Planning & Scheduling Improves Reliability

Transcription

1 Planning & Scheduling Improves Reliability Presented by Matt Midas Senior Account Executive Solufy Users Meeting Tampa, FL April 20,

2 Agenda 2 Introductions Planning & Scheduling Reliability Centered Maintenance Planning & Scheduling Improves Reliability Questions

3 ABS Group of Companies 3 ABS Group is a whollyowned subsidiary of the American Bureau of Shipping (ABS). Founded in 1862 to serve as the non-profit American Classification Society, ABS is the leading classification, certification and verification firm in the world for marine shipping, offshore and onshore industries. ABS Group strives to be the global leader in mitigating risk, improving safety enhancing quality and minimizing adverse environmental impact. Safety, Risk, Integrity and Performance Management Services Management Systems Certification Catastrophe Risk Modeling GenesisSolutions is one of the only fully-integrated EAM service providers from EAM strategy and business process improvement to reliability analysis and PM/PdM programs, to full implementation and support of all major EAM systems and technology. Safetec is a leading provider of integrated risk and asset management offering life-cycle optimization services, from concept evaluation to decommissioning. Protection of life, property and the environment

4 ABS Consulting Global Market Sectors 4 Our mission OIL & GAS GOVERNMENT MARITIME POWER RENEWABLE To help customers manage their industrial assets across the life cycle in order to maximize: Safety Reliability Efficiency PHARMA/BIOTECH MANUFACTURING

5 ABS Consulting Services 5 Sustained SAFETY Managed RISK Optimized INTEGRITY Achieved PERFORMANCE Supporting Both Occupational & Process Safety Needs Safety Management Systems HSE Support Services PSM Audits PSA, PHA Safety Culture Assessments Incident Investigation Root Cause Analysis Providing Total Risk Analysis Needs Natural Hazards Hurricane, Earthquake, Wind Damage Financial Impact Assessments Operating Hazards PRA, QRA, PHA Manmade Hazards Security Threat & Vulnerability Facility Siting Blast & Explosion Modeling Supporting Asset Integrity Needs Project Quality Management (PQM) Procurement Inspection Inspection Mgmt. Risk Based Inspection Mechanical Integrity Engineering Verification Vendor/Supply Chain Audits Maximizing Operational & Business Performance EAM Reliability & Maintenance Mgmt. Project Mgmt. & Technical Staffing Operational Excellence & Performance Mgmt. Training & Competency Assurance

6 GenesisSolutions 6 COMPANY Founded in 1999 Acquired by ABS 2013 Industrial Asset Management Services Sustained Growth Market Leader CUSTOMERS Pharmaceutical/Biotech Oil & Gas Power Utility Manufacturing Municipal Transportation Facilities SERVICES Fully Integrated Global EAM Services: Reliability Services Systems & Technology Maintenance Strategy & Process STATISTICS Headquarters: Ridgefield, CT Operations: US, Canada, Latin America, Europe, Asia Personnel: 150 Revenues: $30M USD (+) Customer Repeat Rate: 90% (+) Customers: 400 (+)

7 Maintenance and Asset Management Services 7 Reliability Services Equipment / Asset Walk Downs Reliability Engineering PM Optimization Predictive Maintenance Program Development & Implementation Spare Parts Program Planning & Scheduling Reliability Program Implementation Strategy & Business Process Services Maintenance Master Planning EAM Strategy Planning & Process Consulting KPI Development / Benchmarking Assessments MRO Supply Chain Optimization Maintenance Best Practices Work Flow Optimization Educational Services & Certifications Systems & Technology Services System Source Selections System Gap Analysis EAM / CMMS (Maximo, InFor, DataStream, SAP PM, JDE, Oracle) Implementations & Upgrades Calibration / Metrology Solutions Document Management & GIS Systems Hand-Held Technologies System Integration System Validation EAM / CMMS Support ASP Hosting Reliability Services Systems & Technology Strategy & Business Process Services

8 8 Planning & Scheduling

9 Asset Management Overview 9 Building Blocks Equipment History Oral & written Equip Failure Investigations MR Analysis Action Plans (by asset, equip or system) PMs Job Plans Task Lines Spare parts ID, Sourcing & Stocking Maintenance Plan. & Sched. Regular PMs Preventive, Predictive & CMs Minor Shutdowns Major Shutdowns Unplanned Shutdowns Scorecard Maintenance Execution Breakdowns Scheduled PMs Predictive Rebuilds Lube Analysis OEM Equip Evaluations RAGs, FEMAs & RCFA Spare Parts & Usage Maintenance Excellent Investigations Lubrication Plans & Routes Asset Strategy Repair, Rebuild, Replace Bad Actor Equip Failure Investigations Update Asset Plans PMs Spare Parts BOMs Lube Plans Asset Strategy PM, PDM Plans Run to fail? Repair, Rebuild, Replace Equipment History Performance Repairs Improvement Statistics by Qtr.

