39
Maintenance Management Maintenance of Historic Structures Lorenzo Fedele Dipartimento di Ingegneria Meccanica e Aerospaziale Area Impianti Industriali Comitato Nazionale Italiano per la Manutenzione

Purdue finale [modalità compatibilità]

Embed Size (px)

DESCRIPTION

Univ. Sapienza - Purdue Univ. - 13-3-13

Citation preview

Page 1: Purdue finale [modalità compatibilità]

Maintenance ManagementMaintenance of Historic Structures

Lorenzo FedeleDipartimento di Ingegneria Meccanica e AerospazialeArea Impianti Industriali

Comitato Nazionale Italiano per la Manutenzione

Page 2: Purdue finale [modalità compatibilità]

Agenda

• Maintenance and its evolution• Organization of Maintenance• Organization of Maintenance• Design of maintenance• Total productive maintenance• Total productive maintenance• Examples

A case st d• A case study• Maintenance of historic structures

Ri k d C• Risk map and Cova• Rome: door to East

13/3/2013Lorenzo Fedele Pagina 2

Page 3: Purdue finale [modalità compatibilità]

Maintenance and its evolution

• Maintenance is in the middle of a strategic crossroad:Maintenance is in the middle of a strategic crossroad:

Crisis? What crisis?

SocietySociety

EnvironmentEnvironment EconomyEconomyMaintenanceMaintenance

SafetySafety

13/3/2013Lorenzo Fedele Pagina 3

Page 4: Purdue finale [modalità compatibilità]

Maintenance and its evolution: some definitions

• It 's the business function that has as its purpose the efficient maintenance of machinery and equipment (Resolution OECD, 1963).

• Combination of all technical, administrative and management actions during the life cycle of an item intended to retain it in, or restore it to, a state it can yperform the required function (EN 13306, 2001).

Today:Today:Maintenance has gone from support service to support production and for the

repair or removal of decay in buildings, systems and structures…

…to…

… all that is directed to the preservation of systems, also complex, both with regard to their consistency and to their efficiency.

13/3/2013Lorenzo Fedele Pagina 4

Page 5: Purdue finale [modalità compatibilità]

Maintenance and its evolution

• The market for maintenance services is growing (Global Service, Facility Management, etc..) for the increasing

f t d t t i th t ll i ifi t 25303540

of a trend to outsourcing that allows significant economies of scale and a better degree of utilization of personnel. 0

510152025

1998 1999 2000 2001 2002 2003 2004

• Maintenance of systems increasingly tends to extend its boundaries and becoming management and remote

Percentage of budget spent on outsourcing

management of systems themselves, thanks to the adoption of technologies and procedures more and more sophisticated.

• Challenges for maintenance projects include:– a) methodologies, techniques and tools;– b) management criteria– c) contracts– d) the qualification of organizations, services and employees.

13/3/2013Lorenzo Fedele Pagina 5

Page 6: Purdue finale [modalità compatibilità]

Maintenance and its evolution: Italian peculiarities

• Ordinary maintenance. It is:preventive (before the fault)– preventive (before the fault)

– periodic (constant or variable)– does not increase the value of the item– maintains constant the degree of aging of the item

Reliability

Value,

Agingmaintains constant the degree of aging of the item– the user is responsible for the ordinary maintenance

• Extraordinary maintenance:Extraordinary maintenance:- it is an after failure/accident maintenance- it increases the value of the good- it restores the operation of the item- it restores the operation of the item- it is not periodic- the owner is responsible for the extraordinary maintenance.

