|CAPACITY ASSURANCE STRATEGIES re Tee ee USMS Common Sense aT Maintenance MCAThs rice focuses on this type of arponch in reohingeome common maintenance Ung oe ‘minennc coe ang Thevoainbetr eee ‘titenocsdchion ling The betes ton of maintenance nc iproved equipment el ‘biny and incu compeny oe Silos, io, sos (Computerised Maintenance Management System), EAMs (Enerprie Aset Management msems) and CM have ws that inhibit heir elec; ere are some of these drawbacks—plus ugetons or ome, |LRCM peys ite atenion to historic data and is fen seen as competitive to the main historical dat source (the CMS) Any objective view, though, sees them complementary to each other. Howe for example, 0 beter tack the occurence frequency of RCM fare ‘modes tan ona CMMS work order? And how bet 0 start RCM analyisthanby examining flute modes tha, Ive actully occurred? The relation link RCM and CMS databases f 2.An RCM realty is that fare modet FMs) are not comprehensive; thee dependent on Wit sensi: ‘ppled by RCM snaps, Studie show thatthe gap Detween the FMs predicted and thote actualy observed ‘an be huge. Relig thir tation rears enhancing "the ROM databace by ein actual maintenance exer ec ast happens rom the CHS. Most ure naps pres the ture by looking back wards (Lathe CMMShisery), Thisapproach however, "ply omis, for example the RCM concep of poten th fares (PS). There are two exons forth Fst, the CMMS doesnot low for sich data to be cole, ‘Second, the tehnicans are not eine 6 ecognne acta Re Song this poten eal fr minor mada: to the MMS work order preessand modicamofraningat ‘the proverbial ol fe (ce for he working in dy day mattenance persion) 4.0M data should prompt intligent decion-making. “The steps ace involved. ist collect the right data (nd stop callecng the wrong data). Second, do the right analysis Third use the dita for making the right dei son In ou experience, upwards of 70% of the dt as ‘no predicive ait and, of coarse, key dss miing ‘A cited point i reution of the problem i that CM lata must reate to the fare mode the question is how to emorsrate this ‘SEPTEMBER 2008 CAPACITY ASSURANCE STRATEGIES Cease) ‘Thesimpl statement above uses a number ofa, 1 Which fates do we predict Refer to the objective of ‘maintenance “edi ale” and we "Cost faite ab the peimary determing factor, defined ee aeease stearate Penalty Costs, on Costs, Fines PAY} ered bation (inion ed seg rere rex) ne know tt an eget tae pay Ise repair cos Sey etonnentl ot poli brane ee So nee toe cto ins ede os ipl are cox report (ig that sey salneanes manages ‘Sold e o ihe ds ach mont Fig 1 Amsintecance mine sbaldrectve Sipe ‘singl ilrcost rope every month ‘That ype of report daws ou attention to the overall tof the faites eater than frequency and duration. ‘Bad Actor are redefined as"Bad Cost Actor” ronune.com (23ay CAPACITY ASSURANCE STRATEGIES 2. How dowe measure resitancet flr! Thi has rest ‘heoreial importance—bul asa praca ise ‘complecand not wel understood. By sabttating perfor mance” ta pron for"relstance oar the concept ‘Dxome simpler nd eae to underand As iltrated in Fig therefore,» 1000-GPM pur has "aed if it pars “ony” 999 gallons per minute (he required amount being necesary for fedtock supp cooing ‘Purpose, etc). Thus an instance of functional fare (FB) canbe gui defined and jut a ety recorded ‘on the work order, 4.2 Tho conoptt“portrncs” sour understand than escent alre” _2.Asperformance slides down the slippery scope of the PF ‘ate, the point of acteration in the tte of dreds tone fen clearly apazetin practic, thus suggerting the PF pla Acne can dene « ec ‘condition value forthe P pont (nthe Fig 2 ea ite1100 gon per minute) Using ePaper tion greatly eases data collection and analy: Equally Important the fact hat the PF acs as warning signal needing a malstenance response What if the PF and FF points are not predicable? ‘Or what if theyre denial? Les use eletonie and slectrieal equipment