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Engineering a Streamlined Fire Protection Life Safety Inspection Process

IMC-2017 Learning Session - 40:46
by John Connell, JFC & Associates

This session will present a case study on improvements to Fire Protection Life Safety (FPLS) inspections at an airport in the Northeast. The focus of the project was to move a paper based process to a handheld solution integrated with Maximo Asset Management. The effort consolidated over 100 paper based forms to a single point of entry. The presentation will cover:

Improved User Experience
Benefits of the Mobile Platform
Increased Accountability and Auditing
Data Integrity and Reporting Improvements
Maximo Integration, Alarms and Follow up Corrective Maintenance
Risks and Regulatory Requirements

Asset Management

Improving Services thru Entitlement and Technology

IMC-2017 Learning Session - 38:48
by David Auton, Cushman and Wakefield Services

All organizations face cost and performance challenges to remain competitive. Additionally, all organizations want to improve and demonstrate good stewardship of their facilities. The reality is that all organizations have process based components that can be assessed to determine the potential performance within existing structures. This presentation strives to help leaders understand how basic awareness of process capability and simple measures can be applied to what are often obscure processes and can be used to identify improvement opportunities. The approaches to determine what actions may be necessary to achieve improvements are reviewed with examples. Methods to estimate the impact of process improvements, technology and tools are reviewed. Using a pragmatic approach, organizations can quickly determine if proposed technology investments are warranted and reasonable.

Asset Management

Smart Infrastructure Asset Management

IMC-2017 Learning Session - 41:20
by Michael Salvato, Metropolitan Transportation Authority

Productivity in infrastructure management is lower than it was 20 years ago. Infrastructure providers have not benefited from modern approaches to management and information technologies available for complex engineering systems and enterprises. Asset management systems, as defined by ISO 55000, outline the management requirements and capabilities necessary for smart Infrastructure, integrated supply chain management, more sustainable and resilient built environment, and better steward of our natural heritage. Smart infrastructure, resulting from the convergence of digital technologies with physical infrastructure, requires a radical paradigm shift in how critical infrastructure systems are managed to support lifecycle optimization and decision making to realize the value for money of continuously improving outcomes.

Reliability Engineering for Maintenance

How to Lead Design for Reliability (DfR) with Stage Gate Triggers

IMC-2017 Learning Session - 42:19
by Marie Getsug, Jacobs, and George Williams, B. Braun Medical

Asset Management has introduced a few key concepts which require a shift from focusing on initial investment to optimizing the life-cycle cost. The basis for such decisions are rooted in a risk-based and science-based approach to understanding the requirements of the asset throughout its useful life. The risk-based approach drives prioritization and optimization; whereas, the science-based approach honors the Subject Matter Experts (SME’s) experience as well as seeking meaningful data to drive decisions. Both must be applied in the concept and design phases to be effective.

Shifting the Project Management Office (PMO) and the Capital Engineering Process from a mindset of initial cost, scope and schedule to a focus on Total Cost of Ownership (TCO) and Life Cycle Cost (LCC) requires a catalyst for change. Design for Reliability (DfR) answers this requirement with a methodology that blends aspects of statistics, probability and reliability theory, and engineering analysis throughout a product lifecycle to evaluate, predict, and verify the application of robust design. Through application of DfR practices, the demand for highly-reliable systems can be met while insuring that the latest methods for the assessment of robust design and risk-management are properly addressed. The design and concept stage gates become the most significant triggers for DfR and the mechanism for the timely application of each DfR element. Experiences introducing and customizing a DfR Program and toolkit to achieve a Corporate Vision and optimize the performance of the assets throughout their useful life will be shared. Stakeholders with any level of responsibility for these assets are being called upon to contribute their experience in the concept and design phases, core to both Front End Planning (FEP) and DfR. A governance structure that supports, funds and allows for the input of these Stakeholders at these timely stage gates is fundamental to the success of a DfR Program.

Asset Management

Optimizing Asset Management in Design Processes - Looking Outside the Box

IMC-2017 Learning Session - 42:45
by Lanny Floyd, University of Alabama at Birmingham

This session will explore lessons from a standard outside the domain of asset management: ANSI/ASSE Z590.3 – 2011 Prevention through Design Guidelines for Addressing Occupational Hazards and Risks in Design and Redesign Processes. This standard provides guidance for a life-cycle assessment and design model that balances environmental and occupational safety and health goals over the life span of a facility, process, or product. While the purpose of this standard is to enable an organization to reduce occupational safety & health risks, its methodology can be applied to reducing risks impacting asset performance. Organizations may realize benefits of aligning resources and processes impacting asset management and occupational safety & health.