T1 T1 T2 T2 T3 T3

t

MTTR

13/3/2013Lorenzo Fedele Pagina 6

Page 7: Purdue finale [modalità compatibilità]

Organization of Maintenance

• The "classical" functional location of Maintenance is as follows:Management– Management

• Production• Logistics

Maintenance

• Main activities within the maintenance division are as in the following:TECHNOLOGIES

MANAGEMENT

PURCHIASING AND

MAINTENANCEMAINTENANCE ENGINEERING

PROCUREMENT

WAREHOUSES

SAFETY AND ENVIRONMENT

ACCOUNTING

13/3/2013Lorenzo Fedele Pagina 7

Page 8: Purdue finale [modalità compatibilità]

Organization of Maintenance

• An example of organization of maintenance:

PLANT MANAGER

Staff

Manager TechnicalServices Production Manager

MTCMTCengineeringengineering

technicaloffice

operativeMTC workshops

13/3/2013Lorenzo Fedele Pagina 8

Page 9: Purdue finale [modalità compatibilità]

Organization of Maintenance• An example of organization of maintenance:

MaintenanceMaintenanceengineeringengineering

Staff

Predictive/Preventive Reliability Information technologyCosts controlmaintenance

y Costs controlReporting

- DiagnosticsNd

-Operational availabilitys - Ndc- Systems analysis- Assessment efficiency- Planning interventions,- Operational Mtc

p ymonitoring- Analysis of issues,- Specifications of interventions- Executive supervision

ManagementInformation System

Act

iviti

es

13/3/2013Lorenzo Fedele Pagina 9

p

Page 10: Purdue finale [modalità compatibilità]

Organization of Maintenance• Roles, Responsibilities and Objectives

– The evolution of maintenance has an impact on skills:

Outsourcing Hw and Sw

New skills

systems

Global Service/ Facility Analytical techniques, / Facility

Management

y q ,simulation and soft

computing, ...

13/3/2013Lorenzo Fedele Pagina 10

Page 11: Purdue finale [modalità compatibilità]

Organization of Maintenance• Roles, Responsibilities and Objectives

– The evolution of maintenance has an impact on skills:

European Maintenance Engineer (Level A)“person with approved engineering background and sufficient theoretical knowledge to perform and co ordinate maintenance”

Level Aand co-ordinate maintenance

European Maintenance Technician (Level B)“person with at least two years of practical

Level B

person with at least two years of practical experience in maintenance and sufficient theoretical knowledge to independently perform and co-ordinate maintenance projects (responsible for medium term decisions)”

Level C

)

European Maintenance Specialist (Level C)“craft person with at least two years of practical Level Cexperience in maintenance and sufficient theoretical knowledge to independently perform and co-ordinate maintenance activities (responsible for short term decisions and communication)”

[Technical Report CEN/TC319/WG9]

13/3/2013Lorenzo Fedele Pagina 11

[Technical Report CEN/TC319/WG9]

Page 12: Purdue finale [modalità compatibilità]

Design of Maintenance• Design of Maintenance involves elements of uncertainty in addition to the

more usual and structural design of material objects.

• You need:- methods of analysis (qualitative and quantitative);- analytical techniques;y q ;- simulation techniques;- soft-computing techniques.

• In general:"Design the maintenance means determining the mix of maintenance policies that

maximize plant availability in a context of global costs containment"AS IS AS IS Ti iTi i TO BETO BE

maintenance total cost

f ilPronto Intervento

100

Costi

Pronto Intervento

Automanutenzione

AS IS AS IS -- TipicaTipica TO BETO BE

preventive maintenance frequency

preventive maintenance

cost

failuremaintenance

cost

Altre Altre

Mtz. Preventiva e Programmata

Mtz. Preventiva(*)

e Programmata

(*) f ibil t di ti P ditti / O C diti

13/3/2013Lorenzo Fedele Pagina 12

(*) preferibilmente di tipo Predittivo e/o On-Condition

Page 13: Purdue finale [modalità compatibilità]

Design of Maintenance

Maintenance ProactivemaintenanceTPM = Total Productive

Policies

maintenanceImproving

maintenance

TPMTPM = Total Productive Maintenance

RCM = Reliability

StrategiesPredictive

maintenanceRCM

Centered Maintenance

Unplanned Planned Improvingpmaintenance maintenance

p gmaintenance

• A guasto • Preventive• On conditionOn condition

•Predictive•Proactive

•Prognostics

13/3/2013Lorenzo Fedele Pagina 13

Page 14: Purdue finale [modalità compatibilità]

