Ins$tu$onalize Reliability Improvement Jason Ballen$ne ARMS Reliability Produced by: Supported by:
ABC Group the typical RCM story 12 Global factory loca4ons SAP since 2005, mostly legacy imports RCM project ini4ated in 2007! Targets: o 10% Reduc4on in Maintenance Cost o 5% Availability improvement o Reduc4on in safety incidents Mastering SAP PM 2013
ABC Group the typical RCM story 8,000 Cri4cal loca4ons iden4fied for RCM 7 Step Excel based process 24 Month process o Es4mate > 20,000 Labour Hrs Many thousands of tasks developed Mastering SAP PM 2013
ABC Group the typical RCM story Some lingering ques4ons post the project. o Will the results actually be implemented? o Project contribu4on to KPI s? o Could the project be turned into a process " The work is not done yet o How could it be made easier i.e. through alignment of SAP & RCM? Mastering SAP PM 2013
RCM & SAP- Addi$onal Ques$ons to Answer What results will (can) I get from RCM? What do I need from SAP to do RCM effec4vely? How do I efficiently update SAP with the results? How do I turn a RCM project into a process? Mastering SAP PM 2013
Group Experience 1. Who has used RCM to develop their opera4ons maintenance tac4cs? 2. Are the results implemented? RCM=SAP 3. Who has a living system? Mastering SAP PM 2013
In excess of 60% of RCM studies are never implemented! Source: Reliability Web Survey
RCM Defined What is the objec-ve of RCM Studies? Iden4fy appropriate maintenance tac4cs and other strategies to mi4gate the risk of asset failures Mastering SAP PM 2013
RCM & SAP for Success What can I expect from my RCM efforts?
RCM & SAP for Success Pareto Predictions Task Interval Optimisation SHARE 2013 10
RCM & SAP for Success Task Interval Optimisation SHARE 2013 11
RCM & SAP for Success Pareto Predictions SHARE 2013 12
RCM & SAP for Success 471 Dump Truck Maintenance Cost Profile ZAR 5,000 ZAR 4,500 ZAR 4,000 ZAR 3,500 ZAR 3,000 ZAR 2,500 ZAR 2,000 ZAR 1,500 ZAR 1,000 ZAR 500 ZAR 0 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Planned Spares (ZAR,000) 398 419 424 428 417 443 423 414 421 422 Correc4ve Spares (ZAR,000) 2,553 3,617 3,728 3,770 3,552 3,757 3,724 3,722 3,650 3,504 Labour (ZAR,000) 253 284 285 292 279 288 291 290 288 282 Total Maintenance Cost (ZAR,000) 3,204 4,320 4,437 4,489 4,248 4,488 4,438 4,426 4,359 4,207 SHARE 2013 13
RCM Defined when is this project finally done?... Mastering SAP PM 2013
RCM Defined.RCM should be a process, not a project! o We make assump4ons (that s what engineers do!) o Changes in Assets (modifica4ons/ acquisi4ons) o New inspec4on technologies and methods (Think P- F Curve) o Skills development may impact failure characteris4cs & P- F o Defect Elimina4on Programs (RCA) o Opera4ng context changes (e.g. changes impac4ng equipment life) o New failure modes come to the fore o Consequence of failure (Down4me cost) changes over 4me should we change our strategies? Mastering SAP PM 2013
RCM Defined The argument is made. RCM should be a process, not a project! Mastering SAP PM 2013
Elements of RCM & SAP Success Mastering SAP PM 2013
RCM & SAP for Success Define overall success:» Jus4fied tac4cs. A transparent & well understood maintenance strategy!» Defined alignment points for SAP & RCM» Plaporm for con4nuous improvement (Process vs. Project)» Educated people Mastering SAP PM 2013
RCM & SAP for Success
RCM & SAP for Success RCM SAP Hierarchy & Loca4ons Maintainable Items Failure modes Failure Characteris4cs Hierarchy & Func. Loca4ons Equipment/ Object Part Symptoms & Cause Details (Catalogues) Failure/ W.O. History Object Parts Consequence Effect PM01 Details Redesign Preventa4ve Maintenance Plans, Items, Task Lists Resources (Labour & Spares) Mastering SAP PM 2013
Cooling Water Pump FMEA Pump Provide cooling water to the process at xx rpm Contain Cooling water No Cooling Water Cooling water leak Bracket Damaged Bracket Corroded Pump Body worn through No cooling No cooling No cooling Water leak Shaft Gland worn No cooling Water leak
Cooling Water Pump FMEA Pump SAP Functional location/equipment Provide cooling water to the process at xx rpm No Cooling Water Bracket Damaged No cooling Bracket Corroded No cooling Contain Cooling water Cooling water leak Pump Body worn through No cooling Water leak SAP Problem Code Shaft Gland worn No cooling Water leak SAP Object Part / Cause Code SAP Effect
SAP Maintenance Plans Maintenance Plan Maintenance Maintenance Maintenance Plan Maintenance Plan Plan Item Task List Task Task List Task List Operation List Document
Task Alignment RCM Task Group Task SAP Plan Item Task List Opera4on Docs
Maintenance Items Mul4ple Maintenance Items per single Maintenance Plan Split on (??) o Maintenance Interval o Volume of work Maintenance Maintenance Maintenance Plan o Resource Maintenance Plan Plan Item o Equipment
RCM & SAP for Success Map your Process! & Include points of RCM & SAP alignment! Mastering SAP PM 2013
Take an Enterprise Approach Taking an enterprise approach o improves efficiency o supports consistent implementa4on o supports con4nuous improvement
The Right Focus The best organisa4ons focus on ins4tu4onalising o Role Defini4on o Competencies o Processes o Standards o Quick Reference Guides (QRG s) o Support o Measurement
RCM & SAP for Success Triggers for review " Calendar " Changes in Consequence The New Reality " Pareto " CI Process (Defect Elimina4on)! COMBINATION OF ABOVE Mastering SAP PM 2013
Process Map
Ins$tu$onalising Successful Implementa4on is the key o Ins4tu4onalising creates the path and supports the processes
Key Points 1. RCM should be a CI process, not just a project! 2. Map your process 3. Ensure SAP & RCM alignment 1. Ensures sustainable use 2. Data can become informa4on and advance your tac4cs (think analy4cs!) Mastering SAP PM 2013
Conclusion SAP & RCM can help you con=nually improve your maintenance strategies! SHARE 2013 33
Ques$ons Mastering SAP PM 2013
Jason Ballen$ne ARMS Reliability jballen$ne@armsreliability.com Produced by: Supported by: