Facebook
RSS
Showing posts with label Reliability. Show all posts
Showing posts with label Reliability. Show all posts

Maintenance Approaches - Proactive and Reactive

0 comments
-
Tom Robertson


Maintenance can be broken into categories – Proactive and Reactive. Proactive is further divided into two classes- Preventive and Predictive while Reactive can be split into – Corrective and Emergency.
Reactive maintenance, the easiest approach, the oft-used approach, the out-of-sheer-habit approach. But look closer and you will find that the worst thing that a company can do is spend a lot of time in reactive maintenance.
Reactive approach includes a lot of unplanned downtime in contrast to planned downtime.

Often many reasons incline a company towards reactive way of maintenance. Like:
1. High pressure environment
2. Rigorous production schedules
3. Heavy targets
4. Top Management’s attitude
5. Poor record-keeping making proactive approach infeasible
6. Lack of automation in production-records and scheduling documents
7. Lack of awareness of means and methods of non-disruptive maintenance
8. Ease of application and out of regime

But, this kind of a company is not always a world-class company. Because world-class companies only apportion about 5 per cent of maintenance time to the reactive approach. The major part is done the preventive way. The reasons for doing that are born out of a long-term mindset, focus on sustainability, regard for safety, well-planned direction and a clear vision.
[ Read More ]

Continue

Importance of Asset Data Analysis

1 comments
-
Tom Robertson



For successful “Asset Maintenance & Reliability Management”, companies not only adopt many methodologies like RCM, TPM, CBM, etc. but they also leverage their asset related data to improve processes & performance. To make data driven informed decisions, companies require much more than just investment in the technology infrastructure they also require quality data consistently for trustworthy analysis. There are many challenges in achieving this...

Quality Data Preparation

• Multiple data sources with voluminous data
• Identification of good & bad data
• Need for reliable analysis
• Lack of data uniformity
• Data in non- reportable format
• Cleansing data manually
• Laborious quality data preparation
• Complex data validation

Advance Data Analytics

• Don’t know how to use data Can't leverage on data for analysis
• Asset health assessment
• Less asset availability
• Increased unplanned breakdown
• Lack of domain expertise & experience to analyze
• Unable to analyze & predict events critical to business operation

Managing Analytics Infrastructure

• Lack skilled & trained professionals
• Hiring full time resources
• Huge capital investment
• Lack expertise & experience
• Developing libraries from scratch
• Losing focus from core business functions
• Cost control

Asset Data Quality

• Asset data audit & quality Analysis
• Asset master data development
• Asset data dictionary development
• Asset data cleansing & validation
• Ongoing support

Data Analysis

• Problem Definition
• Data Availability Analysis vis-à-vis Analytics Feasibility Study
• Solution Modeling Using
• Solution Implementation
• Data gathering,
• Report development
• QA
• Result Analysis & Interpretation
• Report Preparation & Delivery
• Ongoing Model Effectiveness & Performance Monitoring


Statistical Modeling Techniques

• Weibull
• Monte Carlo
• Crow-AMSAA
• Pareto
• Croston
• Poisons
• Log Normal
• ARMA
• Exponential Smoothing
• ANOVA
• IR/Control Charts

Business Issues

• Identify underperforming Assets
• Identify equipment to be replaced
• Avoid unnecessary PMs
• Establish PM & failure relationship
• Identify unusual PM costs
• Monitor impact of strategy & process changes
• Determine future Maintenance cost for budgeting
• Finding equipment which have unusual # of failures
• Identifying most impactful failure causes on reliability
• Find optimum spare parts level

Ready to use models for

• Optimum PM Interval
• EOQ Calculator
• Forecast residual life of asset
• Predict TBF & MTTR
• Mean Residual Life of equipment
• Reliability Growth Models & Plots
• Repair Vs Replace Model
• Root Cause Analysis
• Spare Parts estimation Using Crow
• AMSAA Model
• ABC Analysis
• Spare Parts Demand Estimation
• Proportional Hazard Model
• Failure data Analysis
• Competing risks using survival analysis
[ Read More ]

Continue

Asset performance management

0 comments
-
Tom Robertson



Asset performance management leverages cross-functional data from enterprise asset management and other related applications to enable organizations effectively manage their assets, processes and people.

Asset performance management includes:

Manage Goals & Targets

• Increase Reliability & Availability of asset
• Optimize Asset Performance
• Reduce TCO
• Increase RONA

Monitor Strategies

• Create awareness & culture of RCM
• Leverage Asset related data efficiently
• Increase visibility of corporate goals & performance
• Built corporate culture of decision making based on comprehensive data analysis & use data analysis as an additional management tool

Perform advance statistical analysis based on…

• Large no o assets & Verity of asset classes
• Large volume of asset related data from disparate sources
• Built reporting repository for asset data
• Create Reporting & analytics framework for APM
• Construct statistical analysis & forecasting models

Make Results Visible

• Benchmarking & performance monitoring matrices
• Subject matter scorecards & dashboards
• Alerts for timely action
• Escalate problems
• Broadcast information vis-à-vis corporate asset performance goals
• Deliver reports & analysis to everyone involved in asset management
[ Read More ]

Continue