Design of Maintenance

13/3/2013Lorenzo Fedele Pagina 14

Page 15: Purdue finale [modalità compatibilità]

Design of Maintenance• Maintenance is managed by processes, taking as a basis the maintenance

budget, and using as a guide the maintenance indexes (general, effectiveness, efficiency and governing the organization):effectiveness, efficiency and governing the organization):

OPERATIONSOPERATIONS

DesignDesign PlanningPlanning ProgrammingProgramming ExecutionExecution SummarizingSummarizing.. ControlControl

Engineering Materials (supply and management)Engineering Materials (supply and management)

SchedulingScheduling

Third parties (purchase performance and job control)Third parties (purchase performance and job control)

g g ( y g )g g ( y g )

Computer SystemComputer System MaintenanceMaintenanceComputer System Computer System MaintenanceMaintenance

Management Management processesprocesses

13/3/2013Lorenzo Fedele Pagina 15

Page 16: Purdue finale [modalità compatibilità]

Total Productive Maintenance• Total Productive Maintenance (TPM) is a comprehensive, pervasive and

synergic approach to production problems, with the aim of improving performance through the commitment of all employees and the use of smallperformance through the commitment of all employees and the use of small groups of assets.

• TPM approach aims to reduce the so called "six big losses“:• TPM approach aims to reduce the so-called six big losses :– loss of time

• troubleshooting and preventive maintenance• set-up and adjustments

d l– speed losses• minor stops (reversals, cleaning, ...)• speed reduction

– defectsl i i ld i ti l t t t• losses in yield, in particular at start-ups

• losses due to non-compliance

13/3/2013Lorenzo Fedele Pagina 16

Page 17: Purdue finale [modalità compatibilità]

Total Productive Maintenance

13/3/2013Lorenzo Fedele Pagina 17

Page 18: Purdue finale [modalità compatibilità]

Examples

OEE - Overall Equipment Effectiveness

== Availability Performance level

Quality levelin productionX XOEE level

Losses due to breakage / failure

L f

Minor stops and no-load operation losses

L d t

Losses due to defects in quality and manufacturing

Losses for adjustement and set-up

Losses due to reduced speed Losses due to

instability in the process

13/3/2013Lorenzo Fedele Pagina 18

Page 19: Purdue finale [modalità compatibilità]

Examples

What is the contribution to profit due to an increase of 1% of A, P o Q (OEE)?

Total Time (220 x 24h) = 5280 h

Maximum capacity of production = 25 t/h

Profit margin = 300 E/t

OEE (A x P x Q) Present = 0,9 x 0,9 x 0,9 = 0,729

Improvement of OEE = 0 91 x 0 9 x 0 9 = 0 737Improvement of OEE = 0,91 x 0,9 x 0,9 = 0,737

19

Profit improvement:

(0,737–0,729)x5280x25x300 = 316.800 E316.800 E

13/3/2013Lorenzo Fedele Pagina 19

Page 20: Purdue finale [modalità compatibilità]

Examples

13/3/2013Lorenzo Fedele Pagina 20

Page 21: Purdue finale [modalità compatibilità]

Case study• Improvement of maintenance and increase of productivity in a chemicals-

pharmaceuticals company in Latina.

Blister machine

Tray machine

Shrinkwrapper

Cases machine Boxes machine

13/3/2013Lorenzo Fedele Pagina 21

Page 22: Purdue finale [modalità compatibilità]

Case study• Improvement of maintenance and increase of productivity in a chemicals-

pharmaceuticals company in Latina.

Monitoring system for PRS data(Production Reporting System)

13/3/2013Lorenzo Fedele Pagina 22

Page 23: Purdue finale [modalità compatibilità]

Case study• Improvement of maintenance and increase of productivity in a chemicals-

pharmaceuticals company in Latina.

