“safety is a measure of success” presented by: abdul waheed – reliability engineer qurayyah...

“Safety is a Measure of Success”

Equipment Reliability Initiatives and Challenges

Qurayyah Sea Water Maintenance Div

May 3, 2009

Safety is a Measure of Success

The Ultimate Goal – Reliability Excellence The Ultimate Goal – Reliability Excellence

Key Elements of Reliability

Reliability is the probability that a piece of equipment will

perform its intended function over its intended period. It

directly correlates with ‘Quality of Maintenance’


ChallengesChallenges

Way ForwardWay Forward

OutlineOur Strategy to Build ReliabilityOur Strategy to Build Reliability

Current InitiativesCurrent Initiatives

• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)

• Deployment of Enhanced Business Processes

• Developed Forms for the use of Reliability Engineers




Rapid Improvement TeamsRapid Improvement Teams

Our Strategy to Build ReliabilityOur Strategy to Build Reliability

Expand Improvement Opportunities

Achieve and Sustain Best-In-Class Performance

STABALIZE

IMPROVE

SUSTAIN

Eliminate‘Bad Actors’

Capture Knowledge

Enhance Business Processes

Improve SAP Data Quality

Optimize Support Services

Deploy Predictive

Maint Tools

Max Systems & Resources

Utilization

Optimize Contract Services

Optimize Preventive

Maint

Continuous Awareness &

Team Building

Monitor Results

Journey Towards Maintenance & Reliability Excellence


• Shipping Pumps G-7101 – G-7801• SO2 Gas Fan

• Column Bottom Pumps


Elimination of ‘Bad Actors’ (Frequently Failing Equipment)


Shipping Pumps Trips 2008 – 2009 1st QRTShipping Pumps Trips 2008 – 2009 1st QRTData Source: SWED Trip Report & Operations Logbook (Period: Jan 2008 – March 2009)

1.5 MonthsCurrent MTBF:

60 MonthsDesired MTBF:

Mean Time Between Failure: (MTBF)


Shipping Pumps – Action PlanShipping Pumps – Action Plan


Bad Actor- SO2 Gas Fan Bad Actor- SO2 Gas Fan

Recommendations:

• Short-term- Change Preventive Maintenance interval from 12 to 3 Months.

• Long-term- Implement engineering design package (under development) to eliminate the process upset

Status: ETC: TBD


Bad Actor- Column Bottom PumpsBad Actor- Column Bottom Pumps

Root Cause:• Premature Failure of Pump Wear Rings and Anti-

Rotation pin due to inappropriate “Material” (Nitronic -60) causing “High Vibration”

Long Term Plan:• Inspect other nine (9) pumps module 20 – 28 and replace wear rings• Inform MS to contact the vendor for correct material wear rings and

stocking action

Short Term Plan:• Sent old wear rings to CSD Metallurgy Specialist for Analysis. –

Waiting for recommendations • Overhaul five (5) pumps module 15 – 19 and replace the wear rings

and anti rotation pins, fabricated from correct material


Reporting PM finding – Early detection of problems


Deployment of Enhanced Business Processes

Maintenance Planner & Foreman

PM Supervisor PM Crew

Reports Deficiencies

Develops Monthly Report

Plan & Schedule

No Tracking & Feedback

Operations Foreman

Creates Notification

Old Process

Maintenance Planner & Foreman

PM Supervisor PM Crew

Reports Deficiencies

Create SAP Notification

Plan & Schedule

Reviewed by PM QA /QC

Operations Foreman

Approves SAP

Notification

New Process


Equipment Trips Reporting and Tracking



Current Process

No E- Process, Trip Sheets are manually filled and Tracked.Plant Engineer Plant Foreman Operations

Staff

SAP M2 Notification

Comments Comments

Root Cause Evaluation

Reliability Engineer’s Evaluation and Tracking

Maintenance

Findings

New E-Process


Maintenance Rework Tracking



Reliability Engineer

Plant Foreman Operations Staff

Rework Notification

Comments Comments

Issues Finding & Recommendations

Report

Reliability Engineer Evaluates and Tracks through KPI

Maintenance

Findings

New E-Process

Current Process

No Business Process Exists. No Tracking or Reporting Mechanism available

Definition

Any maintenance work repeated due to same “failure mode” within three (3) months from last completion



