10/14/2016

Reliability Asset
Management

Maintenance Efficiency:
Impact on the Big Picture

Operational Efficiency
Expense
Throughput Equipment Reliability
Inventory

LEAN
Principles
Uptime Maintenance Efficiency
Support
Overall MTBF Productivity LEAN Principles
Systems
Equipment MTTR
Effectiveness
OEE

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Reliability Financial Report

Digging into the Benchmark

MAINT $ STORES $
QUARTILE (%RAV) (% RAV)
% IR % IR % OIL % OTHER % ON
% VIB MECH ELEC ANAL NDT % ON PM BOM

Top 1st 1.2 % 0.3 % 85.7 % 73.6 % 100.0 % 42.9 % 42.2 % 25.0 % 66.0 %

Middle 1st 2.7 % 0.9 % 75.6 % 62.8 % 91.9 % 38.6 % 35.5 % 26.0 % 63.0 %

Top 2nd 3.7 % 1.3 % 64.9 % 54.3 % 87.4 % 32.6 % 30.9 % 27.0 % 58.0 %

Middle 2nd 5.1 % 2.0 % 52.7 % 44.3 % 81.9 % 26.7 % 25.3 % 30.0 % 55.0 %

Top 3rd 6.5 % 3.0 % 44.7 % 36.9 % 76.4 % 22.3 % 20.5 % 31.0 % 49.0 %

Middle 3rd 8.1 % 4.6 % 30.0 % 25.4 % 69.1 % 17.6 % 15.6 % 34.0 % 45.0 %

Top 4th 9.9 % 6.0 % 22.1 % 16.7 % 63.1 % 12.9 % 11.7 % 36.0 % 40.0 %

Middle 4th 13.2 % 8.1 % 10.3 % 4.0 % 57.0 % 6.8 % 7.5 % 38.0 % 36.0 %

Bottom 4th 17.3 % 12.3 % 3.3 % 0.0 % 47.6 % 1.6 % 3.6 % 40.0 % 30.0 %

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C MMS
KPI

A S SET ST RATEGY &

P R OCEDURES
ISO 14224 BOM

ACR Taxonomy Data Integrity

RCM FM EA P M O

KPI
A S SET MASTER
D A TA
TRAINING

A S SET
C R ITICALITY
RELIA BILITY JOURNEY
KPI
S T ART
!

C ON D ITION
M ON IT ORING
OD R
NDT PM
L u b rication
U l t rasound
S c heduling
I n f rared
P l anning Oi l
A n alysis
M o t or PM
t e sting
V i bration

W ORK
E X E CUTION
A l ignment & P recision A n alysis
B a lancing M a intenance
F o llow up

REACTIVE

W o rk Identification
KPI

M R O Optimization

S T OR E
W OR K P rocess C o n dition
M A NAGEMENT P a rameters I n dicators
M R O & SU PPLY C HAIN
M A N AGEMENT A S SET
H E ALT H

KPI
CMMS

Parts
Catalog

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E x ecutive Op e rational H u m an
S p onsorship E x cellence M a n agement
C a p ital
V i sion

I S O 55000

WELCOME TO APM TOWN

I n c id ents SST A v a i lab ility

M a i n tena nce
P r o fit
C o s ts
$

BAD
KPI ACTOR
RCA
D E F ECT W E I BULL MT BF
E L IMINATION

C ON TINUOUS
I M PR OVEMENT

M E ASUREMENT
& C ONTROL

Core vs Support

• Is the Reliability Organization a core or support

function?

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How your company views failure and

where would you like it to be?
Schools of Thought

Normal Accident Institution High Reliability

Theory Theory Theory
- Accidents in complex and - For legitimacy, - Accidents are
tightly coupled systems are compliance as signal of preventable.
inevitable (Perrow 1981) commitment, e.g. Organizations are
with the risk of an accident certification described as “mindful”.
increasing as complexity - Increase sales and - HRT suggests that high
increases or coupling reputation but would reliability benefits all
becomes tighter. not alter production operational performance
- There is a trade-off processes or the outcomes, not just
between safety and other production system’s safety – can prevent
operational outcomes such reliability accidents and failures,
as quality or productivity. quality defects, late
deliveries, etc.

High Reliability Organization (HRO)

• Main principle: “mindfulness”
• Understanding of unexpected events and emerging threats and
respond to them as soon as they appear
• Capable of tracking even the smallest of failures and ultimately
learn from them for future application
• Characteristics of HRO
1. Preoccupation with failure – reporting of errors, learn from
near-misses, articulate mistakes to be avoided
2. Reluctance to simplify
3. Sensitivity to operations – interaction with frontlines,
promote situational awareness
4. Commitment to resilience – capabilities in place to detect,
contain and bounce back to original state or better in times of
error
5. Deference to expertise – encourage expertise (group) vs
groups (singular)

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Reliability Management

• Best view in the context of Asset Management

• ISO 55000:2014 defines:
• Asset Management as: “the coordinated activity of an
organization to realise value from assets” ; and
• An asset as an “item, thing or entity that has potential or actual
value to an organization”
• If integrated with the Operational Management
System, safety and operational efficiency are
optimized.

Asset Management

The first ISO standard for Asset Management

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Asset Management Process

Asset Health Indices can also be referred to as:

• Equipment Health Rating(HER)

• Asset Condition Assessment (ACA)
• Asset Condition Index (ACI)

Essentially, an Asset Health Index can be defined as:

• A way of measuring the overall health of a asset
• A list of data parameters for an asset that feed into a calculated
health rating
• A way of comparing different asserts and asset classes in a
consistent manner
• An output of Big Data and asset analytics
• An input, or building block, to a broader asset management
process

Reliability
Frameworks

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Reliability Framework

• What Reliability Management framework is suitable

for your operation?

Institute of Asset Management

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Novelis Reliability Pyramid

Consisted of 14 Reliability Elements

Chevron’s Surface Equipment Reliability

Improvement Process (SERIP)

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Shell’s Operation Excellence

Marshall Institute’s 8-Phase Reliability

Improvement Model

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Reliasoft’s Asset Performance

Management

RasGas Integrated Asset Management

Model

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Integrity = Reliability

• The Integrity of the • The Reliability of the

System system
• The Integrity of the • The Reliability of the
structure structure
• The Integrity of the • The Reliability of the
brand brand
• The Integrity of the • The Reliability of the
data data
• The Integrity of the • The Reliability of the
person person

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A Journey to Shape Reliability Excellence at

Bristol Myers-Squibb

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CRE Capabilities
 Facilitation of Uptime Elements as basis for Asset Management Plan
 Asset Health Index
 PM Optimization and Work Management
 Reliability Engineering Training with International Certifications
o SMRP Certified Maintenance & Reliability Professional (CMRP)
o AMP Certified Reliability Leader (CRL)
o ASQ Certified Reliability Engineer (CRE)
 Condition Based Maintenance Training with International Certification
o VI USA Vibration Analyst Cat. 1 & 2
o ICML Machinery Lubrication Technician I & Machinery Lubricant Analyst II
o Infrared Institute Certified Thermographer Level 1 & 2
o UE Systems Airborne Ultrasound Level 1
 Engineering and Reliability Management Training
 Maintenance & Reliability Basic Skills Training
 Customized In-House Training
 Consultancy Services
 Technical Books

Thank you!
Erwin Bernal, MLT I, MLA II
Sales Operations Manager
CRE Philippines
2f 718 Bldg. Shaw Blvd.
Mandaluyong City
Philippines 1552

Tel: +63 2 718 3480 loc. 402

Mobile: +63 917 500 8306
Email: [email protected]

www.crephils.com

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