Asset Management System as defined by the Uptime

Asset Management System as defined by the Uptime Elements Framework Session #1 Session #2 Jan. 29 th Monday 8: 30 am – 9: 15 am Champions III Jan. 29 th Monday 9: 30 am – 10: 15 am Champions VII from a Maximo Perspective John Reeve, Author, CRL, CMMS Champion

Speaker Background Grand Gulf Nuclear Station U. S Patent 7, 421, 372 Maintenance Scheduling v 2 nd consultant hired by the company that invented Maximo. v Spent the first 10 years as an international consultant in project management supporting cost/schedule design. Aerospace and defense industries, as well as nuclear power, depended on this software. v U. S. Patent in maintenance scheduling – called the “order of fire” for resource leveling v In the following 20 years, specialized in asset management design. v Certified Reliability Leader 100 Posts v 13, 000 Linked. In followers v 100 postings on industry best practices, numerous trade magazine articles v Frequent speaker at Reliability Web and Maximo software venues v Book: Failure Modes to Failure Codes v Able to comfortably discuss advanced processes for both asset reliability and work force productivity. v Significant overseas assignments include Australian Defence Industry (Sydney), Australian Submarine Corporation (Adelaide), Pohang Steel (South Korea), Guangdong Nuclear Power (China) and Power Generation Company of Trinidad. v Aided in 1 st RCM for Maximo Industry Best Practices course, taught as PSDI consultant

Asset Reliability Journey RELIABILITY LEADERs CMMS PRACTITIONERS MX S/W CONSULTANTs COST/SCHED. ANALYSTs

Asset Management is what you extract from the Asset Management System Advanced processes provide the largest potential return on investment MAXIMO CMMS The software may be world class but you still need someone to state the vision, and then, develop supporting processes.

How to get Certified Read these books Passport set or, attend a 1 week course Five main verticals

What makes up an Asset Management System? What value do the Uptime Elements provide? How do these elements relate to Maximo? Most organizations would benefit from a Long Range Plan

Reliability Engineering for Maintenance Reliability Strategy development Asset Condition information Reliability engineering Root cause analysis Ultrasound testing Capital Project management Reliability Centered design Alignment & balancing Criticality analysis Asset Management Vibration analysis Infrared Thermal imaging Non Destructive testing fluid analysis motor testing Machinery lubrication executive sponsorship operational excellence human capital competency management based learning integrity reliability journey strategy and corporate strategic asset plans responsibilitymanagement plan risk management decision making asset knowledge asset lifecycle management performance continuous indicators improvement

Asset Management Roadmap Assumption: o CMMS is installed. o Organization requests assistance in Asset Management processes o Requests Long Range Plan showing improvement initiatives Capture Failure Mode on WO Although each journey is unique, the Asset Management Roadmap creates a comprehensive long range plan based on organizational priorities and availabilities. The Long Range Plan also supports sustainment activities, such as: § Benchmarking activities § Attending Maximo World § Obtaining CRL staff accreditation § Error Checks and Proactive Audits Define Establish Perform Critical Core GAP Procedures Create Team Analysis Configure Strategic Create Identify System Define Plan 04 Best 06 AS-IS 08 Create Failure Action 10 TO-BE Practices Create Identify Implement Analytic 02 Stakeholders Create Plan Long Range Chronic 07 Reliability Plan Perform 05 Optimize Define Team 12 Load Failure 09 03 Criticality Planning End-Game Analysis Missing Scheduling 20 Impl. 11 Foundation 01 14 Conduct Mobile Data Blended 16 Perform 18 Solution RCM/PMO Training 13 Analysis 15 You can install software, but you cannot install reliability. 17 19

Work Execution Management is one of five verticals within the Asset Management System framework, provided by Uptime Elements. Defects will never stop. They are forever being introduced and perpetuated. Defect Tracking PM, PS and MRO are singled out due to their significance and complexity within Work Execution. ODR and DE are typically new topics within the CMMS community. Lets start here. Reliability Leader. TM, Uptime® Elements. TM, Reliability Framework and Asset Management System. TM and Reliability Leadership TM are the trademark(s) or registered trademark(s) of Netexpress. USA Inc. d/b/a Reliabilityweb. com and its affiliates in the USA and in several other countries.

