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Confidential
Analisi della manutenzione di una industria
Ing. Claudio Vetica
EHS&S Site Lead & Energy Campus Lead
Pomezia Site Johnson&Johnson Roma, 19 April 17
Laboratorio di Sicurezza degli Impianti Industriali Assisted exercise - Safety and Maintenance for Industrial Systems
Focus Areas for the PLANT
Manufacturing Offices Warehouse
Offices Sales &
Marketing HQ
Johnson & Johnson in Pomezia Agile Plant manufacturing >600MM CUs
36 high speed manuf. lines, producing 1000+ SKUS, shipped to 60+ countries
Liquids Oral Care
ESP Cotton Buds
Toiletries
# EMPLOYEES = 510 690.000 pallets / year 12,000 trucks / year
Based on BP15 data
1. Doctors Nurses and Patients
2. Employee
3. Communities
4. Stockholders
3
The values that guide our decision-making are spelled
out in Our Credo. (1943)
Pillar and mission
Mission:
The mission of the department is to support J&J site by enhancing the quality of physical facilities. We do this through planning, designing, engineering, constructing, and maintaining in a responsive, service-oriented, effective, reliable and environmentally-conscious manner.
Facilities & Utilities
Safety and Environment
Quality and Compliance
Efficacy and Availability
What are the Facilities & Utilities?
My personal and passionate
vision of utilities:
• Utilities are the heart and
circulatory system that provide
«oxygen» to all organs • Oxygen are air, water, electrical
energy, gas,etc
• Facilities are the skin of the
plant
Facility & Utilities • Maintenance of Utilities
• Water (DW, SW, DW, PW, WWT, CW)
• Air (HVAC, compressed air)
• Safety system (sprinkler and pomps, lights)
• Heating system (Steam, Super Heat water)
• Electrical and DCS systems (transformer, electrical distribution, PLC, SCADA, UPS, power generator)
• Maintenance of Facilities
• Housekeeping
• Cleaning
• Gardening
• Energy
Pest Control
Vuoto centraliz
zato
Depolveratore ad umido
Depolveratore
Depuratore
Acqua purificat
a
Acqua addolcit
a
Acqua potabile
Acqua refriger
ata
Sensori (gpl, N2, O2, CH4)
Gruppi elettrog
eni
Imp terra
App sollevamento
Antincendio
Acqua calda
Acqua surriscal
data
Vapore industri
ale
Videosorveglianza
antintrusione
UPS
Vapore pulito
App pression
e
Luci
DCS
Filtri
Osmosi inversa
HVAC
Tank EE (MT, BT)
Pesa rifiuti
Aria compres
sa
EHS GMP En
viro
nmen
t Saf
ety
Exercise 1 (15 minutes)
In group of 3-5 people:
-Put systems in appropriate area
Pest Control Vuoto
centralizzato
Depolveratore ad umido
Depolveratore
Depuratore
Acqua purificat
a
Acqua addolcit
a
Acqua potabile
Acqua refriger
ata
Sensori (gpl, N2, O2, CH4)
Gruppi elettrog
eni
Imp terra
App sollevamento
Antincendio
Acqua calda
Acqua surriscal
data
Vapore industri
ale
Vestizione
Videosorveglianza
antintrusione
UPS
Vapore pulito
Facilities
App pression
e
EHS GMP En
viro
nmen
t Saf
ety
Luci
Filtri
Osmosi inversa
HVAC
Tank
EE (MT, BT)
Pti emissio
ne
Pesa rifiuti
Aria compres
sa
Chiller
Scrubber
11
Waste Water Treatment Plant
12
Fire fighting system
13
Boiler & Industrial Steam
14
Deduster
15
Air Compressed
16
HVAC (heating ventilation air conditioning)
17 FACILITY ENGINEERING & MAINTENANCE
What is Reliability?
• Reliability is the ability of a piece of equipment to perform to a certain standard or functionality, for a defined period of time.
• Basically, reliability means the equipment always works the way you want it to work, when you want it. – e.g. a pump will deliver at least 100 litres per hour for 98% of its 20
year life cycle.
• Reliability is all about minimizing unplanned production losses. – Getting unplanned breakdown levels to world class levels of < 10%.
