{"id":7935,"date":"2019-12-18T17:43:30","date_gmt":"2019-12-18T17:43:30","guid":{"rendered":"https:\/\/www.aroraengineers.com\/?p=7935"},"modified":"2020-05-11T14:51:41","modified_gmt":"2020-05-11T14:51:41","slug":"implementing-reliability-based-maintenance-program","status":"publish","type":"post","link":"https:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/","title":{"rendered":"Implementing a Reliability-Based Maintenance Program"},"content":{"rendered":"
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\n

\"Implementing<\/h2>\n

Advanced Processes Offer the Greatest Potential ROI<\/h2>\n

The above chronology emphasizes advanced processes which enhance asset reliability, workforce productivity, and job safety. The goal, as always, is to work on the right asset, using the right strategy, in the safest manner, at the right time, by the right resource, for the least cost. But installing software, even a best-of-breed product,\u00a0will not get you there<\/u>\u00a0without a long-range plan and careful thought of the endgame.<\/p>\n

The Asset Manager Role is Key<\/h2>\n

The Asset Manager position (or similar) identifies the vision for excellence. He\/she is responsible for the vision\/mission statement, SAMP, a CMMS utilization plan, and a long-range plan, plus the implementation of standards across the organization. The Asset Manager would provide a roadmap for the creation of a true knowledge base, the use of analytical reports to manage by exception, and continuous improvement therein.<\/p>\n

20 Steps to Better Asset Management<\/h2>\n
    \n
  1. The Asset Manager introduces a Reliability-Based Maintenance Program<\/strong> across the entire portfolio. All plants would be required to adhere to these standards.<\/li>\n
  2. The review team (led by the Asset Manager) will conduct an AS-IS assessment<\/strong> of the current CMMS design, create SAMP and utilization plan, build-out supporting process and roles, review KPIs and analytical report capability, and assess overall culture and buy-in to asset management.<\/li>\n
  3. The Asset Manager technical specialist will conduct\u00a0technical training of CMMS<\/strong> support staff depending on the assessment. Also, make sure the CMMS admin staff is not under-utilizing any power features (e.g. auto part reorder at ROP; the Autosparepartadd flag; PM-to-WO generation cron; and SR-to-WO conversion).<\/li>\n
  4. The Asset Manager will work with HR to establish positions\/roles for reliability engineer, business analyst, and gatekeeper<\/strong>. The CMMS database and accuracy therein has been questioned since the\u00a0dark ages<\/strong>. It’s time to do something about it. Therefore, I strongly believe in the role of\u00a0gatekeeper<\/strong>. This person would (1) process\/dispatch urgent work, (2) perform WO accuracy\/quality grading by submitter, (3) provide a WO relative ranking of importance, lead craft, and rough estimate, and (4) provide WO completions review to include failure mode and WO feedback.\u00a0A\u00a0business analyst<\/strong> would interview all groups involved with asset management, document essential analytical reports, and take these outputs to the core team to make sure the voice of \u201cworking level is heard.\u201d<\/li>\n
  5. The Asset Manager will create an asset management<\/strong>\u00a0core team<\/strong>. They will establish a definitions library, business rules, and activate data quality error checks. They will also begin tracking a prioritized action list and pursue on-going benchmarking in search of continuous improvement.<\/li>\n
  6. The Asset Manager would lead group discussions on the creation of a resource-leveled long-range plan.<\/strong><\/li>\n
  7. Create a reliability team<\/strong> with charter and purpose. Instruct them to design the bad actor report with drill-down on failure mode and identify RCA trigger points. Combining powerful analytics with meaningful failure data about health\/performance, management can make smarter decisions, increase reliability, and reduce O&M costs.<\/li>\n
  8. Set up\u00a0work order main for failure mode capture<\/strong> (failed component + component problem + cause) as validated fields.<\/li>\n
  9. Start monthly reliability team meetings<\/strong> and run the bad actor report with multiple options for extracting the Top 10, including average annual maintenance cost divided by replacement cost. Drill-down on failure mode (cause) and take corrective action.<\/li>\n
  10. Identify site power users<\/strong>. Get their input on problems and their suggestions.<\/li>\n
  11. Implement chronic failure analysis training<\/strong> for all sites and power users.<\/li>\n
  12. Evaluate the planning<\/strong>\u00a0process and backlog management. I<\/strong>mplement a resource-leveled,\u00a0weekly maintenance schedule<\/strong>\u00a0(inside the CMMS) using a risk-based work order\u00a0prioritization matrix<\/strong>.<\/li>\n
  13. Implement a defect elimination program<\/strong>.<\/li>\n
  14. Implement formal work order feedback<\/strong> to include capture of maintainability, safety issues, ergonomics, design flaws, PM strategy & frequency refinements, missing asset, and missing failure codes.<\/li>\n
  15. Design\/build screen for capturing risk-based asset criticality<\/strong>.<\/li>\n
  16. Embed safety (HSE) program<\/strong> into the reliability-based maintenance program.<\/li>\n
  17. Design\/build RCM failure modes and strategies screen<\/strong> for storing analysis results inside CMMS and create a living program.<\/li>\n
  18. Begin the on-going process of validating the existing PM\/CBT program<\/strong> using RCM\/PMO analysis and WO feedback.<\/li>\n
  19. Implement integrated project cost tracking<\/strong> for STO using WBS cost accounts. Provide scheduling software which facilitates total float calculations, progressing, automatic resource leveling, logic bar charts, histograms, and network diagrams.<\/li>\n
  20. Create reliability leaders<\/strong> throughout the organization (e.g. ReliabilityWeb CRL program)<\/li>\n<\/ol>\n

