Allied Reliability Phase II EMP Development Overview (March 2009)

Asset Reliability Overview

Allied Reliability
Phased Approach to a Successful Reliability Initiative

Presented by:
What would you do
Chris Colson with more free time?

Copyright 2007 Allied Reliability, Inc.


Agenda

• Who is Allied

• Overview of Approach

• Overview of Tools

• Questions / Answers



Allied’s Reliability Success Formula



Impact of a Complete Reliability Initiative
High

+75%
+27%
• Significantly Improved
• Improved Bottom
Bottom Line
Line Performance
Business Process and

Performance
Culture Maturity

• Lack of System
• Practices and Systems
Support
Aligned

Baseline -7%
• Systems are not
•Informal
Complemented by Effective
• Manual Planning
Business Processes
Processes
• Significant Inefficiencies
• Below Average
Business Performance
Low
High
Low Technology Maturity

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


Focused Improvement the Allied Reliability
Transformational Analytics – “5-R” Improvement Process
Way…
Rationalize Ratify
Recognize
Develop
Create and Identify
Known
PR Simulation Conduct Prioritized
(Baseline) Educate Process
Problem or Internal and
and/or Reliability FMEA Blitz Improvement
PR Plots Improvement
Value Stream
External Non
Modeling Plan
Team (PIT)
Mapping
Value-Add
(VSM)
And Wastes
Eliminate ALL
Manufacturing Wastes…
Overproduction
Transporting

FMECA
RCA

Quality
Inventory
(All Defects) Motion

RCM

Sustain the Gains…
Processing
Waiting
Train To New Audit/Monitor
Document
Process Continually
New Process

Resolve Realize


Allied Reliability – Overall AHA Workstream

Asset Registry Module Asset Analysis Module Asset Integration Module

Installed Asset
Component Criticality
Verification Analysis
Technology
Sourcing
Strategy
Asset
RCM Equipment
Definition
Analysis Maintenance
Phase
Plans (EMP’s)
(top 5-20%)
3

Technology
Failure
Asset Standards
Mode
Hierarchy OP1 & OP2
Analysis



Asset Registry Module
Goals: Benefits:
Asset Registry Module
•Defines criteria for Asset selection •Increased planning efficiency due to
•Identifies desired attributes by Asset type hierarchy structure
•Uncovers Asset types requiring •Increased scheduling efficiency due
Installed Failure Mode Analysis (FMA's) to hierarchy structure
Component •Verify/identify installed Components •Hierarchy provides added granularity
Verification •Creation of logical system to when criticality performed
Asset structure •Components tracking through tagging
and functional location
•Improved cost tracking through
Deliverables:
Asset
hierarchy structure
•Accurate Asset count
Definition
•Increased MRO efficiency through
•Complete hierarchy for Assets
accurate Asset list
•Component change control through tracking
•Improved CMMS through addition
•Multiple level cost tracking
of hierarchy structure
•Attribute data for Asset
Asset repairs/replacement
Hierarchy •Logical functional location
•Hierarchy template for CMMS upload
•Targeted seminars supporting
reliability program
•Site support for installed processes


Allied Reliability Phase 2 – Workflow
Asset Analysis Module
Goals: Benefits:
Asset Analysis Module
•Rank Assets using multiple criteria •Additional scheduling efficiency through
•Refines planning and scheduling use of Asset ranking
•Refine Maintenance, Repair and Operational •Input to critical spares through
Asset
Assets (MRO) Asset criticality
Criticality
•Categorize failure modes •Further CMMS improvement by
Analysis
addition of attribute & criticality
•Improved MRO function through
Deliverables:
use of CMMS data
•Ranked Asset list
•Ability to prioritize failures and create
•Defined failure modes for Asset types
RCM “bad actors” list
•Attribute template for CMMS upload
Analysis •Targeted seminars supporting reliability
(top 5-20%) program
Failure
Mode
Analysis



Allied Reliability Phase 2 – Workflow
Asset Integration Module
Goals: Benefits:
Asset Integration Module
•Apply failure modes to Assets •Engineered equipment
•Select Asset coverage model maintenance plans (EMP’s)
•Facilitate condition monitoring •Further planning efficiency gains
sourcing strategy through EMP’s
•Identify PdM/PM gaps •Additional CMMS gains through
Technology •Create condition monitoring creation of PdM & PM tasks
Sourcing operational procedures •Consistent measures and
Strategy reporting across technologies
Equipment •Identify PM’s required to address
Deliverables:
Asset failure modes
Maintenance •Equipment Maintenance Plan for in
Plans scope Assets
Phase
(EMP’s) •Coaching/Mentoring template
3
development for PM’s that address
Technology targeted failure modes
Standards •Documented and maintainable
OP1 & OP2 equipment maintenance plan
•Condition monitoring (CM)
operational standards
•Recommended condition monitoring
sourcing strategy
•Targeted seminars supporting
reliability program



Processes and Tools
• Based on the collection of Best Practices
• Built by “Users”
• Integration Theme
• Enforces Discipline to Standards
• 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 classification sort is
applied.

•A PM recommendation sort
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?


Allied Reliability Phase II EMP Development Overview (March 2009)

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