Asset Management

Best Asset Management Program (Uptime Award Winner) - Southern Gardens Citrus

IMC-2017 Learning Session - 46:56
by Brendon Russ and Jim Sullivan, Southern Gardens Citrus

After the publication of ISO 55000 Asset Management Standards, it shined a light on a need to create an overall plan of how we deal with assets, not just maintenance. Southern Gardens Citrus is a worldwide supplier of Florida orange juice. We have an established Strategic Asset Management Plan (SAMP) that is presided over and reviewed by executive management. The backbone of our asset management is our Management of Change (MOC) process.

This presentation will give an overview of asset management at Southern Gardens, showing the application of ISO 55000 guidelines and how they tie to how we approach creating a SAMP, asset knowledge, asset lifecycle management, performance indicators, continuous improvement, risk management, and decision making.

Asset Management

Are We Actually Realizing Value from Our Asset Management Program?

IMC-2017 Learning Session - 42:44
by Dharmen Dhaliah, Town of Halton Hills

Realizing value is the main focus of asset intensive organizations. Organizations design, build, own, operate and maintain physical assets to derive tangible or intangible, financial or non-financial value from them over their entire life cycle. Eventually it is befitting to spend some time understanding what value is and how it can be realized. As a matter of fact ISO 55000 makes reference to 'value' and 'realize value' in its definitions of asset and asset management respectively. Realization of value requires the achievement of a balance of costs, risks and benefits, often over different timescales. So what does value derived from physical assets means to your organizations? Is it value to customers, value to stakeholders, or value physical assets contribute to achieve organizational objectives? How are these values quantified, measured and tracked to support the overall system? Do you have a process in place to actually identify and visualize the activities contributing to the realization of value from your physical assets? This session will describe the asset management value chain in organizations and explore the existing roadblocks and constraints that are stopping organizations to realize maximum value from their asset management program.

Asset Management

Profitable Reliability Control for Improved Asset Performance

IMC-2017 RAP Talk - 19:07
by Peter Martin, Schneider Electric Process Automation

As the science behind process control advanced over the past 4 decades, the equipment assets in industrial plants were pushed to, and at times beyond, reliability threshold limits. This led to the need for new and more advanced approaches to asset management. As a result, the science behind asset management has advanced significantly over the last 15 years. New approaches to equipment condition monitoring, predictive maintenance and prescriptive maintenance have proven their worth in terms of improved equipment reliability.

The rise of the Industrial Internet of Things (IIoT) is providing new opportunities to consider improving asset performance. With the reduced, cost, size, and power requirements, coupled with increased capability, capacity and interconnectivity of computer technology, new, highly agile automation system architectures are emerging which align tightly with the asset architectures of industrial plants and enterprises. This means that powerful computers in the form of cyber-physical systems can be aligned to individual industrial assets providing incredible compute power for each asset. Additionally, the expansion of control functionality from process and logic control for improved operational efficiency, to include the real-time control of reliability risk and operational profitability to provide the basic components of Asset Performance Control.

This IIoT-enabled, expanded control domain will operate under Asset Performance Management to provide new levels of measurable operational profitability from equipment assets all the way through entire industrial enterprises.

Asset Management

Why Big Data and the Digital Transformation Won’t Deliver Reliability

IMC-2017 RAP Talk - 23:44
by Jason Apps, ARMS Reliability

Bad data or poor-quality data costs organizations as much as 10-20% of their revenue. The premise of this RAP Talk from IMC-2017 is that you can have too much data. And too much data doesn’t deliver anything by itself! The focus at the moment is on asset health and performance monitoring. Let’s get back to basics.

Asset Management

Edge, Cloud and Reliability

IMC-2017 RAP Talk - 21:16
by Jagannath Rao, Siemens

In the manufacturing world, one of the most not talked about phenomena is called the "The Hidden Factory." This can be broadly described as work arounds and other activities which result in poor efficiency, waste and reduction in quality. These phenomena go unnoticed most of the time as the data sources are either too disparate or transparency is lacking due to the inability to address the problem. The reason for the existence of a hidden factory is often multifold and can be categorized into three buckets - a) Reliability issue, both in the process and the machinery, b) Inadequate data transparency to get to the root causes and address them and c) supply chain & logistics bottlenecks.

In this modern age of digital transformation, not only is it possible to address these issues, but in fact a steep change in the manufacturing arena can be made. This demands the adoption of technologies like contextualized data integration, machine learning & analytics and IIoT. This talk is about how Edge Computing, IIoT and adoption of scalable cloud technologies can address and minimize the phenomena of the "Hidden Factory."