    The Purpose of a Plan<\/h2>\n

    Planning, in this case, means schedule. The only perfect schedule is one that is 100% done. But to not have a schedule opens the door to poor craft coordination, not working the critical path, poor scope control, and increased risk. Dates might be missed, but at least you know what to work on, in what order, and by whom. Maybe the best reason to have a long-range plan is to not forget things<\/strong>, plus, it makes a great conversation starter!<\/p>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"

    Advanced Processes Offer the Greatest Potential ROI The above chronology emphasizes advanced processes which enhance asset reliability, workforce productivity, and job safety. The goal, as always, is to work on the right asset, using the right strategy, in the safest manner, at the right time, by the right resource, for the least cost. But installing […]<\/p>\n","protected":false},"author":3,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[39],"tags":[],"class_list":["post-7935","post","type-post","status-publish","format-standard","hentry","category-insight"],"acf":[],"yoast_head":"\nImplementing a Reliability-Based Maintenance Program - Arora Engineers<\/title>\n<meta name=\"description\" content=\"Implementing a Reliability-Based Maintenance Program \u2013 Advanced Processes Offer the Greatest Potential ROI The above chronology emphasizes advanced processes which enhance asset reliability, workforce | Arora Engineers\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Implementing a Reliability-Based Maintenance Program\" \/>\n<meta property=\"og:description\" content=\"Implementing a Reliability-Based Maintenance Program \u2013 Advanced Processes Offer the Greatest Potential ROI The above chronology emphasizes advanced processes which enhance asset reliability, workforce | Arora Engineers\" \/>\n<meta property=\"og:url\" content=\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/\" \/>\n<meta property=\"og:site_name\" content=\"Arora Engineers\" \/>\n<meta property=\"article:published_time\" content=\"2019-12-18T17:43:30+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2020-05-11T14:51:41+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.aroraengineers.com\/wp-content\/uploads\/2019\/12\/Implementing-a-Reliability-Based-Maintenance-Program-760x438.png\" \/>\n<meta name=\"author\" content=\"Arora\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Arora\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"4 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/#article\",\"isPartOf\":{\"@id\":\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/\"},\"author\":{\"name\":\"Arora\",\"@id\":\"http:\/\/www.aroraengineers.com\/#\/schema\/person\/f03df9be4c710f2ceed2f4db6219821f\"},\"headline\":\"Implementing a Reliability-Based Maintenance Program\",\"datePublished\":\"2019-12-18T17:43:30+00:00\",\"dateModified\":\"2020-05-11T14:51:41+00:00\",\"mainEntityOfPage\":{\"@id\":\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/\"},\"wordCount\":801,\"commentCount\":0,\"image\":{\"@id\":\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.aroraengineers.com\/wp-content\/uploads\/2019\/12\/Implementing-a-Reliability-Based-Maintenance-Program-760x438.png\",\"articleSection\":[\"Insight\"],\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"CommentAction\",\"name\":\"Comment\",\"target\":[\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/#respond\"]}]},{\"@type\":\"WebPage\",\"@id\":\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/\",\"url\":\"http:\/\/www.aroraengineers.com\/implementing-reliability-based-maintenance-program\/\",\"name\":\"Implementing a Reliability-Based Maintenance Program - 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