13/3/2013Lorenzo Fedele Pagina 23

Page 24: Purdue finale [modalità compatibilità]

Case study• Improvement of maintenance and increase of productivity in a chemicals-

pharmaceuticals company in Latina.

13/3/2013Lorenzo Fedele Pagina 24

Page 25: Purdue finale [modalità compatibilità]

Maintenance of historic structures: background

• Why speaking of maintenance in Rome:– The first builders?

Th fi t t t l i th G b kli T ( d d hill) i T k (9600 bC)• The first stone temple is the Gobekli Tepe (rounded hill) one, in Turkey (9600 bC)• The first stone towers are the so called ziggurat in the area of Mesopotamia (Sumerian, Babylonian and Assyrian) (4000 bC)• The first stone temple un Europe is the Stonhenge, in UK (3000-1600 bC)• The first pyramids and stones are probably in Egypt (2500 bC)• The first one-stone monument is the Sphinx from Egypt (2500 bC)• The first one-stone obelisks (monoliths) are from Egypt (2300 bC) and they are now in Rome (less in London, Paris, etc.)

– The first engineering handbook?• De Architectura, by Marco Vitruvio Pollione (15 bC)

– The first engineer?• Leonardo Da Vinci (‘500)

– The most visited historic building?• The Flavius amphitheatre or Amphiteatrum (Colosseo) (80 AD): 91 Geuro/year

Quamdiu stabit Colyseus stabit et Roma;cum cadet Colyseus cadet et Roma;cum cadet Roma cadet et mundus

As long as the Coloseum, Rome also exist;when the Coloseum falls, Rome will fall;when Rome falls, the world will fall.

13/3/2013Lorenzo Fedele Pagina 25

Page 26: Purdue finale [modalità compatibilità]

Historic structures in Rome: the monoliths

13/3/2013Lorenzo Fedele Pagina 26

Page 27: Purdue finale [modalità compatibilità]

Historic structures in Rome: the monoliths

13/3/2013Lorenzo Fedele Pagina 27

Page 28: Purdue finale [modalità compatibilità]

Historic structures in Rome: the monoliths

13/3/2013Lorenzo Fedele Pagina 28

Page 29: Purdue finale [modalità compatibilità]

Historic structures in Rome: the monoliths

13/3/2013Lorenzo Fedele Pagina 29

Page 30: Purdue finale [modalità compatibilità]

Historic structures in Rome: the monoliths

SAPIENTIS AEGYPTIINSCVLTAS OBELISCO FIGURASAB ELEPHANTOBELLVARVM FORTISSIMAGESTARI QVISQVE HIC VIDESGESTARI QVISQVE HIC VIDESDOCVMENTVM INTELLIGEROBVSTAE MENTIS ESSESOLIDAM SAPIENTIAM SVSTINERE

Whoever sees here that the symbols of the Egyptian sage, inscribed on the obelisk, are carried by the elephant, the strongest of the beasts: understand that it is a proof of a robust pmind to sustain solid wisdom.

13/3/2013Lorenzo Fedele Pagina 30

Page 31: Purdue finale [modalità compatibilità]

Rome and Maintenance of historic structures• The public spending for the maintenance of historic/artistic structures is (2012)

– 53 Meuro0 003% of GNP (1500 Geuro)– 0,003% of GNP (1500 Geuro)

– X% of the value of the historic/artistic structures– For Industry: maintenance is at least the 4% of the value of the goods– For Health sector: maintenance goes from 8% to 19% of the value of the goods.g g

• What is the value of the Italian monuments (X)?– The brand value of some of the most famous Italian monuments is estimated at nearly 400 billion

euro* (but 2/3 of the archaeological sites are not surveyed).– It is a value that does not affect the tangible heritage but it is linked to the image and visibility of

the brand.

• Then the public spending for maintenance of Italian maintenance should be at least:

– 16 billion euro– 300 times of the present spending.

