Improved

Reliability
through
PM Optimisation
Project Team:
Electrician
Planner
Mechanic
Operator
Reliability Engineer
Facilitator: Steve Turner 1
PMO2000™ www.reliabilityassurance.com
Why investigate the Residue Cell C’s

 PM Optimisation will fall in line with the business

plan for the Site.
 The only cost centre in the plant consistently
over budget.
 Opportunity to improve reliability as Cell C’s
have highest failure rate in the area.
 Opportunity for more consistent performance to
meet plant expansion plans.
 The experience is that there is more work in the
area than there are people assigned.
PMO2000™
Objectives

 Better focus of PM schedules.

 Increase the quality of maintenance.
 Understand the rationale behind each PM task.
 To better manage the Cell C operation and
maintenance.
 Exchange information and increase
understanding of each role ie mech ,elect, process.
 Understand equipment failure history.
 Improve detection and rectification of failures.
 Communicate findings.
PMO2000™
Objectives…cont

 All of the previous will result in greater ability

for us to meet the business plan.

PMO2000™
How we went about it

 Started with the existing PM lists

 Applied the process to the all schedules
including:
 SAP schedules
 Maintenance and Process task lists
 Check sheets
 Created a new daily schedule for both operator
and maintenance technicians.
 Review failure modes and the PM’s which
addressed these.
PMO2000™
How we went about it….con’t

 Review operating logsheets

 Determined the most appropriate maintenance
strategy.
 What task (preventive, predictive or
corrective)
 Who does it
 How often.
 Develop implementation list/plan for approval.

PMO2000™
Opportunities identified

 Numerous new PM tasks that should be done.

 Task frequency could be more effective
particularly in the mechanical area.
 Some job descriptions were not specific or
reflective of actual work.
 Identified a opportunities for reliability
engineering.

PMO2000™
Opportunities Identified…cont

 Betterutilisation of maintenance and operations

resources by eliminating task duplication.
 The maintenance strategy needs to be better
documented so that it can more easily be
reviewed and communicated.
 There is an opportunity to transfer some of the
knowledge to other processes and sites.

PMO2000™
 Outcome PM Optimisation Analysis

Delete
13%

Extend Interval
11%

New Task
Use As Is 7%
60%

Reduce Interval
9%

Overall Breakdown Of 110 Maintenance Tasks

PMO2000™
 Outcome PM Optimisation Analysis

Use As Is
13% Delete
19%

Reduce Interval
25%

Extend Interval
30%

New Task
13%
Analysis of Mechanical Changes

PMO2000™
Downtime Analysis-Mechanical

Table of Overall Downtime for PM on Unit

Sum of Hours Proposed Program Previous Program
Per Per
Interval Total Lab D/time Year Total Lab D/time Year Total
2
Monthly 0.3 1 0.3 6 2

Monthly 5.17 2 3 12 36
Two
Weeks 2.25 1 2.25 26 59 1 8 26 208

Weekly 1.92 1 2 52 104

Grand
Total 9.64 200 208

PMO2000™
Downtime Schedule

10

Original
Total 32hrs
8

Revised
Downtime Hours

Total 30hrs
6

0
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8

PMO2000™
Some interesting issues

 Some valve failures could possibly be managed by

condition monitoring rather than in breakdown.
 Breakdown history was recorded incorrectly. This
precludes any efficient analysis.
 Some task were carried out too often…others not
often enough.
 The existing mechanical PM were difficult to
complete but now broken into three PM’s.
 Not all process tech inspections are recorded.

PMO2000™
Some interesting issues….cont

 Greater involvement of process tech’s in fault

finding is possible for maintenance and
operations problems.
 The justification for each maintenance task is
now documented.
 The existing PMs are not all being completed.
 Pizza Hut do not deliver on public holidays.

PMO2000™
Other benefits...

 More knowledgeable and empathetic workforce.

 More descriptive tasks with acceptable limits.
 Improved team work.
 Greater sense of ownership in the maintenance
and equipment performance.
 Better understanding of failure modes and
objective of tasks
 Planned downtime reduced (1hr per fortnight per
unit).
 Unplanned downtime will add to this.
PMO2000™
Benefits..con’t

 Move to a less reactive environment by adopting

more frequent inspections where warranted.
 The PM program can now be achieved.

PMO2000™
What needs to happen now

 Inputchanges to SAP (already started).

 Implement the Process Tech check procedure.
 Modify Elect Maintenance Tech check sheets.
 Develop Mech Maintenance Tech check sheet.
 Improve failure reporting in SAP.
 Carry out some minor plant modifications.
 Implement new tasks ie NDT and Structural
inspections .

PMO2000™
 Improved Reliability
through
PM Optimisation
Project Team:
• Electrician
• Planner
• Mechanic
• Operator
• Reliability Engineer
Facilitator: Steve Turner 18
PMO2000™ www.reliabilityassurance.com