Asset Lifecycle
– Design and
Maintenance
John Hunter
MAV Conference
30 May 2013
Ability to Influence
Ability to influence
Concept / Preliminary Design
Design / Specification
Procurement / Construction
Commissioning and handover
Operations
Maintenance
Time in the asset’s life cycle
Renewal
Design for…
•
•
•
•
•
•
•
•
Maintainability
Reliability
Durability
Quality
Deconstruction
Safety
Waste prevention
Positive social and environmental impact
Design for Maintainability
Designing features to allow ease of maintenance.
Advantages – Low downtime, continuous LoS.
Examples:
• Grass cutting and steep slopes
• Co-locating into single areas
• Accessibility - light poles
• Bio-retention devices
• Standardisation
Design for Reliability
Designing assets to minimise downtime
Advantages - Repeatable uninterrupted LoS.
Examples:
• Sealed roller bearings to prevent dust ingress
• Traffic signals with diagnostic capabilities
• Fibre optic network with redundant paths
Design for Durability
Failure-free / maintenance-free operating.
Advantages – Long time to renewal.
Examples:
• Galvanise / paint / powder coat / stainless
• Add asphalt additives in plant to counter UV R
• Downpipes – S/S.
• External cladding on Bus Depot Buildings
Design for Quality
Totality of features to satisfy needs of users.
Advantages – Lean; negate rework and 10X rule
Examples:
• QA in design, materials, construction.
• No defects; no rework
• Fit for purpose and meets service levels.
Design for Deconstruction
An opportunity to salvage / reuse components.
Advantages - Ease of disassembly.
Examples:
• Fixing mechs, welding / bolting / adhesives
• Potential for future reuse / recycling
• Prefabric’n rather than permanent structures
• USA – C&D represents ~ 25% landfill waste
Design for Safety
Mitigate / minimise safety risks.
Advantages – protect community and staff
Examples:
• Construction, maintenance, operation
• Locate cabinets away from roads
• Bike-safe storm water grates
• Non-slip materials
Design for Waste Prevention
Minimise waste at each asset life cycle phase
Advantages – Sustainability
Examples:
• Services share same trenches if possible
• Group wet areas together - save pipe lengths
• Reduce, e.g. water, electricity
• Reuse, e.g. Brisbane tuff kerb stones
• Recycle, e.g. asphalt
Design for Positive Social,
Environmental and Economic Impacts
Advantages – To contribute positive impacts to
social, environmental and economic wellbeing.
Examples:
• Sustainability – now and the future
• Green star ratings
• Meet a range of targets.
Design Collaboration
•
•
•
•
•
•
Design
Procurement
Construction
Operations
Maintenances
Service Users
Here’s what we can do
•
•
•
•
•
Think long term
Simplify
Carry a notebook
Implement practical solutions
Involve others
Here are some questions to ask
• “How can I / we make a
whole-of-life difference with
this design?”
• “Who do I need to involve?”
• “What’s possible?”
What are the take home messages?
• Design has the single biggest impact on the
assets’ WOL costs and serviceability.
• Design can impact for 10, 100 years and more.
• We have the opportunity to create the future
• - What can you do differently in your design?
Steve Job’s mantra
Design is not about how things look.
Design is about how things work.
The big difference - outcomes.
Internet sites (Design for…)
Maintainability
http://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Maintainability.pdf
Safety
http://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Reliability.pdf
Manufacturing
http://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Manufacturing.pdf
Deconstruction
http://www.deconstructioninstitute.com/files/downloads/75508728_DesignforDeconstructionPaper.pdf
Asset Lifecycle Maintenance
Maintenance is “end of pipe”
Ability to influence
Concept / Preliminary Design
Design / Specification
Procurement / Construction
Commissioning and handover
Operations
Maintenance
Time in the asset’s life cycle
Renewal
Maintenance
“If all you have is a hammer, every problem
looks like a nail.”
Maintenance Overview
1. Detect
2. Prevent.
3. Remediate
Performance
Inherent Reliability – How the asset was
designed. We cannot change reliability
unless by re-designing or replacing with
better parts
Operating environment – How it will be
operated. ~ 40% of failures are due to
Operator handling.
Maintenance – Detect, prevent, remediate
Performance Indicators
Leading Indicators
Forward looking (windscreen). Allows us to
examine the process.
Lagging Indicators
Backward looking (rear-vision). Allows us to
measure the output of a process.
Condition ratings
Condition
Description of Condition
Rating
1
Very good condition – Only normal maintenance required
2
Minor defects only – Minor maintenance required (5%)
3
Maintenance to enable an asset to provide an acceptable level of
service – Significant maintenance required (10% - 20%)
4
Requires renewal – Significant renewal/upgrade required (20% - 40%)
5
Asset unserviceable – Over 50% of the asset requires replacement
P-F Curve
Planning and Scheduling
P
P
A
A
A
A
A
P
A
A
P
A
A
P
A
A
P
A
A
A
A
Maintenance Contracts
 Inspection – such as checking for wear and tear,
breakage and reporting back.
 Preventive – e.g. In a building or P&E, calibrating
building plant or lubricating.
 Full labour – 100% labour coverage, but no
materials cover.
 Full coverage – 100% coverage for labour, parts,
materials and breakdowns.
Lean
Seven wastes
• Overproduction
• Waiting
• Transport
• Motion
• Over-processing
• Spare parts
• Defects
5S Housekeeping
• Sorting – Keep only the tools essential for your job.
• Setting in Order – Arranging tools to eliminate time
working with them.
• Shine – Keep workplaces clean, tidy and organised.
• Standardising – Systemise activities where possible.
• Sustaining – Maintain new standards and do not
allow to lapse.
Sustainability
•
•
•
•
•
•
•
•
Designing for maintainability
Design for reliability
Design for durability
Design for quality
Design for safety
Design for Deconstruction
Design for Waste prevention
Design for positive social impact
Concluding
Design
Pre - acquisition
Maintenance
Post – acquisition
Opportunities
Questions?