Developing a Sustainable

Maintenance Strategy
A Living Program

ACARP
Roadway Development Operators Workshop
September 2010

Dave Alexander – August 2010

 Winston Ledet 1994 Du Pont Study

Tactic Up time Uptime Downtime

% Change Reduction
Reactive 83.5% 0%
Planning Only + 0.5 %
Scheduling Only + 0.8 %
Preventive /
- 2.4 %
Predictive Only
All three tactics + 5.1 % 88.6 % 30.9%
Plus Defect
+ 14.8 % 98.3% 89.7%
Elimination

Dave Alexander – August 2010 Slide 2

 The Vicious Cycle of Reactive Maintenance

Backlog grows

Standards Drop PM is missed

Head / Budget Resources

Reduction taken
by Breakdowns
More repeat Temporary
work Repairs

Dave Alexander – August 2010 Slide 3

 Holistic Approach

• The Right People

• The Right Time

• The Right Stuff

• Continually Improve

Dave Alexander – August 2010 Slide 4

 Road Map Example

Dave Alexander – August 2010 Slide 5

 A Fundamental Question

As equipment gets older, is it

more likely to fail?

Dave Alexander – August 2010 Slide 6

 Founders of RCM - Nowlan & Heap found that
failures could be grouped into 6 patterns

A 4% D 7%
Conditional Probability
of Failure

B 2% E 14%

C 5%
F 68%

Age
Dave Alexander – August 2010 Slide 7
 Failure Mode Driven Strategy

Dave Alexander – August 2010 Slide 8

 Optimising The Maintenance Plans

PMO is a process which uses principles of Reliability Centred

Maintenance (Failure Mode Analysis) to to rationalise existing
maintenance strategies

Using the structure of the RCM, fitters, electricians and

engineers review all of the PM tasks that are currently utilised in
the CMMS and also analysed the failure history

Tasks not addressing a failure mode are removed

Tasks are rewritten to be descriptive
Specifications are provided
Corrective Actions are written
Illustrations are inserted

Dave Alexander – August 2010 Slide 9

 Maintenance Tasks

Dave Alexander – August 2010 Slide 10

 PMO Analysis

Dave Alexander – August 2010 Slide 11

 Optimising The Maintenance Plans

Dave Alexander – August 2010 Slide 12

 Group Task Libraries

Shuttle Car
- Frame
- Wheel End
- Hydraulics
- Electrics
- Cable Reel
- Drive System

Dave Alexander – August 2010 Slide 13

 Strategy Change Control

Dave Alexander – August 2010 Slide 14

 Governance

• Schedule Compliance

• PM Effectiveness

• Routine Order Start Date

Dave Alexander – August 2010 Slide 15

 Living System (DDA)

Downtime Data Analytics

Major Delay Minor Delay Detail Delay Equipment Level 2 Equipment Level 3 Equipment Level 4 Failure Mode
Continuous Miner 01 - Air/Water 02 - Water Filter Assembly Element   Blockage
Continuous Miner 06 - Hydraulics 05 - Hoses Wing Extension Retraction Hose JIC Fitting Cross Threaded
Continuous Miner 04 - Electrical System 12 - Electrical System Control Solenoid Coil Insulation Fractured

Dave Alexander – August 2010 Slide 16

 Living System (DDA)
Group Library
Downtime Data Analytics
Equipment Level 2 Equipment Level 3 Equipment Level 4 Failure Mode

Filter Assembly Element   Blockage

Wing Extension Retraction Hose JIC Fitting Cross Threaded

Control Solenoid Coil Insulation Fractured

Dave Alexander – August 2010 Slide 17

 Living System (RCA)

Dave Alexander – August 2010 Slide 18

 Questions
&
Answers

Dave Alexander – August 2010 Slide 19