18
Identify & ClassifyEquipment
Conduct FMECA StudyAssess Criticality
Select MaintenanceTechniques
Manufacturer'sRecommendations
Simple FMECA
Simple MaintenanceRoutines
Define:Specific Tasks
FrequencySkills
ResourcesSpares
PrepareJob
Plans
LoadInto
CMMSImplement
Critical
Non-Critical
How design the right maintenance “plan”
Process of availability
20
Unavailability utilities
Emergency process EHS for people
Emergency process for equipment
Business Continuity
Plan
Unavailability 0 – 24 Hours After 24h
Reliability approach
21
Inventory systems
Criticality analisys
E2E utilities - users
STEP
MILESTONE
Working instructio
n
UCFA Utilities Critical Factor
Analisys
Spider diagram
Specific Procedure
Evaluation Connection Action
Criticality assessment
22
EFS Equipment
Factor Score
AFS Addictional Factor Score
TEFS Total Equipment
Factor Score
Class TEFS A <15%
B <35%
C >35%
x =
•Safety
•Quality
•Environment
•Production
•Maintenance
•Waste
5 very high 4 high 3 medium 2 low 1 irrilevant
impact impact
ABC diagram
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
1100000
1200000
1300000
1400000
1500000
1600000
1700000
1800000
1900000
2000000
2100000
2200000
2300000
2400000
2500000
2600000
CAB
INA
3 C
ABIN
A 2
CAB
INA
1 C
ABIN
A D
I CO
NSEG
NA
CO
MPR
K 0
02 -
MD
2 C
OM
PR K
003
- M
D3
CO
MPR
K 0
01 -
MD
1 TH
ERM
A 40
-OW
1 ST
AND
ARKE
SSEL
3
STAN
DAR
KESS
EL 2
ST
AND
ARKE
SSEL
1
ENER
GIA
ELE
TTRI
CA
FM L
IQUI
DI -
CO
NFEZ
EN
ERG
IA E
LETT
RIC
A FM
LIQ
UID
I -M
ANIF
EN
ERG
IA E
LETT
RIC
A D
ISTR
IBUZ
ION
E EN
ERG
IA E
LETT
RIC
A FM
SO
LID
I -C
ONF
EZ
ENER
GIA
ELE
TTRI
CA
LUC
E EN
ERG
IA E
LETT
RIC
A FM
MAG
AZZI
NO
EN
ERG
IA E
LETT
RIC
A FM
SO
LID
I -M
ANIF
40
-PW
6 40
-PW
5 30
-PW
4 40
-PW
3 AC
QUA
DEM
I_M
AJO
R3
40 -
OW
1 - W
S1
Stoc
cagg
io e
dis
tribu
zion
e G
PL-G
PL01
Et
anol
o ET
H01
GEN
ERAT
. EM
ERG
ENZA
4
GEN
ERAT
. EM
ERG
ENZA
3
GEN
ERAT
. EM
ERG
ENZA
2
GEN
ERAT
. EM
ERG
ENZA
1
DEP
URAT
ORE
YO
RK 4
YO
RK 3
YO
RK 9
YO
RK 8
YO
RK 7
YO
RK 6
YO
RK 2
YO
RK 1
2 YO
RK 1
1 YO
RK 1
0 YO
RK 1
YO
RK 5
TO
RRE
EVAP
ORA
TIVA
- A
SSO
RBIT
ORE
C
D 2
AC
QUA
PO
T C
IP 0
1 41
HV5
41
HV6
41
HV3
42
HV2
80
HV1
0 S3
4.10
SA
UTER
EY2
400N
P SA
UTER
EY3
600
41 H
V9
80 H
V13
40 H
V20
SERB
ATO
IO A
CID
O S
8 SE
RBAT
OIO
SO
DA
S9
ACQ
UA A
DD
OLC
ITA_
30
ACQ
UA A
DD
OLC
ITA_
40
POZZ
O 1
PO
ZZO
4
MES
SA A
TER
RA
S21.
01/B
.2
S21.
01/B
.1
CIR
CUI
TO A
RIA
CO
MPR
ESSA
S2
0.01
/B
S20.
01/A
42
HV2
6 S3
4.00
42
HV1
B 42
HV1
A 41
HV4
VU
OTO
VIM
A 80
VU
OTO
VIM
A 40
EN
ERG
IA E
LETT
RIC
A FM
SER
VIZI
UFF
ICI
CIR
C H
2O S
URRI
SCAL
DA
CD
80 H
V10
41 H
V8
30 H
V28
30 H
V29
NOTI
FIRE
BO
ILER
MC
S ST
ILM
ASS
REM
OIN
4&5
RE
MO
IN 2
&3
ACQ
UA S
ANIT
ARIA
_40
ACQ
UA S
ANIT
ARIA
_30
SERB
ATO
IO A
ZOTO
M
OTO
POM
PA 2
M
OTO
POM
PA 1
42
HV2
5 S3
4.09
S3
4.08
UP
S C
ORD
IS 4
&5
UPS
CO
RDIS
2&3
UP
S6
UPS5
S2
0.02
90
HV1
2 S1
0.01
41
HV7
Ab
batti
men
to G
PL- G
PL02
GF1
HV2
0 C
ELLA
+5
Pesa
rifiu
ti H2
O R
EFRI
GER
ATA
_40
H2O
REF
RIG
ERA
TA_3
0 C
D34
.10
CD
34.0
9 C
D34
.08
CD
1
CD
3
HV23
S2
30
HV2
4 40
HV1
6 40
HV1
7 40
HV1
8 40
HV2
1 40
HV2
2 80
HV1
4A
80 H
V14D
80
HV1
4C
80 H
V14B
G
ASO
LIO
S12
G
ASO
LIO
S11
G
ASO
LIO
S10
G
ASO
LIO
INT
S26
G
ASO
LIO
INT
S22
G
ASO
LIO
INT
S18
G
ASO
LIO
INT
S17
G
ASO
LIO
INT
S16
G
ASO
LIO
INT
S15
FL
AKT
1 FL
AKT
2 C
D20
.01/
B C
D20
.01/
A C
IRC
UITO
ANT
INC
END
IO
S34.