Reliability is Everyone’s Job -- including Operations Goal #1: Build a proactive maintenance program which involves failure mode identification by O&M staff; precision maintenance training for technicians; and RCM training for senior staff. Lastly, get Reliability Engineer involved. Goal #2: Operations personnel should be used in 10 -40% of all PM duties. This would free-up maintenance to increase Pd. M activities, and gain a partner in asset reliability. Operator Driven Reliability has operators performing minor & recurring maintenance tasks. Operators need to accept ownership of asset reliability. They can (1) identify and report failure modes sooner, and, (2) perform basic servicing by replacing filters, and performing lubrication. They could also have basic Pd. M tools with them on rounds. ODR Basic Tasks – qualifying criteria 1. 2. 3. 4. 5. 6. No more than one basic skill is involved, such as mechanical or electrical; but no special tool requirements Only minor adjustments or lubrication activities Troubleshooting “if then … then this”, e. g. electrical resets or clearing a jam Defect elimination or improvement activities are encouraged No significant disassembly Before starting ODR program, there should be some type of “buy-off” to verify properator knowledge. Senior maintenance staff should conduct walkdown to discuss possible failure modes. 7. Every operator who is assigned an ODR task should have access to the single point lesson (SPL). Best-in-Class Tips: ü Some organizations have Defect Elimination teams who work together to make improvements. ü In some organizations, the maintenance staff is offered advance training in Condition Based Technologies.

Some Organizations focus heavily on Cost Management How do you optimize Reliable companies will have a competitive advantage due to bestin-class practices. This allows them to maintain a positive margin costs to improve even in a depressed market place. Maximo Advanced Processes reliability?

1. 0 CMMS Select CMMS based on I M P L E M E N T --- U T I L I Z E --- O P T I M I Z E 1. Ability to configure 2. User community size PLAN & SCHEDULE 3. Industry-product ratings 4. Number of available add-ons Design CMMS to manage by exception BACKLOG M A NAGEMENT 1. Identify failure analytic and other key reports 2. Reverse engineer input reqmts. EMER/URGENT – PLANNED CORRECTIVE – PM/Pd. M - MINOR RACI SAFETY-HAZARD REVIEW 1. 3 ORGANIZATION cron WORK PRIORITIZATION + CATEGORIZATION 1. 2 BUSINESS PROCESS üVision-mission WO Initiation üDept Goals üBusiness Rules 1. 1 FOUNDATION DATA üFlow charts üCMMS SOPs üKPIs + metrics ASSET LABOR PM FAILURE CODES INVENTORY M RO auto JOBPLAN CRAFT CALENDAR replenish ITEM LOCATION rop, eoq, COMPANIES lead-time, safety STRATEGIC TACTICAL OPERATOR DRIVEN RELIABILITY DEFECT ELIMINATION RCM ANALYSIS DAILY PM OPTIMIZATION PLAN RCM SCREEN INSIDE CMMS WEEKLY SCHEDULE CRITICALITY ANALYSIS ROOT CAUSE ANALYSIS CHRONIC FAILURE ANALYSIS RELIABILITY TEAM ANALYTICAL REPORT DESIGN ASSET CONDITION WORK ORDER FEEDBACK FAIILURE MODE ON WO MAINT. DOWNTIME CAPTURE STO SCHEDULING PROJECT COST TRACKING RISK BASED PRIORITIZATION MATRIX

IS O- 55 00 0 Strategic Asset Management Policies v v v v Asset Category; Asset Criteria/Definition Replacement Cost; Asset Condition Tracking Expected Service Life; Average Age Levels of Service Maintenance Schedules Cost Tracking; Growth Plan; Capital Projects Disaster Planning; Risk Management Asset Management Plan by Category showing SLA Reliability Leader. TM, Uptime® Elements. TM, Reliability Framework and Asset Management System. TM and Reliability Leadership TM are the trademark(s) or registered trademark(s) of Netexpress. USA Inc. d/b/a Reliabilityweb. com and its affiliates in the USA and in several other countries.

RE COR SP PO ON RA SIB TE ILI TY Design the CMMS to manage by exception 1. 0 SHAREHOLDERS 1. 1 CMMS DATA ASSET MGMT 1. 2 KNOWLEDGE 1. 3 END-GAME MISSION-VISION CORPORATE POLICY ASSET MANAGEMENT STRATEGY ASSET MANAGEMENT PLANS Continuous Improvement This initiative is certainly valid but if left up to the day-to-day worker, minimal benefit may occur. Therein several techniques are warranted such as WO Feedback, asset condition capture, chronic failure analysis, RCA, defect elimination, auditing, SQL error checks, benchmarking, RACI chart, asset owners, story boards, posters, and of course training. FOUNDATION DATA INDUSTRY BEST PRACTICES DECISION MAKING CONTINUOUS IMPROVEMENT ANALYTICAL REPORTS TRANSACTION DATA RISK MGMT The analytical reports could very well impact the data capture requirements. Thus if the CMMS team fails to think ahead, capabilities will be lost. LONG RANGE PLAN (LRP) ACTION TRACKING MANAGEMENT OF CHANGE -- Steven Covey The LRP is a greatly under -utilized tool for consolidating improvement initiatives and adding clarity. KPIs provide measures; analytics provide insight. Too often the CMMS user assumes the product o. o. b. will have the analytics they need.

