RCM within the AMS Webinar 22 may 2015

RCM within the AMS Webinar 22 may 2015 John Reeve Practice Leader Maintenance & Reliability A. RCM and Reliability Centered Maintenance – there’s a difference B. The relationship of AMS to Reliability Centered Maintenance C. What exactly is “failure data”? D. Failure data timeline (“how best to capture this data”) E. Life of a Defect – “that pesky critter” F. Asset Offender report – the world’s best Pareto

O&M Vision Goal Statement

What is purpose of Asset Management The main objective is to make more informed decisions regarding facilities & assets as to recurring problems, repair/replace criteria, failure trending and work force efficiency. We want to Reduce reactive maintenance and 1) reduce unplanned breakdown maintenance, and alsoand Predict optimize use of labor resources prevent as 2) optimize the use of your labor resources. Bythis enhancing asset reliability But requires an accurate database and a opposed to fail and fix. well established process - - an ideal process. + Improving work force productivity because Reactive maintenance has a higher cost

Defining … RCM Analysis … is a structured framework for analyzing the functions and potential failure modes for a physical asset in order to develop a maintenance task that will provide an (a) acceptable level of operability, (b) with an acceptable level of risk, (c) in an efficient and cost-effective manner. 1. What are the functions and associated desired performance standards of the asset in its present operating context (functions)? 2. In what ways can it fail to fulfil its functions (functional failures)? 3. What causes each functional failure (failure modes)? Identify 4. What happens when each failure occurs (failure effects)? PM/Pd. M 5. In what way does each failure matter (failure consequences)? 6. What should be done to predict or prevent each failure (proactive tasks and tasks intervals)? 7. And, what should be done if a suitable proactive task cannot be found (default actions)?

ATM Machine PIN Authentication Dispense Cash Potential Failure Effect Consequences Potential Causes Process Controls DETECTABILITY Process Step Potential Failure Mode Effects SEVERITY Function Failures Maintenance OCCURRENCE Risk Priority Number is to be applied to the Failure Mode (RPN) to help identify priority actions Task Recommended RPN Action

Store FMEA and Strategy in AMS screen CC Combustion Gas Cleaning & Exhaust CCH Activated Carbon (1) Blower Transport air at pressure (2) Silo Provide bulk storage of power activated carbon (3) Piping Convey PAC to ductwork F 1 Motor bearing failure M 1 PDM: Vibration analysis Freq. Unit

Reliability Centered Maintenance The product of Maintenance is Reliability How do you achieve operational excellence? Answer: You create a Maintenance & Reliability Program involving basic advance failure * scheduling analysis techniques RCM analysis * defect condition elimination maintenance task definition monitoring (Pd. M)

Terminology Reliability is defined as the probability that a device will perform its required function under stated conditions for a specific period of time. Maintainability … the relative ease, time/labor with which an item can be diagnosed, retained, and restored. SW Defect Elimination Core Team Business Rules Analytical Reports Long Range Plan

Reliability Centered Maintenance AMS Standards Back- Benchmarking Business Log Asset - 5 -year AMS plan Planning Mgmt Rules - Business rules Management Otg - Change tracking AMS Change Scheduling Mgmt System Work Mgmt PM / Request - Work planning Pd. M Tracking FMEA - Backlog mgmt program Kaizen - Advance ODR (TPM) scheduling WO Feedback Repetitive AMS - Outage mgmt KPIs Failure Long Range PM/Pd. M program Root Cause Analy. History Defect Elimination and WO Feedback Plan ODR/TPM Metrics Bench. Kaizen/brainstorming. End-Game Actual marking FMEA Costs w. Analytical Failure RCA; Defect Data Reports elimination Blended Action Tracking Training Tracking Database accuracy Reliability Job Complete - Failure data Accuracy Maint. updates Centered - Actual costs Playbook Maintenance - Job status End-game: analytical rpts Repetitive Failure

But Challenges Remain Bill Broussard, Emerson Process Management, 07/29/2008 Software Process and Procedure Roles and Responsibilities

The Pd. M Practitioners are doubtful As seeing is believing … … they don’t believe. The key word is “may” Mobius Institute slide Reliability Leaders There are two camps: Pd. M Practitioners Condition Monitoring, RCM, FMEA, RCA, defect elimination advocates and Asset Management System solution providers

The Facts are this and they are undisputed (based on JR field observations) 70% of all installations do not perform any basic failure analysis. 90% do not capture adequate failure data 90% do not capture asset condition WO Feedback is not formally captured Somewhere at the site there is a senior manager asking “Where’s the ROI? ” [ which usually refers to reports]

It all starts with the Failure Data (which is needed for the failure analytic) Work Order Initiation WO # PROBLEM DESCRIPTION Completion STATUS ASSET # FAILED COMPONENT WORKTYPE ACTION VERB TYPE FAILURE CAUSE WO PRIORITY TOTAL DOWNTIME PROBLEM CODE (1) Some of these fields may not be on your AMS screen, a n d (2) The ability to capture failure data depends on working level participation WO FEEDBACK A § § § CTUAL COSTS Labor Material Services

It all starts with the Failure Data Repair Event Work Order Initiation WO # PROBLEM ASSET # DESCRIPTION Select the lowest level asset WORKTYPE FAILURE WO PRIORITY PROBLEM CODE Completion Describe the Problem – not the remedy STATUS FAILED COMPONENT ACTION VERB Select Worktype which indicates R E P A I R § § FULL PARTIAL POTENTIAL DEFECT (1) EMERGENCY OPERATIONS (2) URGENT MAINTENANCE (3) ROUTINE – HIGH (4) ROUTINE – MOD Note: I would capture Asset Condition under monthly PM CAUSE TOTAL DOWNTIME WO FEEDBACK A § § § CTUAL COSTS Labor Material Services

