Improved
Reliability
through
PM Optimisation
Project Team:
Electrician
Planner
Mechanic
Operator
Reliability Engineer
Facilitator: Steve Turner
PMO2000™
1
www.reliabilityassurance.com
Why investigate the Residue Cell C’s
 PM
Optimisation will fall in line with the business
plan for the Site.
 The only cost centre in the plant consistently
over budget.
 Opportunity to improve reliability as Cell C’s
have highest failure rate in the area.
 Opportunity for more consistent performance to
meet plant expansion plans.
 The experience is that there is more work in the
area than there are people assigned.
PMO2000™
Objectives
 Better
focus of PM schedules.
 Increase the quality of maintenance.
 Understand the rationale behind each PM task.
 To better manage the Cell C operation and
maintenance.
 Exchange information and increase
understanding of each role ie mech ,elect, process.
 Understand equipment failure history.
 Improve detection and rectification of failures.
 Communicate findings.
PMO2000™
Objectives…cont
 All
of the previous will result in greater ability
for us to meet the business plan.
PMO2000™
How we went about it
 Started
with the existing PM lists
 Applied the process to the all schedules
including:
 SAP schedules
 Maintenance and Process task lists
 Check sheets
 Created a new daily schedule for both operator
and maintenance technicians.
 Review failure modes and the PM’s which
addressed these.
PMO2000™
How we went about it….con’t
 Review
operating logsheets
 Determined the most appropriate maintenance
strategy.
 What task (preventive, predictive or
corrective)
 Who does it
 How often.
 Develop implementation list/plan for approval.
PMO2000™
Opportunities identified
 Numerous
new PM tasks that should be done.
 Task frequency could be more effective
particularly in the mechanical area.
 Some job descriptions were not specific or
reflective of actual work.
 Identified a opportunities for reliability
engineering.
PMO2000™
Opportunities Identified…cont
 Better
utilisation of maintenance and operations
resources by eliminating task duplication.
 The maintenance strategy needs to be better
documented so that it can more easily be
reviewed and communicated.
 There is an opportunity to transfer some of the
knowledge to other processes and sites.
PMO2000™
Outcome PM Optimisation Analysis
Delete
13%
Extend Interval
11%
Use As Is
60%
New Task
7%
Reduce Interval
9%
Overall Breakdown Of 110 Maintenance Tasks
PMO2000™
Outcome PM Optimisation Analysis
Use As Is
13%
Delete
19%
Reduce Interval
25%
Extend Interval
30%
New Task
13%
Analysis of Mechanical Changes
PMO2000™
Downtime Analysis-Mechanical
Table of Overall Downtime for PM on Unit
Sum of Hours
Interval
Proposed Program
Per
Total Lab
D/time Year
Total
2
Monthly
0.3
1
0.3
6
2
Monthly
5.17
2
3
12
36
Two
Weeks
2.25
1
2.25
26
59
Weekly
1.92
1
2
52
104
Grand
Total
9.64
PMO2000™
200
Previous Program
Per
Lab
D/time Year
1
8
26
Total
208
208
Downtime Schedule
10
Original
Total 32hrs
Downtime Hours
8
Revised
Total 30hrs
6
4
2
0
Week 1
PMO2000™
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
Some interesting issues
 Some
valve failures could possibly be managed by
condition monitoring rather than in breakdown.
 Breakdown history was recorded incorrectly. This
precludes any efficient analysis.
 Some task were carried out too often…others not
often enough.
 The existing mechanical PM were difficult to
complete but now broken into three PM’s.
 Not all process tech inspections are recorded.
PMO2000™
Some interesting issues….cont
 Greater
involvement of process tech’s in fault
finding is possible for maintenance and
operations problems.
 The justification for each maintenance task is
now documented.
 The existing PMs are not all being completed.
 Pizza Hut do not deliver on public holidays.
PMO2000™
Other benefits...
 More
knowledgeable and empathetic workforce.
 More descriptive tasks with acceptable limits.
 Improved team work.
 Greater sense of ownership in the maintenance
and equipment performance.
 Better understanding of failure modes and
objective of tasks
 Planned downtime reduced (1hr per fortnight per
unit).
 Unplanned downtime will add to this.
PMO2000™
Benefits..con’t
 Move
to a less reactive environment by adopting
more frequent inspections where warranted.
 The PM program can now be achieved.
PMO2000™
What needs to happen now
 Input
changes to SAP (already started).
 Implement the Process Tech check procedure.
 Modify Elect Maintenance Tech check sheets.
 Develop Mech Maintenance Tech check sheet.
 Improve failure reporting in SAP.
 Carry out some minor plant modifications.
 Implement new tasks ie NDT and Structural
inspections .
PMO2000™
Improved Reliability
through
PM Optimisation
Project Team:
•
Electrician
•
Planner
•
Mechanic
•
Operator
•
Reliability Engineer
PMO2000™
Facilitator: Steve Turner 18
www.reliabilityassurance.com