Working togetherfor a safer world

Vessel Maintenance and Dry Docking Session 8A

The Classification Society View

John W McKain BSc(Hons) CEng FRINA MIESIS

Asia Marine Engineering Conf 2015 Riviera Maritime

Lloydrsquos Register today

+60000

Clients from SMEs to

Fortune 500 companies

3

Business

divisions

+8500

Employees

worldwide

pound1 billion

Turnover

3

Regions

Asia Marine Engineering Conf 2015 Riviera Maritime

Has Industry Learned or Developed Maintenance Practices

Does the industry really want to improve efficiency

Are choices being Ignored

Asia Marine Engineering Conf 2015 Riviera Maritime

Lloydrsquos Register Marine What is Classification

bull The development and implementation of Rules and

Regulations which together with proper care and conduct by

the owner and operator will provide for

bull Structural strength and watertight integrity of the hull

and its appendages

bull Safety and reliability of propulsion and steering

systems

bull Effectiveness of other features and auxiliary systems to

maintain conditions on board whereby cargoes and

personnel can be safely carried

bull Additionally Consultancy services outside of ClassEngine Control Room

Asia Marine Engineering Conf 2015 Riviera Maritime

Classification ndash What is not covered

Design and manufacturing processes

Type and power of machinery and certain equipment (eg winches)

Number and qualification of crew or operating personnel

Form and cargo carrying capacity of the ship and manoeuvring performance

Spare parts

Life-saving appliances and maintenance equipment

Further Optional Areas to consider to enhance

Planned Maintenance (MCM Notation)

Condition Based Monitoring (MCBM)

Machinery Planned Maintenance (MPMS)

Reliability Centred Maintenance (RCM)

Many options covered by

non mandatory Class

Notations and Marine

Consultancy outside of

Classification

Asia Marine Engineering Conf 2015 Riviera Maritime

Dry Docking Scheduling and Extending

Increased flexibility in choosing the dry docking window and potential for the hull to stay in

water for 7 frac12 years (EDD)

Approval to the scheme is flag and owner specific

Suitable for most ship types except ESP vessels and Passenger vessels

Applicable to vessels up to 15 years of age

Vessel to have been operated by same company from new and always an IACS member

Certain conditions must be met

Asia Marine Engineering Conf 2015 Riviera Maritime

Planned Maintenance

Planned Maintenance Schedule (PMS)

bull ldquoCompared to work performed as needed Preventive

Maintenance conducted at arbitrary intervals is often

unnecessary overly expensive and labour intensiverdquo

Statistically Speaking

bull ldquoAs much as one-third of scheduled PM expenditures are

unnecessaryrdquo

bull ldquohellip50 of scheduled PM tasks have essentially no

valuerdquo

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Lloydrsquos Register today

+60000

Clients from SMEs to

Fortune 500 companies

3

Business

divisions

+8500

Employees

worldwide

pound1 billion

Turnover

3

Regions

Asia Marine Engineering Conf 2015 Riviera Maritime

Has Industry Learned or Developed Maintenance Practices

Does the industry really want to improve efficiency

Are choices being Ignored

Asia Marine Engineering Conf 2015 Riviera Maritime

Lloydrsquos Register Marine What is Classification

bull The development and implementation of Rules and

Regulations which together with proper care and conduct by

the owner and operator will provide for

bull Structural strength and watertight integrity of the hull

and its appendages

bull Safety and reliability of propulsion and steering

systems

bull Effectiveness of other features and auxiliary systems to

maintain conditions on board whereby cargoes and

personnel can be safely carried

bull Additionally Consultancy services outside of ClassEngine Control Room

Asia Marine Engineering Conf 2015 Riviera Maritime

Classification ndash What is not covered

Design and manufacturing processes

Type and power of machinery and certain equipment (eg winches)

Number and qualification of crew or operating personnel

Form and cargo carrying capacity of the ship and manoeuvring performance

Spare parts

Life-saving appliances and maintenance equipment

Further Optional Areas to consider to enhance

Planned Maintenance (MCM Notation)

Condition Based Monitoring (MCBM)

Machinery Planned Maintenance (MPMS)

Reliability Centred Maintenance (RCM)