It all starts with the Failure Data Work Order Initiation WO # PROBLEM ASSET # WORKTYPE FAILURE DESCRIPTION This is the component-part that failed Problem code associated with Component ADJUST, ASSEMBLE, CLEAN, INSPECT, MACHINE, MODIFY, REBUILD, REPLACE-EQ, REPLACE-PART, LUBRICATE, TRAIN WO PRIORITY This is the physical cause. Examples include: PROBLEM CODE ü ERROR-OPER ü ERROR-MAINT ü PM FREQUENCY ü PM/Pd. M WRONG ü PM/Pd. M MISSING ü PWR FAILURE/SURGE ü IMPROPER MATERIAL ü MISSING PARTS ü MISSING DOCS ü NORMAL WEAR Note: There are other CAUSE levels. The system designers could decide to add more cause fields. Completion STATUS FAILED COMPONENT PROBLEM ACTION VERB CAUSE TOTAL DOWNTIME WO FEEDBACK A § § § CTUAL COSTS Labor Material Services

The Failed Component is part of the Failure Mode Centrifugal is the asset Pump the components are

Problem Codes ( an example list ) A problem code is the first observation by an O&M Technician of a problem regarding the asset.

Failure Mode = = Component-Part + Component-Problem COMPONENT PROBLEM CODE TUBE FRAME COLLAPSED SOLAR CELL FRACTURED THERMISTOR OPEN/CLOSED HYDROGEN STORAGE HIGH TEMPERATURE PIPING LEAKAGE CHECK VALVE STUCK SHEET ROLLER JAMMED SWITCH NO-OPEN BATTERY NO POWER MOTOR NO OPERATE

4 Levels of Cause Codes “root cause failure analysis” “failure analysis” to component Physical Human Systemic Latent

Level-2 Cause C 04 • Incorrect-inferior part • 8% C 05 • Design • 21% M AN HU AN AN xx AN Induced flaws 84% can limit asset -----life from 1 some day - 1 year EM / UR C M Careless M PM / Pd. M AN C 03 • Workmanship • 21% ------ M 12% C 02 • Operating the asset • 29% HU Under basic wear & tear asset can last 1 mo. - 7 yrs. B M Basic C 01 • Raw Materials • 21% HU An aging asset 4% can last 25 -50 -----PM / Pd. M years. HU Aging

3 -D Failure Data Model Update AMS OPERATOR GATEKEEPER (reviews new WO; may adjust priority) PLANNER/SCHEDULER (plans/schedules the work) MAINTENANCE TECHNICIAN MAINTENANCE SUPERVISOR (responsible for accuracy) RELIABILITY ENGINEER JOB DONE T A WO INITIATION F A IL U R E D A Type Failure Problem Code Asset PLANNER/ GATEKEEPER SCHEDULER TECH STARTS JOB TECH UPDATES REL ENGR UPDATES Cause Code WO Feedback Asset Downtime Component-Part Component-Problem Actual Costs

Goal: find & remove the Defect

World’s Best Pareto

Create SQL to drill-down on the Failure Mode

What have we Learned? The Problem The Failure Mode is not generally understood or captured on work orders in most AMS products. Failure Data in general is not being captured. Failure Analytics do not generally exist. Database inaccuracy is sometimes a “reason” for NOT running analytics. Database inaccuracy is still an issue however Potential Failure Modes should be identified using RCM Analysis. Short of that, they should be captured on WO failure history – and stored in the AMS. The failure mode should be a concatenation of Component-Part and Component-Problem. This is due to a variety of reasons: The AMS entry screens may need tailoring ; Choice lists need to be created; Rules for entry must be clarified; The timeline for entry needs to be understood; and different roles enter different data pieces. Lastly, the maint. staff needs to be trained on importance. The AMS stakeholders are responsible for designing this report (pen on paper). This can then be built – and implemented. With the report in-hand you may discover that additional failure data fields need to be added to screen & captured. Failure data may be missing or inaccurate but this should never be a reason for not running a Failure Analytic (e. g. Asset Offender report). The “core team” should do everything possible to improve accuracy by getting the right fields on screen; establishing good value lists; conducting training; addressing change mgmt issues; and process audits - - i. e. leave nothing to chance

S T A T U S P R O C E S S I N T E R A C T I O N You Need a Roadmap because it helps to know where you are going

A sset M anagement S ystem Design Failure Data Roadmap The Setup will be Critical

The objective is to improve asset reliability Knowledge Base Failure Data fields Asset Offender report Business Rules Failure History o WO initiation must-enter failure data o WO completion mustenter failure data o Route WO to Reliability Team for asset review where appropriate Operator Planner/Scheduler Maint. Supervisor Reliability Engineer Reliability Team o Verify WO updates correct o Review WO feedback

You, [insert your name], can make a difference Get the Right Data Build the Right Report Make Better Decisions Failure Data Failure Analytics Manage by Exception Thanks for listening All companies have the potential to improve asset reliability and with minimal configuration you can support Reliability Centered Maintenance Contact Information: Presenter – JReeve@Cohesive. Solutions. com Exec. VP CIS – Mlogsdon@Cohesive. Solutions. com Consulting Services Mgr - SMccarthy@cohesivesolutions. com