Create a Culture of Reliability, Responsibility, and Accountability Foundation for Reliability v Leadership for Reliability states that leadership comes from everyone. v Executive Sponsor should be the champion of asset management – at the executive level. He sets the AIM where reliability is an imperative. The executive sponsor communicates goals and helps initiates change, assigns accountability, and explains benefits. He also reviews expectations, addresses resistance, and reviews risks/roadblocks. Lastly, he explains why continuous improvement is critical. Top management is also responsible for creating and resourcing the Long Range Plan – containing improvement initiatives. v Reliability Leader - defined: Reliability Leaders promote excellence; develop innovative ideas in support of improve work force productivity and asset integrity’ plus, they nurture the development of others through demonstration and engagement. Reliability Team is coordination central for improvement ideas. v Anyone can be a reliability leader – including P&M Technicians. To be a reliability leader, you must be able to lead and exercise reliability leadership effectively with no title, no position, and no authority. A reliability leader strives to create a better future that might not otherwise exist. v Reliability Culture is created through leadership. And optimized performance is a principal result of this culture. Reliability Leader. TM, Uptime® Elements. TM, Reliability Framework and Asset Management System. TM and Reliability Leadership TM are the trademark(s) or registered trademark(s) of Netexpress. USA Inc. d/b/a Reliabilityweb. com and its affiliates in the USA and in several other countries.

1. 0 EXECUTIVE SPONSOR SENIOR MANAGERS TE G IC üUnderstand shareholder values üDocument goals & objectives üPromote reliability culture üCommunicate vision 1. 1 PROJECT MANAGER RA ST Someone at the executive level should be the primary sponsor of asset management strategy O RELIABILITY CHAMPIONS PE T A R IO Goal: Create a Culture of Reliability AL CMMS CORE TEAM CMMS ADMIN ASSET CARE SPECIALISTS N 1. 2 STEERING TEAM BUSINESS ANALYST RELIABILITY TEAM P&S MGR RELIABILITY ENGR POWER USERS HSE MATLS MGR OPS MAINT MGR 1. 3 IE R IO IS V Team Based Approach N A DIFFERENCE MAKERS TOTAL PRODUCTIVE MAINTENANCE OPERATOR DEFECT PLANT DRIVEN ELIMINATION SYSTEM RELIABILITY TEAMS OWNERS Strategic alliance between departments that supports shared goals TECHNICIANS S 1. 4 HR MGR OPS SUPV MAINT SUPV OPS MGR MAINT MGR TRAINING MGR VP

Only 11% of all failures are age related Condition Based Technologies are scheduled activities, non-intrusive, and provide early warning. If that is true, why are we doing so many overhauls, replacements and servicing? Age Related Random Reliability Leader. TM, Uptime® Elements. TM, Reliability Framework and Asset Management System. TM and Reliability Leadership TM are the trademark(s) or registered trademark(s) of Netexpress. USA Inc. d/b/a Reliabilityweb. com and its affiliates in the USA and in several other countries.

Goals: Asset Preservation Managed Risks Less Downtime Return on Capital 1. RCM Decision Tree selects tactic 2. Strategy must be viable 1. 0 D e l i v e r y M o d e l 3. Certified staff for CBT 4. Precision skills The life of an asset is documented by transactional data, CBT, SCADA and staff observations. MEET STAKEHOLDER EXPECTATIONS 1. 2 PF Curve Position 1. 1 Opinions from tribal knowledge Low SUSTAINED EXCELLENCE 1. 3 ASSET O&M Technician sensory & log readings Low Decisions to be made TYPE Graded asset condition Mid § Replace asset AND 1. 5 COST AVOIDANCE RPT Mid FUNCTION CMMS failure history § Design change 1. 4 Data historian; SCADA Mid § Repair asset Vibration analysis High § Continue operating Repaired Infrared thermography High but alter frequency before failure Ultrasound High § Install on-line Fluid analysis High monitoring Motor testing High § No action; no defect Training and certification should be Non Destructive Testing (NDT) High supported as incentives for technicians to Preservation Techniques § Machinery lubrication § Alignment & balancing § PM restoration § Visual testing/inspection § Cleaning WORK SCHEDULE CONDITION BASED TECHNOLOGIES (CBT) and PREVENTIVE MAINTENANCE ASSIGNED CRAFT RISK BASED PRIORITIZATION MATRIX WORK BACKLOG ROUTINE & URGENT WORK increase skillset, provide more effective maintenance, and be better compensated. // Jack Nicholas, Jr. , Uptime, Jun-Jul 2017 PRECISION MAINTENANCE SKILLS ASSET RECORD DATABASE CRITICALITY ASSET CONDITION MANUFACTURER/MODEL PURCHASE HISTORY WARRANTY; AGE REPLACEMENT COST FUNCT. CHARACTERISTICS

