Life Cycle Asset Management

Reliability Block Diagrams are a powerful reliability analysis tool. They are visual representation of reliability and risk that exists within machinery or work processes.

They allow the user to notate the reliability of each part or task and calculate the reliability for the whole scenario. The use of Reliability Block Diagrams extends to all aspects of operational processes and procedures, both as series and parallel arrangements.

Once a Reliability Block Diagram is created, you can do “what-if” scenarios to identify the defects that can happen to each part. This information allows you to then make informed decisions about to how to proactively eliminate the causes of each risk or defect, and by extension, eliminate that cause of failure.

From Plant Wellness Way Eam System-Of-Reliability

VITAL PLANT AND EQUIPMENT RELIABILITY TIPS FOR WORLD CLASS PRODUCTION RESULTS WITH A PWW EAM SYSTEM-OF-RELIABILITY

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With Plant Wellness Way EAM you will change to engineering, operating, and maintenance methods that guarantee world class reliability practices are done throughout your company and its operations

Imagine your business without breakdowns, fewer spare parts in a smaller parts Store and lower operating costs everyday. All the while you enjoy world class reliability success that delivers outstanding plant availability in all of your operating plants. To get to this world you will need to Change the Game to one where you guarantee fantastic reliability success! [Read more…]

The total cost of downtime extends across the business. In the worst cases, it impacts the entire organisation and customers.

From the moment of failure to the restart of production, no saleable product is made. Instead, money is spent on repairs, with continued fixed costs, and any potential profits that could have been made from saleable products is lost. The graph below illustrates what happens to production time and costs when operations stop due to equipment breakdown (t1). The time and costs required to repair the equipment to operational levels (t2) is unknown at the start of the breakdown.

During this time (t1 to t2) resources and money are needed to return the equipment to operation. Additional costs due to loss of production and therefore potential profit losses are also incurred in this time.

ISO 55000 and ISO 55001 are frameworks into which you must add the correct policies, procedures, knowledge, and actions that deliver world class physical asset management. They cannot of themselves cause asset management, maintenance and operational excellence. Users of ISO 55000 and ISO 55001 must turn the framework into a full set of the correct and proper processes and practices used business-wide and life-cycle-long in your company to cause it to operate at world class performance. 

What is missing in ISO 55001 you do with the Plant Wellness Way enterprise asset management methodology. There is but one rule to follow in the PWW EAM methodology to get the best asset management and operational excellence solution: Produce the least atomic stress state in component materials-of-construction all the time. Select strategies, procedures and practices that cause that result and you have the best asset management solution to feed into an ISO 55001 framework. Plant Wellness Way EAM perfectly complements ISO 55000 and ISO 55001 so that when used together you build a life cycle EAM system with the processes and practices that ensure outstanding equipment reliability and great enterprise asset management success.

The true cost of maintenance to a company includes the lost production time, cost of utilities not used, overhead costs, handover costs and more.

A 6-step procedure that guides you and your organization, department, and team to analyze your business and operational risks, and develop an enterprise asset management system that is purpose-built to deliver your organization world class reliability.

A Systems Reliability Model 

 Nuclear power stations, nuclear warships and air traffic control centers are renowned amongst industry world-wide for their high-reliability performance. Here is a reliability-based model of how they do it. Your organisation can too.

Keywords: control of human error, failure prevention, defect elimination, accuracy-controlled enterprise, error-proofing 

My brother-in-law, who worked for Japan Airlines (JAL) at the time, tells a story of watching Japanese aircraft maintenance technicians overhaul a JAL airplane jet engine. He tells this story because it is so unusual. During his visit to the maintenance hanger he was enthralled by the extraordinary maintenance procedure that the JAL technicians followed.

Guest post by David Mosaddar

 Data Mining Techniques to Increase Productivity in Maintenance Management Systems 

Let a Plant Wellness Way EAM System-of-Reliability End Your Business Risks Forever 

Today, the use of a Computerised Maintenance Management System (CMMS) and user-friendly software packages have made the job of the maintenance crew relatively easier. The entire maintenance system seems to be at your fingertips, with Key Performance Indicators (KPIs) in flashy dashboards on a computer screen. But is that the absolute best use of your maintenance information? 

Developing Maintenance KPIs, Reliability KPIs, And Enterprise Asset Management KPIs Of Value For Good Decision Making

When developing maintenance KPIs, or any performance measure, you will have no real ‘grass-roots’ support, nor lasting success, until people are involved in setting their own measures and key performance indicators.

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I’ve been tasked with developing maintenance KPIs and equipment reliability KPIs.

I would be thankful if you guide me to a proven list of maintenance and reliability KPI’s. We would like to measure performance on individual plant and corporate levels.

We have 120 plants for various products: metals, chemicals, petrochemicals, fertilizers.

We are not currently using unified measures, i.e. every plant is going in its own direction, and we now are looking to unify maintenance and reliability across the corporation by introducing a reliability solution to create a scientific maintenance strategy. Part of our strategy is to introduce specific KPIs which have to be achieved by all plants.