Many options covered by

non mandatory Class

Notations and Marine

Consultancy outside of

Classification

Asia Marine Engineering Conf 2015 Riviera Maritime

Dry Docking Scheduling and Extending

Increased flexibility in choosing the dry docking window and potential for the hull to stay in

water for 7 frac12 years (EDD)

Approval to the scheme is flag and owner specific

Suitable for most ship types except ESP vessels and Passenger vessels

Applicable to vessels up to 15 years of age

Vessel to have been operated by same company from new and always an IACS member

Certain conditions must be met

Asia Marine Engineering Conf 2015 Riviera Maritime

Planned Maintenance

Planned Maintenance Schedule (PMS)

bull ldquoCompared to work performed as needed Preventive

Maintenance conducted at arbitrary intervals is often

unnecessary overly expensive and labour intensiverdquo

Statistically Speaking

bull ldquoAs much as one-third of scheduled PM expenditures are

unnecessaryrdquo

bull ldquohellip50 of scheduled PM tasks have essentially no

valuerdquo

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Has Industry Learned or Developed Maintenance Practices

Does the industry really want to improve efficiency

Are choices being Ignored

Asia Marine Engineering Conf 2015 Riviera Maritime

Lloydrsquos Register Marine What is Classification

bull The development and implementation of Rules and

Regulations which together with proper care and conduct by

the owner and operator will provide for

bull Structural strength and watertight integrity of the hull

and its appendages

bull Safety and reliability of propulsion and steering

systems

bull Effectiveness of other features and auxiliary systems to

maintain conditions on board whereby cargoes and

personnel can be safely carried

bull Additionally Consultancy services outside of ClassEngine Control Room

Asia Marine Engineering Conf 2015 Riviera Maritime

Classification ndash What is not covered

Design and manufacturing processes

Type and power of machinery and certain equipment (eg winches)

Number and qualification of crew or operating personnel

Form and cargo carrying capacity of the ship and manoeuvring performance

Spare parts

Life-saving appliances and maintenance equipment

Further Optional Areas to consider to enhance

Planned Maintenance (MCM Notation)

Condition Based Monitoring (MCBM)

Machinery Planned Maintenance (MPMS)

Reliability Centred Maintenance (RCM)

Many options covered by

non mandatory Class

Notations and Marine

Consultancy outside of

Classification

Asia Marine Engineering Conf 2015 Riviera Maritime

Dry Docking Scheduling and Extending

Increased flexibility in choosing the dry docking window and potential for the hull to stay in

water for 7 frac12 years (EDD)

Approval to the scheme is flag and owner specific

Suitable for most ship types except ESP vessels and Passenger vessels

Applicable to vessels up to 15 years of age

Vessel to have been operated by same company from new and always an IACS member

Certain conditions must be met

Asia Marine Engineering Conf 2015 Riviera Maritime

Planned Maintenance

Planned Maintenance Schedule (PMS)

bull ldquoCompared to work performed as needed Preventive

Maintenance conducted at arbitrary intervals is often

unnecessary overly expensive and labour intensiverdquo

Statistically Speaking

bull ldquoAs much as one-third of scheduled PM expenditures are

unnecessaryrdquo

bull ldquohellip50 of scheduled PM tasks have essentially no

valuerdquo

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Lloydrsquos Register Marine What is Classification

bull The development and implementation of Rules and

Regulations which together with proper care and conduct by

the owner and operator will provide for

bull Structural strength and watertight integrity of the hull

and its appendages

bull Safety and reliability of propulsion and steering

systems

bull Effectiveness of other features and auxiliary systems to

maintain conditions on board whereby cargoes and

personnel can be safely carried

bull Additionally Consultancy services outside of ClassEngine Control Room

Asia Marine Engineering Conf 2015 Riviera Maritime

Classification ndash What is not covered

Design and manufacturing processes

Type and power of machinery and certain equipment (eg winches)

Number and qualification of crew or operating personnel

Form and cargo carrying capacity of the ship and manoeuvring performance

Spare parts

Life-saving appliances and maintenance equipment

Further Optional Areas to consider to enhance

Planned Maintenance (MCM Notation)

Condition Based Monitoring (MCBM)

Machinery Planned Maintenance (MPMS)

Reliability Centred Maintenance (RCM)