07
40 H
V19
UPS4
UP
S3
UPS2
UP
S1
BOX
DED
USTI
NG 4
BO
X D
EDUS
TING
3
BOX
DED
USTI
NG 2
BO
X D
EDUS
TING
1
SS C
ONT
RO
LLO
UPS
S5
S5
0.01
/1R
S50.
01/2
R 60
.02
S21.
02
S16
SS C
ONT
RO
LLO
ENE
RGIE
H1
26
H125
H3
6 S1
0.02
H3
7 PO
ZZO
2
PUNT
I D
I EM
ISSI
ONE
E4
1 -E
42-E
43-E
44-E
37-E
38
S50.
03
TORR
INI
ESTR
ATTO
RI
ESTR
ATTO
RE G
PL 4
0D35
FI
LTRI
ARI
A/AZ
OTO
PH
FILT
RO A
UTO
CLA
VE
HV 1
5 PO
ZZO
3
ELEV
ATO
RE G
LATT
EL
EVAT
ORE
KO
NE
ELEV
ATO
RE A
RMO
EL
EVAT
ORE
KO
NE 5
0 SW
ITC
H01
BH
S61.
01
S10.
03
PARA
NCHI
AS
CEN
SORE
S1
1 S8
.1
S8 B
IS
S8
S10
FAN
CO
ILS S1
S_
OPE
N_SP
ACE
S71.
02
S71.
01
Category A
Category B
Category C
Total Equipment Factor Scores Category A
Addolcitore osmosi
Osmosi inversa
Major
Addolcitori U30 – U40
Loop PW
Pozzo 1 - 4
Depuratore
Usage Users main Utilities Energy
Electricity
Gas
Lights/FM
HVAC
Compressed Air
Manifattura
Confezionamento
Building Heating System
Steam
Cooling System
Compressed Air
Electricity
Cooling System
Heating System
Output
Flow of Energy
Systems & Complexity Utilities & Facilities
consisting of many diverse and autonomous but interrelated and interdependent components or
parts linked through many (dense) interconnections.
Complex systems cannot be described by a single rule and their characteristics are
not reducible to one level of description. They exhibit
properties that emerge from the interaction of their parts and which cannot be predicted from
the properties of the parts
Utilities diagram
26
Deduster Waste water treatment
Cold water c Steam
HVAC
Compressed air Scrubber
Exercise 2
In group of 3-5 people:
-Describe the machine by functional blocks
-Define main safety & environment risks
-Put systems in matrix EHS/GMP vs SAF/ENV
-Determine the overall risk factors
-For the highest, develop FMECA
Fire Fighting
Confidential |
Factor A – Safety and Health Factor B – Quality Factor C – Environment Factor D – Productivity
Equipment Factors:
Criticality Factors
Additional Factors: Fattore E – Maintenability Fattore F – Energy Fattore G – Waste
Confidential |
Used Factors Factor A: Safety and Health
Factor Description Factor Score No effect 1
Low trascurable effect 2
Possibility of failures that can cause high damage on the machines and require the usage of simple DPI for the operators(Es. Powder Mask)
3
Possibility of failures that require 3 days of machine stop or high damage on the equipment/facilities and that requires special DPI for the operators
4
Very important failures that require a special skill to repair the damage and avoid injuries 5
Factor B: Quality
Factor Description Factor Score No effect 1
Significant rework 2
Not many Scraps 3
Significant Scraps 4
Confidential |
Used Factors
Factor Description Factor Score Damage without effect on the environment 1
Damage with not important effect on the environment 2
Damage with emission in the atmosphere or in the water distribution line and that require a notification to the competency authorities
3
Damage with emission in the atmosphere or in the water distribution line and that require a notification to the competency authorities with the conseguency of a restriction to the plant for the production activity
4
Factor C: Environment
Factor Description Factor Score Spare equipment available or the failure will not have significant impact on the process/output
1
High impact on the equipment output/quality but no impact on the other parts of the plant/line
2
The failure will have an high impact on the ouput/quality of the production and could have impact on the other parts of the palnt/line
3
The failure has a big impact on the output rate and require to stop the line/plant 4
Factor D: Productivity
Confidential |
Used Factors Factor E: Mean Time Between Failure (MTBF)
Factor Description Factor Score More than 1 years 1
More than 3 months 2
More than 1 month 3
More than 1 week 4
Less than 1 week 5
