Allied Reliability Phase II EMP Development Overview (March 2009)

Asset Reliability OverviewAsset Reliability OverviewAsset Reliability OverviewAsset Reliability Overview

Allied ReliabilityPhased Approach to a Successful Reliability Initiative

Copyright 2007 Allied Reliability, Inc.

Presented by:

Chris ColsonWhat would you do

with more free time?


Agenda

• Who is Allied

• Overview of Approach


• Overview of Tools

• Questions / Answers


Allied’s Reliability Success Formula



Impact of a Complete Reliability Initiative

Bu

sin

ess

Pro

cess

an

d

Cu

ltu

re M

atu

rity

+27%• Improved Bottom

Line Performance

• Lack of System

Support

High

+75%• Significantly Improved

Bottom Line

Performance

• Practices and Systems

Aligned


Technology Maturity

Bu

sin

ess

Pro

cess

an

d

Cu

ltu

re M

atu

rity

Source: Brynjolfsson (MIT), Wireman, Troyer, Allied

LowLow

Aligned

Baseline •Informal

• Manual Planning

Processes

• Below Average

Business Performance

-7%• Systems are not

Complemented by Effective

Business Processes

• Significant Inefficiencies

High




Eliminate ALL Manufacturing Wastes…

RatifyDevelop

PrioritizedImprovement

Plan

Identify

Internal and

External Non

Value-Add

And Wastes

Create andEducate Process

ImprovementTeam (PIT)

Conduct FMEA Blitz

Known

Problem or

Value Stream

Mapping

(VSM)

Recognize

Transformational Analytics – “5-R” Improvement Process

Focused Improvement the Allied Reliability Way…

(Baseline)PR Plots

Rationalize

PR Simulation

and/or Reliability

Modeling

OverproductionOverproductionTransportingTransporting


Realize

Train To NewProcess

Audit/MonitorContinually

Sustain the Gains…

DocumentNew Process

Quality

(All Defects)

WaitingWaiting

MotionMotionInventoryInventory

Resolve

RCA

RCM

FMECA

ProcessingProcessing


Allied Reliability – Overall AHA Workstream

Asset Registry Module Asset Analysis Module Asset Integration Module

Installed

Component

Verification

Equipment

Maintenance

Plans (EMP’s) Phase

Asset

Definition

Asset

Criticality

AnalysisTechnology

Sourcing

Strategy

RCM

Analysis

(top 5-20%)


Plans (EMP’s) Phase

3

Asset

Hierarchy

Failure

Mode

Analysis

Technology

Standards

OP1 & OP2

(top 5-20%)


Asset Registry Module

Goals:•Defines criteria for Asset selection

•Identifies desired attributes by Asset type

•Uncovers Asset types requiring

Failure Mode Analysis (FMA's)

•Verify/identify installed Components

•Creation of logical system to

Asset structure

Deliverables:•Accurate Asset count

•Complete hierarchy for Assets

Benefits:•Increased planning efficiency due to

hierarchy structure

•Increased scheduling efficiency due

to hierarchy structure

•Hierarchy provides added granularity

when criticality performed

•Components tracking through tagging

and functional location

•Improved cost tracking through

hierarchy structure

•Increased MRO efficiency through

accurate Asset list

Asset Registry Module

Installed

Component

Verification

Asset

Definition


•Complete hierarchy for Assets

•Component change control through tracking

•Multiple level cost tracking

•Attribute data for Asset

repairs/replacement

•Logical functional location

•Hierarchy template for CMMS upload

•Targeted seminars supporting

reliability program

•Site support for installed processes

accurate Asset list

•Improved CMMS through addition

of hierarchy structure

Asset

Hierarchy


Allied Reliability Phase 2 – Workflow

Asset Analysis Module

Goals:•Rank Assets using multiple criteria

•Refines planning and scheduling

•Refine Maintenance, Repair and Operational

Assets (MRO)

•Categorize failure modes

Deliverables:•Ranked Asset list

•Defined failure modes for Asset types

•Attribute template for CMMS upload

•Targeted seminars supporting reliability

program

Benefits:•Additional scheduling efficiency through

use of Asset ranking

•Input to critical spares through

Asset criticality

•Further CMMS improvement by

addition of attribute & criticality

•Improved MRO function through

use of CMMS data

•Ability to prioritize failures and create

“bad actors” list

Asset Analysis Module

Asset

Criticality

Analysis

RCM

Analysis

(top 5-20%)


program


Failure

Mode

Analysis

(top 5-20%)


Allied Reliability Phase 2 – Workflow

Asset Integration Module

Goals:•Apply failure modes to Assets

•Select Asset coverage model

•Facilitate condition monitoring

sourcing strategy

•Identify PdM/PM gaps

•Create condition monitoring

operational procedures

Deliverables:•Equipment Maintenance Plan for in

scope Assets

Benefits:•Engineered equipment

maintenance plans (EMP’s)

•Further planning efficiency gains

through EMP’s

•Additional CMMS gains through

creation of PdM & PM tasks

•Consistent measures and

reporting across technologies

•Identify PM’s required to address

Asset failure modes

Asset Integration Module

Equipment

Maintenance

Plans Phase

Technology

Sourcing

Strategy


scope Assets

•Coaching/Mentoring template

development for PM’s that address

targeted failure modes

•Documented and maintainable

equipment maintenance plan

•Condition monitoring (CM)

operational standards

•Recommended condition monitoring

sourcing strategy

•Targeted seminars supporting

reliability program


Plans

(EMP’s)Phase

3

Technology

Standards

OP1 & OP2


Processes and Tools

• Based on the collection of Best Practices

• Built by “Users”

• Integration Theme

• Enforces Discipline to Standards

• Drives Transparency


• Drives Transparency


Walkdown Tool



Walkdown Tool – Component Mapping



Walkdown Tool-Attribute Entry



Criticality Tool



Criticality Tool- Category Management



Criticality Tool-Ranking



Asset Health Matrix (AHM) Tool



AHM-Component Management



AHM-Failure Mode Management



AHM- CBM Technology Coverage



AHM-Coverage Model



RCM Blitz Tool



RCM Blitz



RCM Blitz - FMECA



PM Evaluation Tool



PME Tool

•A PM recommendation sort

is applied.

•A PM classification sort is

applied.


is applied.

•Comments are added to

clarify recommendations

and classifications.


PME Tool – Sample Summary Output

PME Classification Total Number %

Administration & Safety 4342 64.39%

Asset Care 491 7.28%

Inspection 1405 20.84%

Quantitative PM 464 6.88%

Regulatory 3 0.04%

Time Based Replacement 38 0.56%


PME Recommendation (Without Safety tasks) Total Number %

No Changes 653 27.20%

No Value Added (Delete) 313 13.04%

Re-Engineer 883 36.78%

Replace with PdM or NDT 552 22.99%


Developing Effective Work Procedures Tool



What is required in a procedure?



Driving consistency in procedures



DEWP Tool



Questions?


Questions?