as an example. The PF and FF points cleat exs—but are simultaneous, Condition ‘monitoring will not help excep o advise of complete fare Here, we tespond wih standby uns, pug-out gin placements nd sir techniques-(Note the ‘Sagar in Fig 3) Stow does age Bt into the equation? As Nowlan and Heap pointed outage deel impact fare in only 2 all umber of ser. et intitivey, we el hat ae 24) wanTenance TEcaNOLOGY 3. Conon nostro wil at blp when PE ad FF nr apredcabie rental an lnportant factor AS an aleratv lets define ia "wothing ge” This has wo implications for poy of failure: bad and stress neptve) and aut orice Sa te Ln on dca eh swe deta to operating hous hgh equls tot time ‘minus outof-service time). Thi" equires us to record “pensions” on the work ble (aba alteratie @ 2 ProranF. 9 6 Hom dower the multe sears ofCM dato the we nse Proprtonl Hats Moding ee tcl showing which veal bare rece ipa on th fate ode ih te ie pone Techie it no EXAKT, 1 proc devloped by Dr Aten Jasin tthe ‘aie oan Repent we of hs tool a Shr mot CM dat a le norton he Incidence of fle and th, ame gore preicorSck dt doesnt wed colin ya ‘chr wrtng og nd oe coin veri re frequen nising 7am predicting fale, the predictive ability of Co data ‘st be acre and content. EXAKT achies this by providing probaly of fallure in «given period (Completion of» mission, prioe to « mainunance shutdown, ete), and applying statistical test showing ‘onfdenclevels Relating the thee elements of flare probability confidence levels and cot of falure proves Song insght into the “bes” maintenance tac 12 follow Low confidence levels prompt both conservative sexion (6 preempt the FF point) and enhanced data ‘collection, specially when the cos flares high ‘Sepreween 20aa CAPACITY ASSURANCE STRATEGIES eat oe These shortcomings of CM asa trv predictor of file rrompt the development of a beter apposch. The ‘gueedoutput bimproved eelabityanalsrbt here tre akeny many eee ella tol on the ‘aah Whats the mising a? Let lt relablity ‘nbase—olleting and holding the many data inputs randy for the analy Relablydetabose Key to he elblty database oe the sources of data Here is aproposed structure: 1. Historical data—primaiy rom the CMMS—but with smple modifications tothe work ode to accommodate themising FR, PFand Suspersiondata Also asexplained er thie ade a cos eference tothe appropriate BEM htabase record. 2 Garren status data—primaiy from the CM sensors “These il ie us (long with PLCs SCADA and others) the beating nto the current equipment condition. ta. These willl ws which fares should expected bated on equipment asessment ‘operating coer asin the RCM database “p accommodate these data sources, Living RCM (LRCM) software (a shown in Fig 4) as been devel- opel I links the dita soures and acts a a data tac ‘op cole, cleansing and toring the dat create « relly database. This the feedstock for commer rely tool (sch s EXAKT and other). > Fi, Ug REM software inks data sore an ac ade tre cop, collecting clenig ad trig data to crete # reli databan Using logic, statistics and ‘well-accepted techniques, we can improve maintenance decision-making. ater, weliked the RCM and CMMS databases. These are lay complementary in prompting a beter snder nding of fare and reablty. Contrary t common practic, the best output ofan RCM anal snot sty tomes in the engnering office, bu an Improved work order Sars attctoryoutps of «work order ean improved RCM recorder the work ads new nowt ‘ge oF anew flue mae Looking atthe activity flow in ig 5, the advantage of inegrating CMMS and RCM are lie eident: 1. Inspection romp identi of til fares » ee rec (ert, an on-thespot emi reventive action} 22a Neely deed prewntecn ph ae ete ion failure, we need to challenge the value of mw 4 LRCM prompts the tedtnician completing the work ‘order not to use the pial Fault Code (he vale of thick is highly questionable, and in our experience ‘arly ued), bt rather te acces