Developed Forms for the use of Reliability Engineers

Preventive Maintenance Deviation

To track the PM delays due to Operational requirement

Maintenance Rework To record the findings and corrective action taken for any maintenance rework

Bad Actor – Root Cause Analysis and

Recommendations

To track frequently failing equipment – coordination for Root Cause Analysis and recommendations tracking

PM Deviation

Rework

Bad Actor Tracking


• Firefighting – Reactive Maintenance Culture – Low Schedule

Compliance

• Historical data for ‘Failure Analysis’ is not available

• Lack of Quality Assurance

• Incomplete Equipment SAP Database and Bill of Materials

• Equipment without PM program

• Lack of Condition Monitoring Tools and Skills

• No defined Maintenance Strategy to transform from PM to PdM

• Non availability of Standard Job Plans

• No Reliability KPIs deployed



• Deploy new business process and Reliability Tracking Forms

• Conduct SAP awareness sessions

• Develop a ‘Best Practice’ • KPIs and Monitoring• Involve Crafts in RCA• Audit SAP M2 Notifications

Repaid Improvement Teams Repaid Improvement Teams

Enhance Equipment Trip Tracking and Monitoring

Scope Champion :

Abdul WaheedReliability Engineer


• Arrange training workshops• Develop template for

quality history input• Develop ‘Quick Reference’

pocket books for crafts• Facilitate SAP authorization

for Quality data


Improve the ‘Quality’ of Equipment Repair History and Knowledge Sharing

Scope Champion :

Salah Al-Shihri Maintenance Foreman


• Facilitate the Schedule Compliance Improvement

• Measure the current manpower utilization and improve the process

• Deploy a system for Crafts daily assignment through work ticket.

• Identify the causes for Material delays


Improve the Planning & Scheduling Process and Manpower Utilization

Scope Champion :

Khalid Al-Shehri Reliability Engineer


• Establish an action plan to improve the SAP Equipment data quality

• Link Bill of Materials and e-copy of equipment manuals / URL of smart drawings

• Assign appropriate PM for the new equipment through PM Coordinator.


Improve the SAP Equipment Data Quality and Bill of Materials

Scope Champion :

Mohammad Al-Garrash Reliability Engineer


• Develop PM QA scope• Tour Plant and identify

deficiencies from Maintenance Perspective

• Track and Monitor the deficiencies reported by PM Crew

• Balance PM workload for next year


Lead the PM Quality Team

Scope Champion :

Mohammad Al-FadhalMaintenance Foreman


• Develop guidelines for stepping jobs to Contractor

• Deploy KPI to track and monitor the emergency mobilization

• Monitor repeated work on ‘Short Form Contract’ and peruse for a Long Form Contract


Contracts Optimization and Effective Utilization

Scope Champion :

Hani S Nogaidan Contracts Engineer


• Continue on Quarterly Reward and Recognition for Maintenance

Crafts in taking the “Proactive Maintenance approach”

• Involve Maintenance Crafts in improvement projects

• Continue capitalizing on PM findings to develop appropriate

Maintenance Strategies

• Strengthen the PM QA process

• Conduct PM optimization using PMO 2000 in 2011.

• Deploy Predictive Maintenance Tools (IR Camera – Ultra sound)

• Deploy Wireless technology for Vibration Monitoring

• Purchase hand held vibration monitors

• Strengthen the OCM Program



Scattered knowledge

Inconsistent actions

What Maintenance Work?

At What time?

Current RealityCurrent Reality


The Right Work

at

The Right Time

consistent action

Information System provides easy access to a Common Knowledge Repository

actionableknowledge

Consistent organized way to capture and use Knowledge & Information

business process and practices

Future OutlookFuture Outlook


“We are what we repeatedly do. Excellence then, is not an act, but a habit.”

~ Aristotle, 4th century BC Greek philosopher

Thank You


QSMD PM Workload

0.0 HR

500.0 HR

1,000.0 HR

1,500.0 HR

2,000.0 HR

2,500.0 HR

3,000.0 HR

3,500.0 HR

4,000.0 HR

200904

200905

200906

200907

200908

200909

200910

200911

200912

201001

201002

201003

201004

QSMD

“safety is a measure of success” presented by: abdul waheed – reliability engineer qurayyah...

Documents

mtbf slide

quality of maintenance

tbd slide

pumps module

bad actors capture knowledge

old wear rings

piece of equipment

months current mtbf