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Production and Operations Management. 4th ed. Oxford: Alden Press. 792p. Measuring and Managing Maintenance Page 74 Appendix A- Maintenance Strategy for a Heavy Engineering Environment MAINTENANCE VISION Operational Excellence through world class maintenance MAINTENANCE MISSION To provide a maintenance function that adds maximum sustainable value through the optimization of asset performance, availability and reliability MAINTENANCE PHILOSOPHY Preventive and predictive maintenance SAP(CMMS) Computerised Maintenance Management System • • • • • • Preventive and predictive maintenance. Training of production on the first line of maintenance systems & philosophy. Integrated holistic approach regarding performance of production and maintenance. Common basic maintenance approach for the Works, along SAP principles and system discipline. Adhering to basics: • Minimum tolerance for failure repetitions. • Minimum patch up jobs or temporary quick-fix repairs. Continuous Improvement • Increased condition based maintenance. • Improving operation stability by the prevention of breakdowns. • Annual benchmarking Measuring and Managing Maintenance Page 75 MAINTENANCE OBJECTIVES AND STRATEGY STRATEGY OBJECTIVES • • • • Move from reactive to preventive and predictive maintenance. Achieve 80% planned and 20% unplanned maintenance. Establishment and tracking of fixed maintenance measurements on order to continuously evaluate the quality of maintenance. Establish a culture of holistic approach within both maintenance & production disciplines on all levels of the organisation (know each other's business). • • • • • • • 80% of all maintenance activities are planned well in advance on the CMMS 20% of maintenance tasks are planned after condition monitoring and inspections. There is zero or 0% tolerance for failures Utilising RCM II approach to determine maintenance phins for equipment. Condition monitoring to ensure that no unmanaged failures occurs. • Structured inspection system • Statistical process control • Vibration measurement • Tribology • Thermography Formally documented root cause analysis of failures. Enhanced maintenance training on all levels of maintenance personnel. MANAGEMENT. PROCESS MONITORING AND TRACKING Daily • • • Weekly • • • Monthly • • • 6 Monthly Ensure proper execution of planned maintenance tasks. Updating of system with future plans. Root Cause Analysis on equipment failure and rectify data packs and maintenance plans. Ensure 80% of work planned 1 week in advance with resource balancing. Follow up on RCA targets. Report on maintenance process performance and disciplines together with equipment performance. Condition monitoring of Critical on Critical equipment. Plant availability tracking. Full maintenance audit to ensure compliance with stated goals according to fixed measurements set. Measuring and Managing Maintenance Page 76 Appendix B- Question set for evaluation of Maintenance Performance Elements Maintenance (capability assurance) Question Type AID: Element: 1 Plant condition monitoring Practice: 1.1 Equipment maintenance plans Question: How is equipment maintenance plans applied to ensure the capability of equipment is assured according to the user's needs? Question Type AID: Element: 1 Plant condition monitoring Practice: 1.2 Careful operations Question: How is maintenance departments involved in setting up of operational procedures regarding the careful operations of equipment, what is the approach and how is it deployed? Question Type AID: Element: 1 Plant condition monitoring Practice: 1.3 Equipment inspections Question: How is the frequency and scope of work regarding equipment inspections determined? Question Type AID: Element: 1 Plant condition monitoring Practice: 1.4 Predictive maintenance Question: How do you approach predictive maintenance and to what extent is this approach deployed? Question Type AID: Element: 1 Plant condition monitoring Practice: 1.5 Preventive maintenance triggers Question: How are the principles of preventive maintenance used and utilised in order to improve the condition of equipment and reduce losses? Question Type R: Element: 1 Plant condition monitoring Question: A) What principles are used to identify the areas of measure for determining the equipment's condition? B) Is an effective historic database of these results kept? C) Is this data being used to determine the current condition of the equipment by