equipment
availability and reliability. The business metrics of maintenance
are man-hours and costs.
The basic functions are corrective and preventive actions.
Corrective actions may be planned or reactive. Preventive actions
are always planned.Preventive To Predictive MaintenancePreventive
maintenance improves the safety factor for critical equipment, but
may be more expensive than reactive maintenance from the
maintenance departments perspective alone.Reactive maintenance is
known to be more expensive for a plant overall, and much more
dangerous in hazardous industries. Unplanned Downtime is the result
of system failures.
Whats wrong with Preventive Maintenance?Preventive To Predictive
Maintenance
Whats wrong with Preventive Maintenance?Preventive To Predictive
MaintenancePredictive maintenance offers an optimization mechanism
to allocate funds and activities according to risk.
This is a more complex process requiring better equipment
condition information and computational abilities. Whats wrong with
Preventive Maintenance?Preventive To Predictive Maintenance Whats
wrong with Preventive Maintenance?
Review the overall Risk Matrix - it is the CONSEQUENCES that are
most important!
Consequence x Probability = Risk LevelProbability is a direct
result of the Maintenance activities.
Preventive To Predictive Maintenance
Will this function without THESE parts?A critical piece of
equipment requires reliability and availability of all critical
components in order to continue to be reliable.Preventive To
Predictive Maintenance
Preventive To Predictive Maintenance
Preventive To Predictive MaintenanceIntervene at the best time,
not just at any time!
Preventive To Predictive MaintenanceMaintenance actions can be
seen as the difference between the protected and unprotected
incident probabilities times the event consequence cost.
Preventive To Predictive MaintenanceThe impact of predictive and
preventive maintenance can also be shown against the realized cost
of reactive repair that includes the opportunity losses of
production interruption as well as the direct repair costs.The
calculation of Safety Integrity Levels (SIL) in calculating the
reduction in risk due to actions can be used to show the cost
savings due to maintenance.
Bow-Tie DiagramPRIMARY Maintenance FocusPreventive To Predictive
Maintenance
Preventive To Predictive Maintenance
Planned UnplannedPreventive To Predictive Maintenance Benefits
of Predictive Risk-Based MaintenanceThere are useful parallels to
training programs for predictive maintenance: both require current
expenditures to avoid future errors or faults.
A survey in 2007 by the Aberdeen Group highlighted some key
management factors for a successful program, including the key cost
factors, which in our context may be considered the Cost of Risk
Reduction through maintenance.Preventive To Predictive
MaintenanceCommitment and involvement are required from plant,
production and maintenance management. there are no overnight
results. they must contribute to the success of the program
Plant Manager: Money spent on the training program (possible
overtime, labor cost, development & instructor costs, material
cost).
Production Manager: Longer down time to repair machines properly
(MTTR).
Maintenance Manager: Trying to juggle breakdowns, scheduling
work and training with personnel. Preventive To Predictive
Maintenance Benefits of Predictive Risk-Based MaintenanceLong-term
rewards of the program:
Plant Manager: Decreased downtime, reduced operating and
maintenance costs, increased employee morale, better safety
performance.
Production Manager: Increased production uptime and equipment
efficiency.
Maintenance Manager: Reduced breakdowns, more scheduled and less
reactive maintenance, less panic, less stress, better employee
morale, better safety performance.Preventive To Predictive
Maintenance Benefits of Predictive Risk-Based Maintenance
Unplanned Breakdown Maintenance (BK)Planned Corrective
Maintenance (CM) Preventive Maintenance (PM):Calendar Time
BasedRunning Hours Based
Predictive Maintenance (PdM) Condition MonitoringCondition Based
Maintenance
Preventive To Predictive MaintenanceFormulate the Correct Mix
Benefits of Predictive Risk-Based MaintenanceTo Build Optimal
Sustainable ProductionMMS10. Set KPI11. Audit6. Identify Tasks
& Recourses5. Review and Update Equipments Job Plans4. Select
Maintenance Type Based on equipment Criticality Assessment3.
