Companies are bombarded daily with recommendations from various sources regarding the tools they should use for improvement, leaving most people in a quandary regarding their selection and application. Unfortunately, there are any number of tools being offered, with little guidance regarding which one is best in a given situation, how the tools might relate to each other, or perhaps more importantly, the enabling practices or readiness that any given organization might need in order to effectively apply the tools.
This paper describes the background, content, and use of a newly created document derived from the "Reliability Centered Maintenance (RCM) Scorecard." The RCM Scorecard document is organized around a set of metrics developed by Anthony M (Mac) Smith (author of the Reliability Centered Maintenance[1] text and co-author (with Glenn Hinchcliffe) of RCM: Gateway to World Class Maintenance[2]). The latter text addresses analysis during RCM projects and provides examples of metrics from many real (fully identified) clients.
The manufacturing industry continues to be a pillar of the U.S. economy, underpinning its essential role in ensuring national security. It contributed to 11.9 percent of total U.S. gross domestic product (GDP) in 2012, and when compared to other industries, manufacturing provides the largest multiplier effect — every $1 spent in manufacturing generates $1.48 in additional economic activity.1 Manufacturing also provides direct employment to nearly 12 million Americans.2
The June/July 2012 Uptime article, “Bridging the Gap Between Construction and Operations for New Capital Assets” (Robert DiStefano, et al, 2012), illustrates the business value of preparing new assets to operate beginning in the design phase. Bruno Storino expanded on DiStefano 2012 with “Capital Projects Operational Readiness and Business Risks: Maximizing Returns on New Assets” (Storino 2012), which provides an overview of a comprehensive program that optimizes the transition from engineering to operations for new assets.
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by Abayomi Carmichael CEng MBA BEng, Bermuda Electric Light Co. Ltd.
There is an abundance of data supporting the effectiveness of RCM in a broad range of industries. Yet when staff at the Bermuda Electric Light Co. Ltd researched RCM, precious little data was found regarding its application to a primarily large diesel driven power utilities. The company subsequently decided upon a PMO (Planned Maintenance Optimization) based approach with aggressive targets and timelines. 20% increase in productivity. Chop downtime in half. Deliver this within 1 year. All in unproven territory.
Pump reliability is an old topic, but it is just as relevant today as it was the first time we heard it a few decades ago. There are some very good reasons to focus on improving pump reliability:
My first introduction to equipment reliability came in 1988 at Eastman Kodak Company in Rochester New York. Jerry Haggerty one of the founding members of SMRP (Society of Maintenance and Reliability Professionals) had begun to assemble a steering committee of Kodak Maintenance professionals who would begin working together sharing information on equipment reliability. As a member of this team I remember well the emphasis Jerry put on understanding the P-F curve and the P-F interval. Jerry knew that if we could get our managers to understand the P-F curve we could begin to make the transition into predictive technologies and reduce the amount of reactive maintenance being performed at our plants.
IS BETTER THAN 50 PERCENT accuracy an objective or goal for a condition monitoring program? Do you measure accuracy of recommendations as an output of your program? It is not unusual for paper mills with mature condition monitoring programs staffed by competent, skilled and experienced technicians to achieve over 95 percent accuracy in the prediction of a failure, and somewhat less accuracy, due to lack of knowledge and data, of the recommended corrective action, which for some, is still a whole lot better than flipping a coin. But how about a goal of zero unpredicted failures?
The author, Mr Steve Turner, is a professional engineer who has been extensively trained in RCM methods and has deployed them over a 20 year period in various roles as an airworthiness engineer, a maintenance manager, as part of a design team and as a consultant. Over the past five years, Mr Turner has developed a process of PM Optimisation known as PMO2000. This method is currently in use at 12 major industrial sites in Australia and the Asia Pacific Region.
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".
Uptime is named after the single most important topic in process manufacturing. Uptime is a result of doing all the right things. Even safety is a byproduct of doing all the things necessary to get uptime.