Revamps 2024 Issue

Update of existing programme

3 Site - level process (Phase 1)

Add safety - critical definition Create reliability risk index Develop tool for workshops

Gap between current PMs and updated PM tasks/ freq. from

Create criticality standard and process

Site validation of PM changes workshop

Site criticality validation workshop

Obtain site data

Assign 1st pass criticality

ID failure modes Add criticality level tasks Compare peer frequencies

Challenge session with industry SMEs

Site provides: PFD, LPOC, incident investigations, bad actors and previous criticality studies

Upload to SAP

Review with corporate SMEs

O - site resources Site resources

Follow-up and tracking of results

Agreement with site advisory groups

Updated PM tasks and frequencies for MI equipment

Figure 4 Organisation chart of the programme planned for minimising impact on site resources

were asked to comment on the results and indicate which were more consistent with their experiences. The SMEs were also asked to provide input if a task could be performed by a different method. An overall recommendation for changes based on the PM Libraries and SME comments was devel- oped for each equipment type and criticality. A major objec- tive of the programme was to minimise the impact on site resources (see Figure 4 ). To accomplish this, several key decisions were made: • Development of the criticality standard, process, and updates to the PM programme would be done at the corpo- rate level, with sign-off at the end by site advisory groups. • Site criticality workshop length would be minimised by performing a first-pass equipment criticality at the corporate level. • Existing site PM would be extracted and compared to the new standard with a recommendation provided by off-site resources. • Changes to site PM would be implemented by off-site resources. Conclusion A check performed when comparing the existing site PM programme with the PM standard was to ensure that all equipment defined as safety-critical had an appropriate PM

task. There were several cases where PM tasks were added for equipment now deemed safety-critical. Although it is too early to determine if there has been an impact on availability, a reduction in overall hours for PM was achieved at all sites. The results from the first four sites are shown in Table 1 .

Abbreviations BOM

Bill of materials

CMMS

Computerised maintenance management system

EOQ FAA

Economic order quantity

Federal aviation administration

FMEA Failure mode and effects analysis FRACAS Failure reporting, analysis, and corrective action system OEE Overall equipment effectiveness PM Preventive maintenance PMO PM optimisation PS&O Planning and scheduling optimisation RAM Reliability availability modelling RCA Root cause analysis RCM Reliability-centred maintenance SRCM Streamlined reliability-centred maintenance TPM Total productive maintenance 5S Sort, set in order, shine, standardise, and sustain (originally Seiri, Seiton, Seiso, Seiketsu and Shitsuke). References 1 Ford Motor Company, Ford Manual for Owners and Operators of Ford Cars and Trucks Detroit, Ford Motor Company, 1919. 2 History of Maintenance, Boeing Aeromagazine, QTR_04, 2006. 3 Moubray J, Reliability-centred Maintenance , ISBN 0-7506-3358-1, 1991. 4 Poor P, Zenisek D, Basl J, Historical Overview of Maintenance Management Strategies: Development from Breakdown Maintenance to Predictive Maintenance in Accordance with Four Industrial Revolutions, Proceedings of the International Conference on Industrial Engineering and Operations Management , 2019, pp.495-504. Charles Maier is the Global Maintenance Lead at Becht and resides in Charlotte, North Carolina. He has more than 30 years of experience in operations, maintenance and reliability, mainly leading improvement programmes at manufacturing sites. He holds a BS in marine engineer- ing and naval architecture from Webb Institute, Glen Cove, NY and an MS in engineering management from Southern Methodist University, Dallas, Texas. Email: cmaier@becht.com

Table 1 Reduction in overall hours for preventative mainte- nance was achieved at all four sites Note: Amount of PM hours vary based upon size of the site

Revamps 2024