Carry-out FMEA2. Review Equipment History8. Failures after
implementing RCM7. Amend in CMMS1. Equipment Criticality9. - What
are the failure modes?RCMFMEA CYCLEPreventive To Predictive
MaintenanceMoving to Proactive MaintenanceReliability is the
responsibility of all employees, not just maintenance.
Unreliability or failure, and thus downtime and potential
Process Safety Incidents, are the consequence of poor processes,
not events.
Therefore, considerable effort must be devoted to eliminating
defects that cause failure - this is basically Reliability-Centered
Maintenance. Preventive To Predictive MaintenanceMeasurements, or
KPIs (Key performance indicators), are used to convey strategic
direction. They allow organizations to select and evaluate tactics
needed for direction and monitoring of operational performance.The
Avantis Solution to Asset Performance and Reliability - Reliability
Centered Maintenance Enablements of Avantis, 2006 Invensys Systems,
Inc
Preventive To Predictive Maintenance
Moving to Proactive Maintenance25Benchmarks provide a specific
comparison of relevant KPIs against known standards of performance
or complementary processes or companies considered as good examples
of achievement.
15Preventive To Predictive MaintenanceMoving to Proactive
MaintenanceA survey done by the Aberdeen Group in 2007 provided a
great deal of support to the importance of integrated, proactive
maintenance activities in Best-in-Class manufacturers.Best-in-Class
manufacturers see significant reduction in year-over-year
maintenance costs (more than twice as likely as Industry Average
and Laggards to see >10% reduction) while enjoying improved OEE,
OTD, and throughput.5Preventive To Predictive MaintenanceMoving to
Proactive MaintenancePreventive To Predictive Maintenance
Moving to Proactive MaintenancePreventive To Predictive
MaintenanceCollaborative Asset Maintenance Strategies, Source:
Aberdeen Group, December 2006Maintenance Strategies Employed% of
RespondentsPreventive Maintenance88%Predictive
Maintenance58%Reliability Centered Maintenance28%Table 1:
Preventive Maintenance (PM) Most Commonly Used Strategy
Preventive Maintenance (PM) Most Commonly Used Strategy
Best-in-Class Use Proactive Maintenance Strategies More
FrequentlyMoving to Proactive MaintenancePreventive To Predictive
MaintenanceCollaborative Asset Maintenance Strategies, Source:
Aberdeen Group, December 2006Maintenance ProcessAverage
PerformanceStandardized, enterprise-wide proactivemaintenance
processes such as predictivemaintenance, reliability
centeredmaintenance, total productive maintenance,and root cause
analysisAsset uptime and availability = 88.8%Asset productivity (as
a % of capacity) = 84.2%Service & maintenance cost (as a % of
revenue) = 17.2%None or ad hoc and limited use of
proactivemaintenance processes. Routinepreventive maintenance the
most widelyaccepted approach to service assets andequipmentAsset
uptime and availability = 87.2%Asset productivity (as a % of
capacity) = 81.9%Service & maintenance cost (as a % of revenue)
= 20.8%Reactive break/fix work is the primaryapproach with little
to no preventive orother proactive maintenanceAsset uptime and
availability = 81.8%Asset productivity (as a % of capacity) =
79.2%Service & maintenance cost (as a % of revenue) =
23.5%Table 7: Proactive Maintenance Processes Boost Performance
MetricsProactive Maintenance Processes Boost Performance
MetricsMoving to Proactive MaintenancePreventive To Predictive
MaintenanceCollaborative Asset Maintenance Strategies, Source:
Aberdeen Group, December 2006Table 7: Proactive Maintenance
Processes Boost Performance MetricsBest-in-Class Reap Significant
BenefitsKey Performance Indicator (Change over past two
years)Performance (% of respondents in class reporting
improvement)LaggardAverageBest-in-classIncreases in Asset
Reliability18%62%91%Greater Asset Uptime and
Availability27%67%91%Reduction in Cost of Servicing
Assets3%21%39%Fewer Unexpected Downtimes or Outages12%48%77%Growth
in Return on Invested Capital7%21%66%Greater Asset
Productivity39%54%79%Higher Yields of Quality Goods
Produced19%36%62%Reduction in Cost of Spare Parts (MRO
Inventory)3%13%14%Longer Usable Asset Life11%29%58%Fewer Safety
Related Incidents29%54%77%Return on Assets (ROA)3%22%50%Moving to
Proactive MaintenanceStrategic actions implemented by the
Best-in-Class tend to be focused on optimizing asset availability
and utilization. Implementing advanced APM and analytical
capabilities was the top strategic action of the Best-in-Class
(46%), followed by implementation of continuous improvement
initiatives and continuous improvement teams. (Note: APM includes
Reliability Centered Maintenance (RCM), Condition Based Monitoring
(CBM), APM, and optimization capabilities.)Preventive To Predictive
MaintenanceCollaborative Asset Maintenance Strategies, Source:
Aberdeen Group, December 2006Moving to Proactive MaintenanceThis is
followed by improving effectiveness of maintenance operations,
which is intrinsically tied to continuous improvement programs.