comparing the actual trend data to the baseline data of the equipment? Measuring and Managing Maintenance Page 77 Question Type 1: Element: 1 Plant condition monitoring Question: What systems are in place to ensure that the use of condition monitoring of equipment .is improved over time. How is the effective use of condition monitoring measured to ensure reduction of losses? Question Type AID: Element: 2 Work origination Practice: 2.1 Information required to originate work Question: What data is used in order to originate work, how is the quality of this data verified in order to ensure effective work planning and execution? Question Type AID: Element: 2 Work origination Practice: 2.2 Work origination methodology Question: What systems and procedures are in place to identify and automatically generate new work? How and what data is captured for historic reference? Question Type AID: Element: 2 Work origination Practice: 2.3 Review and feedback Question: Is the requestor of the work timely informed of the progress and status of the work? Question Type 1: Element: 2 Work origination Question: Is historically captured data on the CMMS utilised to improve the creation of routine maintenance tasks? Question Type R: Element: 2 Work origination Question: A) Is work origination measured in different categories? B) Are these categories trended and communicated? C) Is this data effectively used to improve the reduction of losses over the long term? Question Type AID: Element: 3 Planning Practice: 3.1 Information required for planning Question: What systems & structures are in place to determine the need for information required to do effective planning? Measuring and Managing Maintenance Page 78 Question Type AID: Element: 3 Planning Practice: 3.2 Planning methodology Question: How are new jobs prioritised with respect to planning and resource scheduling? Question Type AID: Element: 3 Planning Practice: 3.3 Creating a standard job library Question: Are standard jobs compiled using a scientific approach based on the OEM specifications. Are these tasks reviewed according to the current state of the equipment's condition? · Question Type R: Element: 3 Planning Question: A) Is effective planning compared to not performing planning at all in terms of actual and potential losses? B) Is a database of this information kept and available? C) Is historical data being used as an input for planning new tasks? Question Type 1: Element: 3 Planning Question: Are post mortem meetings being held after job execution and compared to the baseline planning in order to serve as future improvement initiatives? Question Type AID: Element: 4 Scheduling Practice: 4.1 Scheduling (two weekly, monthly) Question: How are resources scheduled over the medium term (two weekly and monthly), how does this interact with the planning process? Question Type AID: Element: 4 Scheduling Practice: 4.2 Scheduling (daily) Question: What is the availability of resource for scheduling on the short term (daily)? Question Type 1: Element: 4 Scheduling Question: How are the systems and procedures regarding scheduling of resources reviewed and improved? Measuring and Managing Maintenance Page 79 Question Type R: Element: 4 Scheduling Question: A) How is scheduling measured? B) Are all the parties involved in scheduling identified and is scheduling data communicated? C) Is historical data used to improve the results obtained from scheduling? Question Type AID: Element: 5 Work allocation and execution Practice: 5.1 Information for allocation and execution Question: What information is currently being used for effective work execution? Question Type AID: Element: 5 Work allocation and execution Practice: 5.2 Methods of allocation and execution Question: Is the efficiency of work execution measured against the original planning? Question Type AID: Element: 5 Work allocation and execution Practice: 5.3 Communicating shift handover Question: What systems are being used to communicate the information required to hand over work from one team to another, how is this information required determined? Question Type AID: Element: 5 Work allocation and execution Practice: 5.4 Equipment handover Question: Is there a system in place to hand over equipment to the user; is a checklist in place to ensure that all the needs of the user are satisfied after work completion? Who are the parties involved in the official handover (maintenance disciplines and customers)? Question Type R: Element: 5 Work allocation and execution Question: A) How is the effectiveness of work allocation and execution measured? B) Is historical data being kept of work execution measures? · C) How is this data being used to explain gaps between baseline planning of work and the actual execution of the work? Question Type AID: Element: 6 Work Completion and recording Practice: 6.1 Work completion and history recording methodology Question: What approach is followed in determining what data must be recorded and captured? Measuring and Managing Maintenance Page 80 Question Type AID: Element: Element: 6 Work Completion and recording Practice: 6.2 Information recorded as history at closure Question: Is data recorded at completion of work stored in an understandable manner for easy future reference. Are deviations recorded to ensure effective benchmarking for the future? Question Type 1: Element: 6 Work Completion and recording Question: Is data recorded being used to improve work completion and how is this integrated with planning and scheduling? Question Type R: Element: 6 Work Completion and recording Question: A) Is the quality of work completion data being verified? B) Is this data being used to communicate the current state of effective work completion? C) Is the data effectively interpreted in order to understand the gaps that exist? Question Type AID: Element: 7 Shutdown management Practice: 7.1 Shutdown formulation Question: What method is being used in order to effectively collect information required for shutdown planning? Question Type AID: Element: 7 Shutdown management Practice: 7.2 Shutdown planning Question: What tools are being used in order to plan shutdowns (e.g. Bar charts, resource planning, process pipeline planning)? Question Type AID: Element: 7 Shutdown management Practice: 7.3 Shutdown execution Question: How is shutdown execution managed especially towards scope changes, what criteria is being used to accept scope changes? Question Type AID: Element: Element: 7 Shutdown management Practice: 7.4 Start up and commissioning Question: How is commissioning managed especially from the customer and safety point of view? Measuring and Managing Maintenance Page 81 Question Type AID: Element: 7 Shutdown management Practice: 7.5 Post shutdown review Question: Is post mortem meetings being held and are all deviations (from planed time and planed scope) of the original plan recorded with reasons in order to eliminate future losses? Question Type R: Element: 7 Shutdown management Question: A) Is baseline planning of downtime and the scope of work available? B) Is the progress of work measured against the baseline and communicated? C) Is the data being used to understand the gaps that exist? Question Type 1: Element: 7 Shutdown management Question: Is previous historical data being used as inputs to planning with respect to improvement? Question Type AID: Element: 8 Facilities, equipment and tools Practice: 8.1 Tools Question: What criteria are being used to determine the tools required for the work (e.g. safety)? Question Type AID: Element: 8 Facilities, equipment and tools Practice: 8.2 Facilities and equipment Question: How are the facilities and equipment required, determined to ensure minimum losses (e.g. workshop location etc.)? Question Type AID: Element: 9 Determining root cause of losses Practice: 9.1 Determining root cause of losses Question: To what extent is an analytical and scientific approach followed to determine areas of improvement for RCA? Question Type R: Element: 9 Determining root cause of losses Question: A) Is the actions implemented from RCA processes measured to determine the loss reduction achieved? B) Are the actions measured against the expected completion date? C) Are implemented RCA actions reviewed for effectiveness after implementation? Measuring and Managing Maintenance Page 82 Question Type 1: Element: 9 Determining root cause of losses Question: How regular is the RCA process reviewed in order to improve it? Question Type AID: Element: 10 Achieving improvement in Capability assurance Practice: 10.1 Routine improvement Question: What approach is followed to improve the capability of equipment and to reduce losses, are losses recorded in different categories and analysed to focus improvement initiatives? Question Type AID: Element: 10 Achieving improvement in Capability assurance Practice: 10.2 Focused improvement Question: Are improvement initiatives aimed at improving