Factor Description Factor Score No waste or energy loss 1
Little waste or energy loss 2
Moderate waste or energy loss 3
A lot of waste or energy loss 4
Factor F: Waste
Confidential |
FMECA: the concept
Confidential |
Subsystem Comp/Elem Failure Mode
Failure Effect
Failure Cause MTBF E/H Occ
Rtg Sev Rtg RPN Maint
Option Maintenance Task Unit
Manufacturer Description Function Model Type
Unit/Equip Nr Location Machine Group Plant
Facilitator Date W.Sheet Ref
Sht No
Of FMECA 1 WORKSHEET
Deterioration Characteristic
Pre fail. warning
Fmeca 1 Worksheet
Confidential |
Part FailureMode
FailureEffect
FailureCause
Pre-Failure
Warning
Sev.Rating
S
Occ.Rating
OMTBF
Charac-teristic
& H or E
Maint-enanceOption
RiskPriorityNumber
O*S
Enter identificationor name of part
being considered
Enter chosenmaintenance optione.g. “CBM” and task
Enter mode of failureor inverse function
of failure
Calculate RiskPriority Number
RPN (O*S)
Enter effect offailure for thismode of failure
Enter the severity offailure due to this cause
(1-10 see table)
Enter cause offailure for thismode of failure
Is there a deterioration characteristicand if so what e.g. random, war?
Is failure hidden or evident to user?
Is there a warningand if so how and
what?
Enter estimate of MeanTime Between Failures
due to this cause
Enter the likelihood offailure due to this cause
(1-10 see table)
Fmeca 1 Worksheet
Confidential |
Criteria
Rating
Possible Failure Occurrence Rate (Days)
REMOTE probability of occurrence. It would be unreasonable to expect failure to occur.
1
>1:700 (days)
LOW probability of occurrence. Generally associated with equipment or components similar to above with a relatively low number of failures per unit.
2 3
1 : 700 (days) 1: 350
MODERATE probability of occurrence. Generally associated with equipment or components that have shown up occasional failures, but not in major proportions.
4 5 6
1 : 200 1 : 100 1 : 60
HIGH probability of occurrence. Generally associated with equipment or components similar to ones that have traditionally caused problems.
7 8
1 : 30 1 : 10
VERY HIGH probability of occurrence. Near certainty that major failures will occur.
9 10
1:5 1:1
Occurrence Ratings
Confidential |
Criteria
Rating
MINOR SEVERITY - A very minor failure which would have no noticeable effect on the system performance. Operator would probably not notice the failure.
1
LOW SEVERITY - A minor failure causing only slight system annoyance. Operator would not notice any deterioration of system performance.
2 3
MODERATE SEVERITY - A failure which would cause some system dissatisfaction, discomfort or annoyance, or would cause noticeable deterioration in system performance.
4 5 6
HIGH SEVERITY - A failure which would engender a high degree of system dissatisfaction (e.g. inoperative control). Does not affect safety or ability to meet regulations.
7 8
VERY HIGH SEVERITY - A failure which would affect safety or ability to meet regulations.
9
CATASTROPHIC - A failure which may cause damage to property, serious injury or death.
10
Severity Ratings
Confidential |
Criteria
Rating
Sure: The operator is able to identify the failure or the probable cause.
1
Probable: The operator could be able to identify the failure
2
Remote: The operatot can’t be able to identify the failure
3
Detections Ratings
Confidential |
S*O
S*O>”X”
RPN=S*O*D
RPN>40
OTFFTM
S*O>80DOM
RPN=S*O*D
MTBF BASSO(tanti guasti)
RPN>80
DOM CBM
RPN>80
CBM
DOM (peridentificare meglio
I guasti)
CBM
NO SI
NO
NO
NO NO
SI
SI
SI
SI
CBM
FTM (in funzionedei guasti)
NOSI
X= 15-25
OTF
CBM(semplice)
FTM (in funzionedei guasti)
FTM (in funzionedei guasti)
FTM (in funzionedei guasti)
OTFOTF
CBM(semplice)
MTBF = Mean time between failures OTF = Operate to failure DOM = Design out maintenance FTM = Fixed time maintenance CBM = Condition based maintenance
Parole chiave
Select the right maintenance