Asset Condition Management

Using Discipline in the Basics to Solve Today’s Complex Problems

IMC-2017 RAP Talk - 20:41
by Brian Gleason, Des-Case

In this RAP Talk from IMC-2017, Brian Gleason of Des-Case outlines helpful leadership tactics. Wherever you are on your leadership or reliability journey, you didn’t get there overnight, and you won’t get into the next step overnight either. Join Gleason as he talks about leadership, work-life leadership, and how it ties together for him on his own personal journey.

Asset Condition Management

Defining Asset Care Strategies

The RELIABILITY Conference Learning Session - 22:19
by Tabby Conrow, General Mills

It’s 1AM in the morning, and your phone rings. There is breakdown at the plant. When you hang up the phone, your head spins running through items like safety risks, production downtime, stocked parts. Now imagine all those worries – gone. We have to improve human safety, improve equipment efficiency, reduce maintenance cost and all while increasing system capacity.

The goal is to develop asset care strategies that balance our current capability and asset availability with the needs of the equipment. The scope is to look at our current organization capability, our PM systems, process rigor and craft skills and stabilize the relationship. The process to improve is a 4 part approach:

Asset spare parts list cleanup – it ensures inventory asset link, provides failure mode by work type and consumable BOM that is searchable in Maximo.
Identify the plants asset care gaps by running a CMMS Maximo query to identify if parts were reactive maintenance, corrective maintenance or preventative maintenance work orders. With this data we then research if the RM parts have a component strategy.
Modify job plan content by defining “time based versus inspection based” for components, pairing usage history with component manufacturer calculations and ensuring that all time based parts are planned to job plans.
Perform the PM balance – create Gantt chart of PMs for the system, eliminate unnecessary PMs and align PM start times with maintenance schedule.
The asset care approach has led to unmanaged spend improving by over 22% from the previous year. As more parts are correctly charged to the asset, we can clearly find the gaps. Since the launch of asset care 2 fiscal years ago, plants have saved over 2 million dollars in parts spend!

We implement asset care strategy at our plants to be a way of maintenance life. Planned maintenance will continue to improve and reactive maintenance will ultimately make it to zero occurrences.

A Maximo Implementation with Reliability

MaximoWorld 2017 Learning Session - 37:03
by Aaron Schofield, Electronic Data, Inc. and Scott Smith, Greater Toronto Airport Authority

When implementing a new EAM system, most enter with a desire for greater reliability. It can be a difficult task to determine what’s the best way to achieve greater reliability and the steps to take to get there. It is easy to fall into the trap of implementing your new system to function the way you have always done business and assume that the new system will “take care of it.” The key to success is to implement with Reliability in mind. In this session, we will discuss how the Greater Toronto Airport Authority (GTAA) implemented Maximo with Reliability in mind. We will discuss their current successes, use of new IoT technologies and their plans for future ways to enhance reliability. This in-depth look will not only discuss how GTAA achieve their reliability goals but will show you how to get on the path to reliability.

Asset Management

Enabling Asset Integrity

The RELIABILITY Conference Learning Session - 44:03
by Jeff Smith, Acuren

There are seven integrity enablers that must be managed, if they are managed not only is reliability insured it is cost optimized. The primary mistake observed in thirty years of reliability study is focusing on maintenance as a reliability optimization tool. To maintain is to keep in current state, so what is it the moves your asset out of its manufactured state? What type of loading creates stresses and strains that damage the asset? What operational parameters move your asset outside its comfort zone? How do your operators react to abnormal conditions? Is your automation control system protecting your asset or just notifying you of impending failures? Are your restoration and renewal programs aligned with your operational campaign?

Value optimization is enabled with integrity management; this complex problem is simplified by applying the simple process covered in this presentation. This process ties together all the value destruction issues and provides a methodology to enable integrity optimization.

You don’t “Maintain” the integrity of an asset you enable the integrity and maintain the results of that effort.

Asset Management

Insights From the Nuclear Power Industry Implementation of Value Based Reliability

The RELIABILITY Conference Learning Session - 27:29
by Derek Valine, PG&E

Developing cost-effective equipment maintenance strategies is a complex and data-intensive task, but necessary to realize an effective reliability program in a competitive environment. Historically, in the nuclear power industry, maintenance strategies have not been objectively risk-based, but rather they have been based on prevention of all failures regardless of cost. This approach to maintenance leads to expensive strategies that do not necessarily deliver higher levels of reliability.

Last year, the nuclear power industry identified the need to reduce overall O&M costs while still maintaining high levels of equipment reliability. This requires the ability to analyze and understand the impact of a strategy change not only on reliability but on overall cost of the strategy as well. Diablo Canyon Power Plant determined Preventance Precision by Asset Performance Technologies was the tool best able to provide reliability and cost projections in order to enable the development of cost-effective maintenance strategies.