specific losses identified? Question TypeR: Element: 10 Achieving improvement in Capability assurance Question: A) Are losses and the causes thereof determined? B) Are losses displayed in revenue lost and well communicated? C) Is the data being used to understand the nature and cause of the loss; are actions being implemented in order to reduce 1 eliminate these losses? Question Type R: Maintenance (capability assurance) Question: What are the results achieved form overall equipment capability management? Question Type 1: Maintenance (capability assurance) Question: What initiatives are currently being implemented in order to improve the overall equipment efficiency management? Measuring and Managing Maintenance Page 83 Results from Maintenance Performance Appendix C- Elements Evaluation Maintenance (capability assurance) Measurement Ref. 0.0 Maintenance (capability assurance) ES* NS* R 3.0 2.5 3.0 I 3.7 2.5 3.5 0.0 1.0 1 Equipment maintenance plans R 2.5 3.0 3.6 I 2.0 3.0 3.0 A 2.0 3.0 3.5 3.0 3.0 1.0 1.1 1.1 Equipment maintenance plans 1.1 1.2 1.2 Careful operation 1.2 1.3 3.0 2.0 3.2 3.0 2.1 4.0 4.5 D 3.0 3.5 4.0 A 1.5 2.0 4.0 D 1.2 2.0 3.5 R 0.6 3.5 3.0 Preventive maintenance triggers I 2.0 3.5 3.0 2.1 Information required to originate work A 2.5 4.0 4.5 D 3.5 3.8 3.5 2.2 Work origination methodology A 3.5 4.0 4.0 D 2.0 3.8 3.0 A 1.5 3.5 3.0 D 1.0 3.0 3.0 R 3.5 2.5 4.0 2.3 Review and feedback , 3 Planning 3.0 3.1 3.1 Information required for planning 3.1 3.2 3.2 Planning methodology 3.2 3.3 3.3 Creating a standard job library 3.3 4.0 4 Scheduling 4.0 4.1 4.1 Scheduling (two weekly, monthly) 4.1 5.0 5 Work allocation and execution 5.1 5.1 Information for allocation and execution 5.1 5.2 5.2 Methods of allocation and execution 5.2 5.3 5.3 Measuring and Managing Maintenance 3.5 D 2.2 2.3 4.0 A 2.1 2.3 2.0 Predictive maintenance 2.0 2.2 3.0 2.0 1.4 Work origination 2.1 3.0 1.2 2.0 1.5 2 2.0 D A 1.5 2.0 A Equipment inspections 1.4 1.5 D 1.4 1.3 1.3 1.4 WA* QT* Communicating shift handover I 1.5 2.2 3.0 A 3.6 3.0 2.0 D 2.5 2.8 2.0 A 4.0 3.5 4.0 D 3.0 2.8 3.0 A 2.0 2.0 4.0 D 1.6 2.5 3.6 R 4.0 3.0 4.0 I 2.5 2.5 3.8 A 3.5 3.0 3.5 D 3.0 1.5 2.5 R 2.5 3.0 3.0 A 2.5 3.5 3.0 D 1.5 3.0 2.5 A 3.6 3.5 4.0 D 3.1 2.0 3.0 A 0.0 3.5 4.5 Page 84 5.3 5.4 5.4 Equipment handover 5.4 6.0 6 Work Completion and recording 6.0 6.1 6.1 Work completion and history recording methodology 6.1 6.2 6.2 Information recorded as history at closure 6.2 7.0 7 Shutdown management 7.0 7.1 7.1 Shutdown formulation 7.1 7.2 7.2 Shutdown execution 7.2 7.3 7.3 Start up and commissioning 7.3 8.1 8 Facilities, equipment and tools 9 3.0 1.0 2.0 2.5 3.0 I 1.5 2.6 2.5 A 3.0 2.8 4.0 D 2.0 2.0 3.0 A 2.5 3.0 4.0 D 2.0 2.0 3.0 R 1.5 2.5 4.0 I 2.0 3.0 4.0 A 2.5 3.0 4.0 D 2.0 2.6 4.0 A 2.5 3.5 4.5 D 2.0 3.0 4.0 A 2.0 3.0 4.0 D 1.0 2.5 3.5 4.0 D 2.0 4.0 3.0 Facilities and equipment A 4.0 3.5 4.0 D 3.0 3.5 4.0 Determining root cause of losses R 3.0 2.0 4.0 I 2.0 2.2 2.5 A 3.5 2.5 3.7 D 2.0 2.0 3.6 R 3.5 2.6 3.6 10.1 Routine improvement A 3.5 3.0 3.0 D 2.0 2.0 2.5 10.2 Focused improvement A 3.0 3.0 5.0 D 2.0 2.0 4.0 Achieving improvement in Capability assurance 10.1 10.2 1.3 R 8.2 9.1 10 D 4.0 Determining root cause of losses 10.1 4.5 2.0 9.1 10.0 4.5 3.5 A 9.0 9.1 3.0 Tools 8.2 9.0 0.0 3.0 8.1 8.1 8.2 D A 10.2 QT = Question Type ES = Engineering Services NS = North and South Plants WA =West and Advalloy Plants Measuring and Managing Maintenance Page 85 aoueualU!BII'J 6u!5eueii'J pue 6upnseaii'J IB!lU8P!JUO:) 98 a6ed s~re 0 0 0 ~ ~ ~ ~ ~ 0 ~ 0 ~ w 0 w ~ ~ ~ ~ 0 ~ 0 Equipment maintenance plans Careful operation Equipment inspections Predictive maintenance Preventive maintenance triggers Information required to originate work Work origination methodology Review and feedback )> Information required for planning "0 "0 .... g Planning methodology (") ::r Creating a standard job library m 1D 3(1) :I c(1) Ill n 0 s:::: CD Scheduling (two weekly, monthly) til =. 0 Information for allocation and execution ::I :;o CD Methods of allocation and execution til :::1. 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Cl) . c: 6unnpa4os Z' 0 c: c: Cl) 0 E - Q. ·c: u 1/) G) - ~~ ... c. 0 cG): ·0 "'C ... <o E (,)_ E G) 6U!UUeld iii (,) . ... .. c: 0 (,) Cl) en Cl) UO!jeU!61JO c. ~JOM (/) Cl) ·c:::I t: 0 c. c. sue1d aoueua1u!ew 1uawd!nb3 0 (aouemsse Al!l!qedeo) aoueualU!eLAI q o.q L() N L() c) 0 c) aJO!