Many options covered by

non mandatory Class

Notations and Marine

Consultancy outside of

Classification

Asia Marine Engineering Conf 2015 Riviera Maritime

Dry Docking Scheduling and Extending

Increased flexibility in choosing the dry docking window and potential for the hull to stay in

water for 7 frac12 years (EDD)

Approval to the scheme is flag and owner specific

Suitable for most ship types except ESP vessels and Passenger vessels

Applicable to vessels up to 15 years of age

Vessel to have been operated by same company from new and always an IACS member

Certain conditions must be met

Asia Marine Engineering Conf 2015 Riviera Maritime

Planned Maintenance

Planned Maintenance Schedule (PMS)

bull ldquoCompared to work performed as needed Preventive

Maintenance conducted at arbitrary intervals is often

unnecessary overly expensive and labour intensiverdquo

Statistically Speaking

bull ldquoAs much as one-third of scheduled PM expenditures are

unnecessaryrdquo

bull ldquohellip50 of scheduled PM tasks have essentially no

valuerdquo

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Classification ndash What is not covered

Design and manufacturing processes

Type and power of machinery and certain equipment (eg winches)

Number and qualification of crew or operating personnel

Form and cargo carrying capacity of the ship and manoeuvring performance

Spare parts

Life-saving appliances and maintenance equipment

Further Optional Areas to consider to enhance

Planned Maintenance (MCM Notation)

Condition Based Monitoring (MCBM)

Machinery Planned Maintenance (MPMS)

Reliability Centred Maintenance (RCM)

Many options covered by

non mandatory Class

Notations and Marine

Consultancy outside of

Classification

Asia Marine Engineering Conf 2015 Riviera Maritime

Dry Docking Scheduling and Extending

Increased flexibility in choosing the dry docking window and potential for the hull to stay in

water for 7 frac12 years (EDD)

Approval to the scheme is flag and owner specific

Suitable for most ship types except ESP vessels and Passenger vessels

Applicable to vessels up to 15 years of age

Vessel to have been operated by same company from new and always an IACS member

Certain conditions must be met

Asia Marine Engineering Conf 2015 Riviera Maritime

Planned Maintenance

Planned Maintenance Schedule (PMS)

bull ldquoCompared to work performed as needed Preventive

Maintenance conducted at arbitrary intervals is often

unnecessary overly expensive and labour intensiverdquo

Statistically Speaking

bull ldquoAs much as one-third of scheduled PM expenditures are

unnecessaryrdquo

bull ldquohellip50 of scheduled PM tasks have essentially no

valuerdquo

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Dry Docking Scheduling and Extending

Increased flexibility in choosing the dry docking window and potential for the hull to stay in

water for 7 frac12 years (EDD)

Approval to the scheme is flag and owner specific

Suitable for most ship types except ESP vessels and Passenger vessels

Applicable to vessels up to 15 years of age

Vessel to have been operated by same company from new and always an IACS member

Certain conditions must be met

Asia Marine Engineering Conf 2015 Riviera Maritime

Planned Maintenance

Planned Maintenance Schedule (PMS)

bull ldquoCompared to work performed as needed Preventive

Maintenance conducted at arbitrary intervals is often

unnecessary overly expensive and labour intensiverdquo

Statistically Speaking

bull ldquoAs much as one-third of scheduled PM expenditures are

unnecessaryrdquo

bull ldquohellip50 of scheduled PM tasks have essentially no

valuerdquo

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Planned Maintenance

Planned Maintenance Schedule (PMS)

bull ldquoCompared to work performed as needed Preventive

Maintenance conducted at arbitrary intervals is often

unnecessary overly expensive and labour intensiverdquo

Statistically Speaking

bull ldquoAs much as one-third of scheduled PM expenditures are

unnecessaryrdquo

bull ldquohellip50 of scheduled PM tasks have essentially no

valuerdquo

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

How do we maintain assets

First Generationbull Fix it when it Breaks

Second Generation

bull Scheduled Overhauls

bull Systems for planning

and controlling work

bull Big Slow computers

Third Generation

bull Condition Monitoring

bull Design for reliability and

maintainability

bull Hazard studies

bull Small fast computers

bull Failure Modes and

effects analyses

bull Expert systems

bull Multi skilling and

teamwork

Fourth Generation

bull Data Lead

bull Algorithm Based

bull Remote Monitoring

bull External experts

bull Assurance Driven

bull Compliance +

bull Business Aligned

1940 1950 1960 1970 1980 1990 2000

The skill for the modern

maintenance strategist is to

define the optimal mix of these for

any given asset base

Changing maintenance

techniques

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Maintenance Scheme Comparison Table

