Asset Lifecycle– Design andMaintenance
John Hunter
MAV Conference
30 May 2013
Ability to Influence
Time in the asset’s life cycle
Abi
lity
to in
fluen
ce
Concept / Preliminary Design
Maintenance
Design / Specification
Procurement / Construction
Commissioning and handover
Operations Renewal
Design for…• Maintainability• Reliability• Durability• Quality• Deconstruction• Safety• Waste prevention• Positive social and environmental impact
Design for MaintainabilityDesigning features to allow ease of maintenance.
Advantages – Low downtime, continuous LoS.
Examples:• Grass cutting and steep slopes• Co-locating into single areas• Accessibility - light poles• Bio-retention devices• Standardisation
Design for Reliability
Designing assets to minimise downtime
Advantages - Repeatable uninterrupted LoS.
Examples:• Sealed roller bearings to prevent dust ingress• Traffic signals with diagnostic capabilities• Fibre optic network with redundant paths
Design for Durability
Failure-free / maintenance-free operating.
Advantages – Long time to renewal.
Examples:• Galvanise / paint / powder coat / stainless• Add asphalt additives in plant to counter UV R• Downpipes – S/S.• External cladding on Bus Depot Buildings
Design for Quality
Totality of features to satisfy needs of users.
Advantages – Lean; negate rework and 10X rule
Examples:• QA in design, materials, construction.• No defects; no rework• Fit for purpose and meets service levels.
Design for Deconstruction
An opportunity to salvage / reuse components.
Advantages - Ease of disassembly.
Examples:• Fixing mechs, welding / bolting / adhesives• Potential for future reuse / recycling• Prefabric’n rather than permanent structures• USA – C&D represents ~ 25% landfill waste
Design for Safety
Mitigate / minimise safety risks.
Advantages – protect community and staff
Examples:• Construction, maintenance, operation• Locate cabinets away from roads• Bike-safe storm water grates• Non-slip materials
Design for Waste Prevention
Minimise waste at each asset life cycle phase
Advantages – Sustainability
Examples: • Services share same trenches if possible• Group wet areas together - save pipe lengths• Reduce, e.g. water, electricity• Reuse, e.g. Brisbane tuff kerb stones• Recycle, e.g. asphalt
Design for Positive Social, Environmental and Economic Impacts
Advantages – To contribute positive impacts to social, environmental and economic wellbeing.
Examples:• Sustainability – now and the future• Green star ratings• Meet a range of targets.
Design Collaboration
• Design• Procurement• Construction• Operations• Maintenances• Service Users
Here’s what we can do
• Think long term• Simplify• Carry a notebook• Implement practical solutions• Involve others
Here are some questions to ask
• “How can I / we make a whole-of-life difference with this design?”
• “Who do I need to involve?”• “What’s possible?”
What are the take home messages?
• Design has the single biggest impact on the assets’ WOL costs and serviceability.
• Design can impact for 10, 100 years and more.• We have the opportunity to create the future• - What can you do differently in your design?
Steve Job’s mantra
Design is not about how things look.
Design is about how things work.
The big difference - outcomes.
Internet sites (Design for…)
Maintainabilityhttp://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Maintainability.pdf
Safetyhttp://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Reliability.pdf
Manufacturinghttp://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Manufacturing.pdf
Deconstructionhttp://www.deconstructioninstitute.com/files/downloads/75508728_DesignforDeconstructionPaper.pdf
Asset Lifecycle - Maintenance
Maintenance is “end of pipe”
Time in the asset’s life cycle
Abi
lity
to in
fluen
ce
Concept / Preliminary Design
Maintenance
Design / Specification
Procurement / Construction
Commissioning and handover
Operations Renewal
Maintenance
“If all you have is a hammer, every problem looks like a nail.”
Maintenance Overview
1. Detect 2. Prevent. 3. Remediate
Performance
Inherent Reliability – How the asset was designed. We cannot change reliability unless by re-designing or replacing with better parts
Operating environment – How it will be operated. ~ 40% of failures are due to Operator handling.
Maintenance – Detect, prevent, remediate
Performance Indicators
Leading Indicators
Forward looking (windscreen). Allows us to examine the process.
Lagging Indicators
Backward looking (rear-vision). Allows us to measure the output of a process.
Condition ratings
Condition Rating
Description of Condition
1 Very good condition – Only normal maintenance required
2 Minor defects only – Minor maintenance required (5%)
3Maintenance to enable an asset to provide an acceptable level of service – Significant maintenance required (10% - 20%)
4 Requires renewal – Significant renewal/upgrade required (20% - 40%)
5 Asset unserviceable – Over 50% of the asset requires replacement
P-F Curve
Planning and Scheduling
P P A A A A A
P A A P A A P A A P A A A A
Maintenance Contracts
Inspection – such as checking for wear and tear, breakage and reporting back.
Preventive – e.g. In a building or P&E, calibrating building plant or lubricating.
Full labour – 100% labour coverage, but no materials cover.
Full coverage – 100% coverage for labour, parts, materials and breakdowns.
Lean
Seven wastes
• Overproduction
• Waiting
• Transport• Motion
• Over-processing
• Spare parts
• Defects
5S Housekeeping
• Sorting – Keep only the tools essential for your job.
• Setting in Order – Arranging tools to eliminate time working with them.
• Shine – Keep workplaces clean, tidy and organised.
• Standardising – Systemise activities where possible.
• Sustaining – Maintain new standards and do not allow to lapse.
Sustainability
• Designing for maintainability• Design for reliability• Design for durability• Design for quality• Design for safety• Design for Deconstruction• Design for Waste prevention• Design for positive social impact
Concluding
Design
Pre - acquisition
Maintenance
Post – acquisition
Opportunities
Questions?