How can you guarantee Reliability? You can’t But we can improve the odds Reliability Leader. TM, Uptime® Elements. TM, Reliability Framework and Asset Management System. TM and Reliability Leadership TM are the trademark(s) or registered trademark(s) of Netexpress. USA Inc. d/b/a Reliabilityweb. com and its affiliates in the USA and in several other countries.

Goal: The organization must continually improve 1. Perform investment planning processes, reduce costs, 2. Ensure reliability in design and cut waste to 1. 0 IDENTIFY & MANAGE RISKS remain competitive. 3. Manage capital projects 4. Operate & maintain It’s not possible to design out all possible defects therefore the organization must deploy methods to detect failure, find true cause and mitigate it’s RCA Trigger effects. Points CBT = Condition Based Technologies 1. 6 1. 2 PR LI O VIN G G RA M 1. 3 Store RCM Analysis results inside CMMS RCM ANALYSIS 10 -15% PMO ANALYSIS 70 -75% 1. 4 OEM 10 -15% RECOMMENDATIONS 1. 5 CMMS PM/CBT LIBRARY 1. 1 CRITICALITY ANALYSIS Time. Usage based Work Orders CBT Discovery ROUTINE + URGENT REPAIR WORK One-off WO failure mode comparison O&M TECHNICIAN PERFORM PRECISION MAINTENANCE NORMAL PLANT OPERATION SIGNIFICANT EVENT Root Cause Analysis Monthly Meeting RECURRING FAILURE 1. 7 Chronic Failure Analysis WO COMPLETION UPDATES 1. 8 WO Feedback Pareto sort identifies worst offenders and drills down on failure mode to find true cause

Present LRP to Stakeholders Upper Mgmt Conduct Review LRP Setup/Configure Fields: • 5 Annual Maint Costs to Asset • Functional Failure on WO • Out-of-Service on WO • Type. Work field (with pic list) • WO Feedback Activate CMMS Functionality: • Type-Ahead • Prefix WO with “YY-” • Capture Actions Performed • Setup Capital Tool Tracking • Meter-based PMs Setup Create Power Applications: • Defect Tracking • RCM Analysis Screen • WO Ranking Matrix • HSE Accident/Incident Tracking • PM Basic & Commitment Repository Failed Component Problem Cause Code Asset Install Date, Warranty Expiry, Replacement Cost Setup Asset Cond. Capture Autoscript for Oper. Downtime Autoscript for Avg Ann Maint $$ Formalize Core Team Conduct User Surveys • Build Charter • Build RACI • Formalize WORM team • Create Business Rules • Build CMMS Definitions • Create Error Checks • Define Business Analyst • Maintain Punchlist • Solidify Vision/Mission • Create Posters • Setup Book Club Bus. Rule: CM Worktype for Repair Capture Failure Mode Perform RCM Analysis Cost Avoidance Report Store RCM Analysis inside CMMS Perform PMO Analysis Perform Criticality Analysis Gather OEM Recommendations Setup Reliability Team Perform Defect Elimination Design. Build Failure Analytic Perform Precision Maint. Training Design-Build Pass-Down Report Improve CMMS SOPs Auto. Script for Backlog Ranking Promote Job Safety Create Backlog Growth Report Improve Job Planning Punchout Spare Part Integration Imp. Backlog Management Make Oracle WO required Integrate MX PR to Oracle Understanding the end-game gives an organization significant competitive advantage. Optimize O&M Costs with ROA Root Cause Analysis Allow Pareto Sort on Report: • # Work Orders • Operational Downtime • Asset Condition • Avg Annual Maint Cost / ERV • Asset Age Auto. Script for Rough Estimate Enhance Asset Reliability Chronic Failure Analysis Capture Accurate Failure Data Incident Reporting Road Map CRL Accreditation Improve Workforce Productivity Provide Ease -of-Use for Core System use Setup SR Web Based Evaluate Speed/ Performance Organizations that deploy the best reliabilitybased maintenance practices provide the best availability at lower cost. TRM John Reeve Rev 1, 11/02/2017

Authors Breakfast – IMC 2017 Benchmarking: An Essential Strategy for every CMMS Core Team John Reeve maximo world Aug. 2018 Failure Modes to Failure Codes *** Short Course *** John. Reeve@TRMNET. COM