The solution contains templates for over 700 asset types based on operating context and risk. The templates contain content that was developed as a industry collective and then used by numerous international companies over the last 20 years. Leveraging this content has enabled Diablo Canyon and other nuclear power plant operators to quickly and effectively develop and revise maintenance strategies to provide for required levels of reliability for the least overall cost.

Reliability Engineering for Maintenance

Reliability Centered Maintenance (RCM)-Driven Asset Management for Major Capital Projects

The RELIABILITY Conference Case Study - 43:16
by Walter Sanford, PinnacleART

You spent 10 billion USD conceiving, designing, constructing, and commissioning a major capital project for an offshore production asset. Now, how are you going to manage it? A comprehensive, proactive, risk-based maintenance plan is an integral part of your asset management program. Another essential component is a risk-based operational spare parts strategy – identification of the parts needed to complete proactive and corrective maintenance tasks for operating equipment, and how these parts will be made available when needed. This case study reviews the methodology used and the results achieved for using RCM to drive the comprehensive Risk Management strategy for a major capital project. Development included critical Asset Management elements, such as the Asset Hierarchy, Risk Based Maintenance program, Operator Driven Reliability, Risk Based Spare Parts Strategy, and all associated procedures and plans, fully populated in the CMMS and other management systems. The results demonstrated significant benefits over traditional approaches. For example, performing the detailed spare parts analysis and making risk-based decisions for stocking quantities resulted in a cost savings of over 10 million USD in reduced part stocking requirements, compared to following the vendor recommendations.

Managing Multiple Site Implementations in an Ever-Changing Business Climate

MaximoWorld 2017 Learning Session - 42:10
by Roy Cline, Medtronic

In today’s business climate of a global economy, you must have strong project management skills to support the ever-changing requirements of asset management and tracking. Medical devices companies are changing on an almost daily basis; acquisitions, divestitures, mergers, closings and opening of new manufacturing sites. The team overseeing these projects must have the flexibility to change quickly to provide both strong guidance in processes and accountability while being able to show maximum ROI. These individuals must realize they are providing guidance in support sustainable productivity and incorporating advances in technology to provide the greatest outcome for both the companies and the customers it services.

Asset Condition Management

The Evolution of Proactive and Condition Based Maintenance: Get More Out of Your Data

The RELIABILITY Conference Learning Session - 40:54
by Frederic Baudart, Fluke Corporation

How maintenance teams are using tiered maintenance, wireless tools and IIoT data management to get around the barriers to predictive maintenance implementation.

The combination of tiered maintenance, wireless tools/sensors and integrated technician/manager data management is allowing teams to move past long-standing barriers to predictive maintenance implementation. By reducing the level of difficulty and therefore the perceived degree of change and hardship, these techniques allow teams to implement a scaled approach to reliability, reflective of available resources and priorities. This paper evaluates how tiered maintenance is being applied and where it’s successful; examines the role that ease-of-use and automatic data capture plays regarding wireless thermal, vibration and electrical test tools and sensors; and assesses the workflows between technician and manager, with IIoT-facilitated data management and communication at the core.

Work Execution Management

Improving Maintenance Management for the U.S. Army Corps of Engineers

IMC-2016 Learning Zone - 36:34
by Bob Leitch, U.S. Army Corps of Engineers

The U.S. Army Corps of Engineers (USACE) Civil Works oversees and administers an asset portfolio with more than $250 billion in capital investments and 3,000 operating projects located in all 50 states, as well as several international river basins. The portfolio continues to deliver daily benefits to almost every U.S. household that range from clean hydro-electric power and low-emission transport to recreational opportunities and flood mitigation. Reliable performance of the nation’s investment in infrastructure is essential to the asset portfolio’s ability to deliver safe and dependable service. The cornerstone of reliability is a maintenance management strategy developed to meet the organizational performance objectives.

This effort began in 2012, after USACE finished deployment of the U.S. Department of Defense’s Facilities and Equipment Management (FEM) system (based on IBM’s Maximo software) and completed a series of internal assessments of maintenance practices. This led to a surprising conclusion: while there was a proven track record of maintaining facilities well beyond their design life at the local project levels, USACE lacked a maintenance management strategy with which to enhance that reliable performance corporately. Although certain USACE maintenance management practices were identified as “best practices” for innovative and successful methods to maintain assets, the majority of existing maintenance management activities were very inconsistent nationally.

In response to this, USACE developed a corporate life-cycle maintenance management strategy as a fundamental part of its overall Asset Management strategy. The Maintenance Management Strategy addressed all maintenance practices and responsible elements (Planning, Engineering & Construction, Operations, and Logistics), and developed a framework for consistent maintenance planning, execution, and analysis.