the lure mode inthe ROM database and insert in the work order. “significant” tak alde to our knowledge (eg. new fire mode or new eee compared tothe RCM record), «temporary record is erated by LRCM and awaits validation by the ECM analysis team (6 Add the RCM record number to record the occurrence and frequency ofthe REM lure mode—e very vale ahleanalysisaid 7. Binal an unexpected ocarrence of failure mode in rita equipment demands several responses therepie ofthe equipment the repair ofthe REM record AND the epi ofthe RCM logic AND all the other records that used the sume log ase of access the RCM dts ‘base om the CMMS thes becomes crcl to creating s regime of Living Reliab,CAPACITY ASSURANCE STRATEGIES oes maitonancs improvement actully happen? The bottom linet Does application of the techniques described here ad vale —doritimprove deo making? Here are sever indore . Ue rep. The cost model optimies the eStbination ‘of preventive work and runt allure, compared to the ‘current mie of maintenance tactics A second modeling ‘option provides the optimum balance of PM and run {o fade (RT) to achieve the minimum downtime or (eodel thre) to achieve a given minima evel of rel bility. Indatral experience shows cot redacsone of, ‘shout 20% to 46 of curent maintenance cost ung {he customer cost at athe buen Subetential cost reduction certains achierable 21 the qualy of maintenance improved? Refer to one ‘of RCM fandamentas A hey insight isthe ue of PFs to prevent Fema easly measurable and sfchacking [PL hich sb int the nai program would bes ‘emarlable improvement if our vibration sna or i tnalyis programs could tel ur whether they ae doing ‘hai job propery Or not 26| MANTENANCE TECHNOLOGY Fi. § The advantages ligating CMM and RCM ae gue evident. 2. Von ming prod neve hi "lade flowing bese gk Sorrow pay o eo eT ees ee downgncnatca tele ena” un Risk = Cos of Failure x Probability of Failure ‘Nox, calculate the PM cost (sing paral! loge, but ferent cot number) ines the probably of doing ‘the PM (whichis 10%), We an then define he"PM. Rik” ‘PM Risk = PM Cost x 100% «By comparing the Rn Risk the PM Risk we can deep Rain isk Ratio = Ratio of Run Risk to PM Risk ‘Wie can now decide whether «$40,000 investment in 2 PM to avoid the Rn Risk of $200,00 (comprising 22336 probabil of an $800,00 flare) is» good decision —a ‘Rk Ratio of 51. Or, should we spend $360.000 to eli SEPTEMBER 20085) eri ___CAPACITY ASSURANCE smearzcs A ; The result is better selection of maintenance tactics, improved | equipment reliability and increased company value. ‘aethe 15% probabiityofariskot1 33 milion falure—a__Adalogialnecatep wecanetabishif tek Ra (atis + Risk Rati of 1.1 (se Fy 6) tisappzent tat thehigher ce) litte npr ns poi Inadidon, || the Rsk Ratio the grever the PM's leverage in reducing by racking change inthe Reka troughtine (Fg iwe || | tisk Likewise the highe the PMS ROL, the more value ster the ne cede hutdown o end fhe on, eed othe company ‘whether th Rk ai rend eens opting Frames mnie — ina teponer = |e ae (og) SE 5S i faeces ae sleneene peal | efi ik Ue mi cet Tine Oa. fet | mie SoS A mo om el] | vali adtaa te fenpem. 2K days 1 ame TOS BE ne eer PMI SENSORS Taltrontush atte Heer tne We stand! hehind ALL of our protucts! SEPTEMBER ate MronuNe.com 127DR caraciry In other words, if it does net add value, don't do it. a ia ‘Shutdown Date en | fl B : Voces | ae i> busines lope leads to msntenance improvements tod heed elgg: cot: Pong an cbeie name of ba new ks ofgarong fundaton for improved decor ang: Eh Sep ib saighforvard and ean be plemented wih nial cane oan (ching Sade pos: Moret wh each Fen we pt coe ose i “hats to done Garb that maimeance says prove of baie MT ‘Ben Stevens is present of OMDEC Inc, bused in Godfey, ON, Canada OMDEC (Optimel Maintenance Decions Inc) provider axet management ‘onlin taining and sofware solutions for Cents around tke globe. E-mail ‘ecereacn sce