13/3/2013Lorenzo Fedele Pagina 31

Page 32: Purdue finale [modalità compatibilità]

Risk Map• The "Risk Map" is the geographic information system of scientific and administrative support to the

government agencies responsible for protecting the territorial and cultural heritage.

• For the construction of the risk model was adopted a statistical approach, based on which the individual assets are valued as a "unit" of a "statistical population" of which the aim is to assess the level of vulnerability and risk.

• The Risk factors have been divided into:- Individual Vulnerability (V), ie a function that indicates the level of exposure of a given item to the aggression of environmental and territorial factors

• - Territorial Hazard (P), ie a function that indicates the level of potential aggressiveness of a given geographical area, independently of the presence or not of historic structures.

• The ISO 31000 (2009) (“Principles and Guidelines on Implementation of risk management”)/ISO Guide 73:2002 (“Risk Management - Vocabulary”) definition of risk is the 'effect of uncertainty on objectives'.

13/3/2013Lorenzo Fedele Pagina 32

Page 33: Purdue finale [modalità compatibilità]

Risk Map• The search fields available are all self-explanatory and search clauses are linked by a relationship type

logic AND.

13/3/2013Lorenzo Fedele Pagina 33

Page 34: Purdue finale [modalità compatibilità]

Risk Map• Clicking on the voice Schede (cards) on the side menu you get the list of all cards associated with the

item selected. Such cards can also be selected in turn by clicking on the card identification code.

13/3/2013Lorenzo Fedele Pagina 34

Page 35: Purdue finale [modalità compatibilità]

Risk Map• Through the side menu you can navigate completely card information that are in a hierarchical/tree

structure.

13/3/2013Lorenzo Fedele Pagina 35

Page 36: Purdue finale [modalità compatibilità]

COVA, Crowd funding for cOnserving and

COVA is the project by Sapienza University which aims to enhance the minor

VAlorizing minor monuments

• COVA, is the project by Sapienza University which aims to enhance the minor assets of Italian cultural heritage through virtual models and augmented reality applications.

• The idea is designed to:– create digital reconstructions of monuments to monitor the state of conservation– to return the enjoyment of works otherwise inaccessible to the general public.

• The vital parameters for the preservation of monuments, obtained from wireless sensor networks, are received on tablets and other computing platforms, so to plan actions for protecting the sites and manage emergencies in real time.

• The digital model allows a remote user both a visit in 3d sites in its present state of preservation, and a journey into their history reconstructed.

13/3/2013Lorenzo Fedele Pagina 36

Page 37: Purdue finale [modalità compatibilità]

COVA, Crowd funding for cOnserving andVAlorizing minor monuments

• COVA site visits are enhanced by augmented reality apps that extend and enrich the sensory perception of the visitors with tourist information and culture.

g

• COVA technology is designed for those monuments that are not part of the main tourist circuits and are often relegated to the margins of cultural g gconsumption.

13/3/2013Lorenzo Fedele Pagina 37

Page 38: Purdue finale [modalità compatibilità]

Inside Rome: Rome door to East

• Eastern wind always caressed Rome and it blowed over the Tiber valley well before that within the seven hills was founded a city named Rome (4/21/753 bC).

• Magic and esoteric rituals always lived there with the ancient babylonic and egyptian culturesMagic and esoteric rituals always lived there, with the ancient babylonic and egyptian cultures.

• The Devil? It existed there well before that the Pope established.

• Rome? She was a young lonely and romantic girl gentle as a sea flower but so strong to strike the will of• Rome? She was a young, lonely and romantic girl, gentle as a sea flower, but so strong to strike the will of Aenea with whom, together with other Troyans, she escaped from the annihilation of Troy.Rome could use the art of magic, of love and of the other more deep and sacre human feelings.(Stesicoro, VI sec. b.C.).

10/1/2013Lorenzo Fedele Pagina 38

Page 39: Purdue finale [modalità compatibilità]

Inside Rome: Rome door to East

10/1/2013Lorenzo Fedele Pagina 39