10 Maintenance Planning Principles 10 1 Separate Department for Planners 2 Focus on Future Work 3 Maintain Component Level Files 4 Estimates Based on Planners Expertise & Historical Data 5 Recognize the Skill of the Crafts 6 Measure Performance with Work Samplings Source: Maintenance Planning & Scheduling Handbook by: Doc Palmer

11 Maintenance Scheduling Principles 11 1 Plan for the Lowest Required Skill Level 2 Schedules and Job Priorities are Important 3 Schedule from Forecast of Highest Skills Available 4 Schedule for Every Work Hour Available 5 Crew Leader Handles Current Day s Work 6 Measure Performance with Schedule Compliance Source: Maintenance Planning & Scheduling Handbook by: Doc Palmer

12 KPI s for Planning & Scheduling 12 Planning & Scheduling Metrics Schedule Compliance Work order completion (timing) Jobs completed vs. jobs scheduled hours completed vs. hours scheduled Percent Planned Work work orders processed thru planning over total work Planned work vs. Unplanned corrective work By work type Percent Scheduled Work Work order labor hours scheduled vs. total labor hours available Backlog Work Orders with Hours Number of Work Orders Planning Efficiency (Estimation Accuracy) based on activity Labor Hours -Est. vs. Actual Downtime MTBF, MTTR Parts & Materials Maintenance Productivity Wrench Time

13 13 Reliability

14 Reliability Strategy 14

15 Seven Elements of EAM 15

16 What is Reliability? 16 the ability of a person or system to perform and maintain its functions in routine circumstances, as well as hostile or unexpected circumstances. - Wikipedia Capable of being relied on; dependable - American Heritage Dictionary The probability that a component part, equipment, or system will satisfactorily perform its intended function under given circumstances, such as environmental conditions, limitations as to operating time, and frequency and thoroughness of maintenance for a specified period of time. - Answer.com

17 What is Reliability? 17 Reliability r(t) d dt r( t) t 1 0 f ( τ ) dτ 1 r ( t) d dt r e ( t ) 1/ x [ λπgt] Density Function f(t) λ t 0 t e ( ) λ ( τ ) dτ λ(t) Failure Rate t f ( t) ( τ) 1 f dτ 0

18 What is Reliability? 18 Metrics and Analysis Work Order Hours Total Hours Worked Planned Work Order Hours Total Work Order Hours Work Order Hours by Work Type Total Hours Worked Work Order Hours by Asset Class Total Hours Worked PMs Completed PMs Scheduled Desired Asset Uptime Downtime Desired Asset Uptime = % of hours captured on Work Orders = % of Planned vs unplanned hours = % of Work Order Hours by Work Type = % of Work Order Hours by Asset class = PM Compliance = % of Asset Availability

19 Reliability Centered Maintenance 19 A Reliability Centered Maintenance Process answers the following seven questions: 1. What are the functions and associated desired standards of performance of the asset in its present operating context (functions)? 2. In what ways can it fail to fulfill its functions (functional failures)? 3. What causes each functional failure (failure modes)? 4. What happens when each failure occurs (failure effects)? 5. In what way does each failure matter (failure consequences)? 6. What should be done to predict or prevent each failure (proactive tasks and task intervals)? 7. What should be done if a suitable proactive task cannot be found (default actions)? Source: SAE JA1011 standard

20 20 Planning & Scheduling Improves Reliability

21 Reliability Centered Maintenance 21 A Reliability Centered Maintenance Process answers the following seven questions: 1. What are the functions and associated desired standards of performance of the asset in its present operating context (functions)? 2. In what ways can it fail to fulfill its functions (functional failures)? 3. What causes each functional failure (failure modes)? 4. What happens when each failure occurs (failure effects)? 5. In what way does each failure matter (failure consequences)? 6. What should be done to predict or prevent each failure (proactive tasks and task intervals)? 7. What should be done if a suitable proactive task cannot be found (default actions)? Source: SAE JA1011 standard

22 Reliability Centered Maintenance 22 Components of Reliability Centered Maintenance Program: 1. Complete Master Equipment/Asset List (Functions) 2. Asset Criticality Ranking (Effects, Consequences) 3. Complete List of Job Plans and Tasks; including labor, material, tools (Default Actions) 4. PM Optimization (Proactive Tasks and Task Intervals) Calendar Based PMs Condition Based PMs Event Based PMs Predictive PM Inspection PM 5. Complete list of Inventory Items, Bill of Materials for Assets 6. Planning and Scheduling Processes 7. Standardized Maintenance processes 8. Communities of Practice