Specifically, the Best-in-Class are 77% more likely than the
Industry Average and 84% more likely than Laggards to invest in APM
capabilities such as CBM, RCM, performance monitoring, and
Statistical Process Control (SPC) tools.Preventive To Predictive
MaintenanceCollaborative Asset Maintenance Strategies, Source:
Aberdeen Group, December 2006Moving to Proactive Maintenance
Preventive To Predictive MaintenanceMoving to Proactive
MaintenancePreventive maintenance covers the range of periodic
tasks (from inspections and adjustments to component replacement)
that are performed on assets on an elapsed time, or preferably, a
usage basis in order to keep assets functioning.
Preventive To Predictive MaintenanceMoving to Proactive
MaintenancePredictive maintenance goes a step further by using
non-destructive testing methods and condition monitoring to uncover
hidden or pending failures in their primary mode.
Preventive To Predictive MaintenanceMoving to Proactive
MaintenanceWith the fundamental elements in place, the organization
is empowered to truly influence asset performance and reliability.
The proactive level includes:
Condition monitoring involves tapping directly into control data
sources for statistics to manage preventive maintenance and enable
instant reaction to failures when they occur, or preferably, before
they occur.
Preventive To Predictive MaintenanceMoving to Proactive
MaintenanceReliability-centered MaintenanceRCM is defined as A
process used to determine what must be done to ensure that any
physical asset continues to do what its users want it to do in its
present operating context. 2Failure modes and effects analysis
(FMEA) is a structured analysis based on experience and what
if.Decision algorithm determines the maintenance action plan and
its execution.3. Age exploration - The continuous analysis,
revision and upgrade process2 Reliability-centered Maintenance by
F. Stanley Nolan and Howard F. Heap, 1978
Preventive To Predictive MaintenanceMoving to Proactive
Maintenance39Demonstrate safety achievements through Maintenance
Performance.Fewer breakdown or trip events = Reduced risk due to
hazardous conditions.
Fewer reactive jobs = Less personal exposure to dangerous
activities.
Preventive To Predictive Maintenance3940Fewer/ smaller leaks =
Less personal exposure risk and greatly reduced fire risk.
Planned work = More alert, less stressed workforce.
Make Safety a key driver for performance.Preventive To
Predictive Maintenance4041We will not have a safe plant unless it
is a well-maintained plantConclusion
Preventive To Predictive Maintenance41The importance of
Maintenance is not about keeping a plant running well.
It is that keeping it running well means that it is running
safely.
It is improving the employees workplace safety through
preventive and predictive maintenance of safety-critical
equipment.Preventive To Predictive MaintenanceDo the Right Thing at
the Right Time in the Right Way with the Right People.Preventive To
Predictive MaintenanceADGAS Asset Integrity and Reliability
Management System can be summed up with a simple sequence:Steven J.
Cooke, MChE, CQE, CQASenior Quality Management Engineer
Thank you!
Questions?
Email: [email protected]
WINNER of theGOLD AWARD - 2012
Plan on 25-min. presentation and 5-10 minutes questions.44