dave alexander – august 2010 developing a sustainable maintenance strategy a living program acarp...
TRANSCRIPT
Dave Alexander – August 2010
Developing a Sustainable Maintenance Strategy
A Living Program
ACARP
Roadway Development Operators Workshop September 2010
Slide 2Dave Alexander – August 2010
Winston Ledet 1994 Du Pont Study
Tactic Up time % Change
Uptime Downtime Reduction
Reactive 83.5% 0%
Planning Only + 0.5 %
Scheduling Only + 0.8 % Preventive /
Predictive Only - 2.4 %
All three tactics + 5.1 % 88.6 % 30.9% Plus Defect Elimination
+ 14.8 % 98.3% 89.7%
Slide 3Dave Alexander – August 2010
The Vicious Cycle of Reactive Maintenance
Backlog grows
PM is missed
Temporary Repairs
More repeat work
Resources taken by Breakdowns
Head / Budget Reduction
Standards Drop
Slide 4Dave Alexander – August 2010
Holistic Approach
• The Right People
• The Right Time
• The Right Stuff
• Continually Improve
Slide 5Dave Alexander – August 2010
Road Map Example
Slide 6Dave Alexander – August 2010
A Fundamental Question
As equipment gets older, is it more likely to fail?
Slide 7Dave Alexander – August 2010
Founders of RCM - Nowlan & Heap found that failures could be grouped into 6 patterns
Co
nd
itio
nal
Pro
bab
ilit
y o
f F
ailu
re
Age
CC 5%
A 4%
B 2%
F 68%
D 7%
E 14%
Slide 8Dave Alexander – August 2010
Failure Mode Driven Strategy
Slide 9Dave Alexander – August 2010
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 removedTasks are rewritten to be descriptiveSpecifications are providedCorrective Actions are writtenIllustrations are inserted
Slide 10Dave Alexander – August 2010
Maintenance Tasks
Slide 11Dave Alexander – August 2010
PMO Analysis
Slide 12Dave Alexander – August 2010
Optimising The Maintenance Plans
Slide 13Dave Alexander – August 2010
Group Task Libraries
Shuttle Car
- Frame- Wheel End- Hydraulics- Electrics- Cable Reel- Drive System
Slide 14Dave Alexander – August 2010
Strategy Change Control
Slide 15Dave Alexander – August 2010
Governance
• Schedule Compliance
• PM Effectiveness
• Routine Order Start Date
Slide 16Dave Alexander – August 2010
Living System (DDA)
Downtime Data Analytics
Major Delay Minor Delay Detail Delay Equipment Level 2 Equipment Level 3 Equipment Level 4 Failure ModeContinuous Miner 01 - Air/Water 02 - Water Filter Assembly Element BlockageContinuous Miner 06 - Hydraulics 05 - Hoses Wing Extension Retraction Hose JIC Fitting Cross ThreadedContinuous Miner 04 - Electrical System 12 - Electrical System Control Solenoid Coil Insulation Fractured
Slide 17Dave Alexander – August 2010
Living System (DDA)
Downtime Data AnalyticsEquipment 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
Group Library
Slide 18Dave Alexander – August 2010
Living System (RCA)
Slide 19Dave Alexander – August 2010
Questions&
Answers