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Articles: Asset Management

5 Critical Success Factors for Effective BOMs

Presentedy by: Doug Wallace

If your company was manufacturing automobiles, appliances, iPads, or even cardboard boxes, you certainly wouldn’t think about scheduling production without a complete and accurate Bill of Materials (BOM) for each finished product so you could determine your raw material requirements from a master schedule. So why is it that many process industries not only begin operation without equipment BOMs, but go for years, sometimes decades, without them?

When we ask people to assess the quality of their equipment BOMs, the comments we get most often are either, “they don’t exist,” or, “we have some of the data, but we don’t know if it’s accurate.” When we ask why that’s the case, the response is usually, “we don’t have the information,” or more likely, “we don’t have the resources to do all that work.”

7 Years of Sustained Reliability Culture Change at Alcoa Warrick Smelter

Mark Keneipp, Alcoa,
and Randy Heisler, Life Cycle Engineering

Background

It is not often that one runs across an organization that is able to undertake a significant business transformation, implement the changes successfully, and then sustain the gains for seven years with no end in sight. Here is the compelling story of one organization that has succeeded-Alcoa Warrick Smelter.
The story began in 1997 when Alcoa decided to implement the Toyota Production System globally across all 250 locations. Significant progress was made, but the Alcoa Primary Metals division leaders were not seeing the results that they expected. A business unit level internal analysis showed that their assets and reliability processes were lacking stability and this was holding lean manufacturing gains hostage. Stability is a foundational element to the Toyota Production System. If one is familiar with the Toyota House, or any other house for that matter, having a solid foundation is the key to long-term sustainability. (See Figure 1)
In 2002 Vince Adorno, Vice President of Engineering for Alcoa Primary Metals, decided to form a corporate-led team to develop a business case and reliability implementation strategy. External consultants were included in this process to ensure that best practices and reasonable estimates of potential savings were incorporated into their strategy. They also looked at their own pockets of excellence and best practices that were in place in the plants.

A New Opportunity for the Maintenance Reliability Community

By John S Mitchell

A new term has risen above our horizon. It is being embraced by companies committed to being the best and has great interest and cachet at the highest executive levels. Further, it states a clear objective that must be achieved to remain successful in today's fiercely competitive industry. The question is whether we, the, maintenance reliability community, will embrace the term, recognize its ability to mandate broader activities that are absolutely essential to achieve and sustain real success, and utilize the principles to gain value and results that really matter.

Achieving a Higher Level of Maintenance and Reliability

By Augie DiGiovanni and John Renick

Progressive companies already implementing predictive maintenance are looking for proactive solutions to manage asset performance.

An Introduction to PAS 55 – Optimal Management of Physical Assets

Asset Management goes well beyond the separate disciplines of engineering and maintenance.  It is a discipline that deals with the entire life cycle of our physical assets and until recently there was no widely accepted guideline or standard on what Asset Management was and was not. PAS 55 is a Publicly Available Specification (PAS) published by the British Standards Institution in 2004 now satisfies that demand. Since publication, PAS 55 has continuously increased in popularity both in the UK and around the world. It is now used as a framework outlining good management practices for many asset intensive industries around the world.

Analyzing and Quantifying Your Company Asset Management Opportunity

A methodical approach to measuring your company's current reliability profile and establishing your "Asset Management Opportunity" in dollars and cents for upper Management by James W. Davis, PE, SAMI 

Applying the Guidelines of BSI PAS 55 to Facility Management

The emergent understanding of asset management across all industry sectors has triggered a subsequent need for a standardised approach. The Institute of Asset Management (IAM) in collaboration with the British Standards Institute (BSI) and other industry groups first developed PAS 55 - Part1: Specification for the optimized management of physical assets in 2004. This was developed in response to industry demand for a standard for asset management and was recently revised in 2008 following international collaboration from industry and asset management associate groups.

ArcelorMittal Tubular Products Increases Asset Availability

Sponsor Case Study: ArcelorMittal Tubular Products Increases Asset Availability with Ivara EXP Enterprise Asset Performance Management Software

ArcelorMittal Tubular Products is one of the largest most diversified mechanical tube manufacturers in the world, with 21 plants operating in 11 countries with a capacity of more than 3 million MT annually. The company's product portfolio spans the entire range of steel tube products - seamless, DOM & ERW.

Asset Integrity: What to do after an Economic Crisis

Being Prepared

Most companies have reduced cost during these tough economic times in order to survive, shutting down equipment, lay off staff, extending time between rebuilds and preventive maintenance without thinking about the preparation they should be taking in order to take advantage of the economic turnaround. There will be winners and losers once the world economy turns around. Companies who are prepared will win by shutting down their competition, demonstration profits never heard of before. This can be obtained by focusing on "optimizing asset integrity at optimal cost".

 

Asset Management: concepts and practices

PAS-55 - Asset Management: concepts & practices by John Woodhouse, Managing Director, TWPL

Balancing Without Phase

Dennis Shreve, CMRP

Sometimes it may be required to balance a rotating machine or part under conditions where a conventional phase measurement is either impossible or unavailable. In this situation, a four-run method can be used to arrive at an amount and position for a corrective weight.

BSI-PAS 55 The Benefits for Utilities - A Regulator’s View

Ofgem has a long standing interest in asset risk management, for example surveying practices within the energy network companies in 2002.

Following the publication of BSI PAS 55, Ofgem is now encouraging GB Network Companies to undertake certification to PAS 55 and is monitoring each company's progress towards certification and is expecting that by 2008 companies will be certified and report their certification status to Ofgem on an annual basis.

Ofgem has also participated in the development of the IAM assessment methodology. The presentation will review current status and how PAS 55 implicitly benefits the customer.

Business Case for Data Integrity

By Robert DiStefano and Stephen Thomas

Introduction to the Business Case
A vast and growing amount of data is being accumulated in businesses today, yet many people in business intuitively know there is not a corresponding improvement in reliable information on which to base good decisions. In fact, in many cases just the opposite is happening-despite more and more data, finding information that can be trusted is increasingly difficult.

Challenges in Asset Management And ways that you can deal with them

by Michael Israel

Disclaimer: In our efforts to make readers aware of technology innovations, this Reliabilityweb.com article make extensive mention of a specfic product.  This should not be taken to imply endorsement.  The product names were used to support the informational delivery of an innovation for the maintenance and reliability community.  - Editor   

Asset Management: An Explanation

What is asset management?

There are varied points of view, no doubt. So let's get a generally acceptable perspective from two reliable sources:

Design Management: Reliability at the Start

abacunas_3 for installations and modifications to plant systems and equipment should go beyond engineering calculations, bids and drawings. While the engineering is important, items related to reliability and maintainability are sometimes treated as afterthoughts. To reduce the chance of premature failure and frustration and reduce the unexpected, a Design Management Program should be implemented and enforced. The Design Management Program should place an emphasis on reliability and maintainability with participation from all levels of the plant including engineering, maintenance, operations, safety, and purchasing. The program should also establish the review process with an incremental methodology. All design projects, whether capital or non-capital require the same methodology for inputs and review. Of course the larger the project the longer the process so enough planning time should be allowed, often a year or more in advance of the actual installation start date.

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