Accuracy Controlled Standard Operating Procedures Use The 3T’s – Target, Tolerance, Test – For Work Quality Assurance

Assure production and maintenance work quality with accuracy controlled standard operating procedures containing 3t precision work instructions where work is done right-first-time, every time

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An Accuracy Controlled Enterprise (ACE) is focused on getting things ‘right first time’. The quality focus in an ACE is about doing a job, every job, masterly, whether done on the shop floor or in the boardroom. That is achieved with accuracy controlled standard operating procedures in which every task is proven to be completed accurately before continuing to the next task. It is about being a master of what you do so you deliver world-class results in your work. You can read about being an ACE in the white paper The Accuracy Controlled Enterprise.

 The article was written to cause people to question traditional approaches to FRACAS. In time senior managers in companies will come to realise that FRACAS has little chance of successfully improving their company. They then can instead look for what does work to move their operations to world class production performance.

That drive a reliability growth and improvement.

A RELIABILITY IMPROVEMENT POLICY IS A DOCUMENT CONTAINING A SET OF PRINCIPLES TO GUIDE DECISION MAKING AND ACTIONS. IT TELLS HOW RELIABILITY WILL BE ACHIEVED IN AN OPERATION. IT COVERS THE WHOLE ASSET LIFE CYCLE AND SAYS WHAT WILL BE DONE AT EACH PHASE TO DELIVER RELIABILITY.

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Unfortunately, we have been operating in a crisis manner without a reliability improvement policy. Have you samples of a Reliability Improvement Policy that I can use as a basis of crafting one for my organization — do you have anything to share?

As I have stated in the past, the materials you post have been a big blessing to my work. You have definitely empowered me with great information that I see changing the way people work.

Hello Friend,

Industries using machines require them to run reliably (no failures or unplanned stoppages) with high availability (ready for immediate use) and high utilization (continuously in use) all their working life.

A RELIABILITY IMPROVEMENT POLICY IS A DOCUMENT CONTAINING A SET OF PRINCIPLES TO GUIDE DECISION MAKING AND ACTIONS. IT TELLS HOW RELIABILITY WILL BE ACHIEVED IN AN OPERATION. IT COVERS THE WHOLE ASSET LIFE CYCLE AND SAYS WHAT WILL BE DONE AT EACH PHASE TO DELIVER RELIABILITY.

Unfortunately, we have been operating in a crisis manner without a reliability improvement policy. Have you samples of a Reliability Improvement Policy that I can use as a basis of crafting one for my organization — do you have anything to share?

As I have stated in the past, the materials you post have been a big blessing to my work. You have definitely empowered me with great information that I see changing the way people work.

[Read more…]

 Improved reliability has a cause. Just like a failure has a cause, so too is there a cause for improved reliability. You can wait for a failure to happen and then learn from the experience and change your processes to prevent it. That is root cause failure analysis. But it is not proactive behaviour. Such an approach quickly buries you in firefighting. It helps you fix a few terrible failures, but not the tens of thousands of defects that are waiting to create the next lot of disasters. Permanent reliability growth requires proactive methodologies that identify all potential problems and stops them from starting. This is what is done in high reliability operations – they never allow defects to begin. 

The process maps of your business processes, the workflow diagrams of your operating procedures and the bills of materials for your equipment are the foundation documents for improving equipment reliability. They are used respectively to control the business processes, to control human error and to address limitations in materials of construction and parts’ health practices.

The Accuracy Controlled Enterprise: Using Accuracy-Controlled 3T SOPs for Production and Maintenance Quality Assurance

 Reliable equipment is necessary to reduce production costs and maximise production throughput. High reliability from operating equipment requires high quality reassembly, coupled with the correct operating practices. You can guarantee correct maintenance and proper plant operation by specifying a target and tolerance in maintenance and operating procedures. 

Having a target and tolerance sets the recognised acceptance criterion. A simple proof-test will confirm if it has been met. Specifying a mark and tolerance range changes the focus from one of simply doing the job; to now doing the job accurately. This results in high quality trades’ workmanship and sound equipment operator practices that deliver reliable equipment performance. Those organisations that use ‘target, tolerance, proof-test’ methodology in their procedural tasks move from being a quality-conscious operation to being an Accuracy-Controlled Enterprise (ACE). 

Plant Wellness Way Enterprise Asset Management is used by companies to successfully get world-class engineering asset management, maintenance, and reliability.

Welcome to the start of the training users get on how to build a Plant Wellness Way enterprise asset life cycle management system-of-reliability once their company begins using the PWWEAM methodology.

Throughout the course we interchange the name of the methodology commonly called ‘Enterprise Asset Management’ with engineering asset management, physical asset management, and asset life-cycle management. All these names mean the same thing. We also will switch between referring to Plant Wellness Way Enterprise Asset Management methodology to shorter versions, such as PWW EAM or PWW.

[Read more…]