23 Maintenance Maturity Continuum 23 Performance Measures Fix it AFTER it fails Reactive Defer Maintenance Fix it BEFORE it fails Planned Plan Schedule Coordinate Measure & fix Predictive Predict Plan Schedule Coordinate Don t just fix it, improve it Reliability Eliminate Defects Improve Precision Redesign Value Focus Improve & sustain Enterprise Alignment (shared vision) Integration (Supply, Operations, Engineering) Differentiation (System Performance) Alliances People Fire Fighting Heroes Overlapping Responsibilities Role Based Training Defined Roles & Responsibilities Cross Trained / Bench Strength Processes Limited Development Planning Materials & Inventory Management Kitting Materials & Scheduling Technicians Monitoring Technician Work Execution Total Productive Maintenance Systems CMMS PM Management CMMS Planning & Inventory Management CMMS Scheduling & Robust Reporting CMMS Automated Work Generation CMMS Lifecycle Cost Tracking Technology Limited Utilization Electronic Document Management Systems Predictive Technologies Mobile Handheld Devices Barcoding & RFID Utilization Governance Minimal Performance Tracking Lagging Indicators Leading & Lagging Indicators Continuous Improvement Efforts Organizational Metrics Aligned

24 Benefits of Planning & Scheduling 24 Maintenance Practice - Planning and Scheduling Typical Job Planned On-the-Run Same job if Professionally Planned Planning Activity Work Activity Typical Maintenance Worker s Day - Reactive vs. Proactive Receiving instructions Obtaining Tools and materials Travel to and from job (both with and w/o tools and materials) Coordination Delays Idle at job site Late starts and early quits Authorized breaks and relief Excess personal time (extra breaks, phone calls, smoke breaks, slow return from lunch and breaks, etc.) Sub-Total Reactive without planning & scheduling 5% 12% 15% 8% 5% 5% 10% 5% 65% Proactive with Planning & Scheduling 3% 5% 10% 3% 2% 1% 10% 1% 35% Direct actual work accomplished (as a % if whole day) 35% 65%

25 EAM System Sample Report 25 * Asset Type provides a simple method for analysis of Asset Performance based on PM work vs Reactive work

26 Planning & Scheduling Improves Reliability 26 Foundational element of EAM and Reliability Planning maximizes maintenance productivity & work quality Optimizes equipment/asset uptime Scheduling maximizes maintenance productivity by eliminating lost time between jobs Improves asset efficiency Better asset and maintenance data being captured in system Improved reports Increased time to analyze data leading to improved decisions More accurate metrics can be displayed Drives a Reliability Culture within the organization Overall improvements to EAM and Reliability

27 Maintenance Maturity Continuum 27 Performance Measures Fix it AFTER it fails Reactive Defer Maintenance Fix it BEFORE it fails Planned Plan Schedule Coordinate Measure & fix Predictive Predict Plan Schedule Coordinate Don t just fix it, improve it Reliability Eliminate Defects Improve Precision Redesign Value Focus Improve & sustain Enterprise Alignment (shared vision) Integration (Supply, Operations, Engineering) Differentiation (System Performance) Alliances People Fire Fighting Heroes Overlapping Responsibilities Role Based Training Defined Roles & Responsibilities Cross Trained / Bench Strength Processes Limited Development Planning Materials & Inventory Management Kitting Materials & Scheduling Technicians Monitoring Technician Work Execution Total Productive Maintenance Systems CMMS PM Management CMMS Planning & Inventory Management CMMS Scheduling & Robust Reporting CMMS Automated Work Generation CMMS Lifecycle Cost Tracking Technology Limited Utilization Electronic Document Management Systems Predictive Technologies Mobile Handheld Devices Barcoding & RFID Utilization Governance Minimal Performance Tracking Lagging Indicators Leading & Lagging Indicators Continuous Improvement Efforts Organizational Metrics Aligned

28 Why implement P&S? 28 EAM, Reliability or World Class Maintenance EAM is the management of assets across departments, locations, facilities and/or business units. The goal of EAM is for organizations to maximize the return on investment from their asset base by managing the asset throughout its life. Benefits Acquisition (design, construction, commissioning) Operations Maintenance Decommissioning/Replacement Improve Asset Utilization and Performance Reduce Capital Costs Reduce Asset-related Operating Costs Extend Asset Life Maximize Overall Asset Productivity Minimize Total Cost of Ownership Know whether it is more cost-effective to continue to maintain, overhaul or replace a failing asset.

29 Questions 29 Questions? Matt Midas GenesisSolutions An ABS Group Company Phone: (443)