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Journey from Repair Focused to Reliability Focused culture

Regressive

Reactive

Planned

Improved

Precision

World Class

Rewards

Driver

Behaviour

Staged Decay Short term

savings

Meet Budget

Decaying

Overtime Heroes

Breakdowns

Responding

No Surprises

Competitive

Avoid Failures

Planning

Competitive

Advantage

Uptime

Org Discipline

Best in Class

Growth

Org Learning

-Predict

-Plan -

Schedule -

Coordinate

-Cost focus

-Eliminate

Defects

-Improve

Precision

-Redesign

-Value Focus

-Alignment (shared

vision)

-Integrating (supply

logistics Prod mktg)

-Differentiating (new

system performance)

-AlliancesPerf

orm

an

ce M

easu

res

Donrsquot Fix It

Fix it after

it breaks

Fix it before it

breaks

Donrsquot Just Fix It

Improve It

Innovation

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Machinery Condition Based Maintenance -

(ShipRight MCBM Descriptive Note)

bull Machinery maintenance procedures on a

Condition Based Maintenance scheme

(MCBM) basis of Criticality and

Probability of Failure

bull The maintenance system is based

around condition monitoring with due

dates for maintenance removed

bull Maintenance and survey inspections will be based on Condition Monitoring Results

bull Lloydrsquos Register will accept this approach for survey purposes providing certain requirements

for operation of the scheme are met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

RCM ndash Structured approach to developing a maintenance strategy

bull Defining the maintenance strategy

bull Creating the asset register

bull Prioritising through criticality assessment

bull Identification of maintenance task and frequency

bull Carrying out the maintenance task

bull Recording the results

bull Assessing effectiveness of task

bull Right people right processes and right time

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Reliability Centred Maintenance -

(ShipRight RCM Descriptive Note)

bull Machinery maintenance procedures on the results of a Reliability

Centered Maintenance study

bull The study looks at machinery Reliability Criticality and Failure

Modes and from there the maintenance system is optimized to

ensure that Maintenance is Only Conducted When Required

bull Lloydrsquos Register will accept this approach for survey purposes

providing certain requirements for operation of the scheme are

met

bull Office audits of the scheme records and methodology are required

bull The ship must be operating an approved Machinery Planned

Maintenance Scheme

Asia Marine Engineering Conf 2015 Riviera Maritime

Conclusion Are Choices being Ignored

bull Relying on old methods costs time and money and can also

affect company image and reliability

bull Proper planning and involving Class can reduce down time

bull Investing in new methodologies can give benefits

bull Class will accept various methods for machinery and

component monitoring

bull Owners reluctant to take on new methods as benefit not clear

bull We can make a difference in efficiency and avoid those choices

of repeat mistakes

bull Is the industry misguided or just reluctant

Lloydrsquos Register and variants of it are trading names of Lloydrsquos Register Group Limited its subsidiaries and affiliates

Copyright copy Lloydrsquos Register Asia October 2015 A member of the Lloydrsquos Register group

John W McKainBSc(Hons) CEng FRINA MIESIS

Shipowner Newbuilding Support (SNS) Manager (SNS Service)

Regional Consultancy Project Manager

T +65 3163 0580

E johnmckainlrorg

Lloydrsquos Register Asia

1 Fusionopolis Place 09-11

Galaxis Singapore 138522

Working togetherfor a safer world

Lloydrsquos Register and variants of it are trading names of Lloydrsquos Register Group Limited its subsidiaries and affiliates

Copyright copy Lloydrsquos Register Asia October 2015 A member of the Lloydrsquos Register group

John W McKainBSc(Hons) CEng FRINA MIESIS

Shipowner Newbuilding Support (SNS) Manager (SNS Service)

Regional Consultancy Project Manager

T +65 3163 0580

E johnmckainlrorg

Lloydrsquos Register Asia

1 Fusionopolis Place 09-11

Galaxis Singapore 138522

Working togetherfor a safer world