>S Confidential Measuring and Managing Maintenance Page 105 Appendix D- The ARDI Cycle for Improvement AMC - Quality and Improvement The ADRI cycle is similar to the Plan-Do-Act-Check model found in many quality systems. Both are designed to prompt the user to ask simple questions that will assist in the implementation of improvement initiatives. How to undertake a quality improvement project (using the ADRI cycle) Quality improvement projects are best conducted as a team exercise. The people in your work-group are the best people to understand quality issues affecting their everyday work life. Form a small team of interested people, have a discussion on the variety of issues affecting your work and start swapping ideas on how to improve things. Before commencing a quality improvement project, staff members are encouraged to read through the ADRI users guide below:- Stage 1 - Approach What the user should do and what questions to ask Useful information 1. What are the objectives of the organisation and how The AMC Strategic Plan contains the organisations' will my quality improvement project assist with mission, vision, goals, strategies and KPis. This will achieving those objectives? help you identify those projects which have the greatest value to the organisation. 2. Are these objectives well established and accepted by all stakeholders? Confidential Measuring and Managing Maintenance The objectives in the AMC Corporate Plan should be widely disseminated and reflected in other plans such as Faculty Plans and polides in the Document Library. This will help you assess the suitability of existing KPis and whether new KPis are needed. Page 106 3. Define the problem you are trying to resolve or the process you are trying to improve. Is the resolution of this problem in line with the organisations' objectives? As above 4. Briefly define the current situation using readily available data to establish a "base-line" A quick review of existing KPI's will often assist you in "setting the picture" so you can readily see opportunities for improvement. 5. Sketch out a plan for your quality improvement project and discuss it with others. The Management & Projects Analyst can advise you on planning your project and point you towards other data sources or other people in the organisation with similar interests. The Quality Enhancement Committee (QEC) and its associated working parties may be able to offer some valuable advice or support. Stage 2 - Deployment What the user should do and what questions to ask Useful information 1. How am I going to put my quality improvement project into action? The document AMC Principles and Approaches to Quality & Improvement will give you some guidelines on how to pia A a project. Likewise the Management & Projects Analyst can also give you some advice. 2. Who will work on this project and are they suitably trained? Do I need additional resources? If you need assistance resourcing your project you can approach your Program or Faculty Head and brief them about the value of your idea. Alternatively the QEC through the Management and Projects Analyst can also give you some advice on suitable training courses or resource availability. 3. What additional data will I need to measure the success of my project? Before deploying any plan it is wise to first think of how you are going to measure the impact of your initiative. You may be able to use existing KPI's or you may need to develop entirely new measures. The Management and Projects Analyst can give you some direction on this topic. 4 . Analyse the data and identify some possible solutions. This part relies heavily on team-work. Use the available data to brainstorm possible solutions in your work-group. This may require gathering new data and undertaking some root-cause analysis, or it may involve some simple discussions. The greater the number of ideas - the better. You may also choose to get advise from someone outside your work-group - a fresh set of eyes will often see different solutions. 5. Set a target and implement your quality improvement plan. Use the available data to set a challenging but realistic target for your project. This may involve some benchmarking to see how well we perform against other like-organisations. Implement the plan. Stage 3 - Results What the user should do and what questions to ask Useful information 1. What are the results from implementing this plan? Monitor the progress of your project by collecting data (eg KPI's) that you had earlier decided would be a suitable measure of success. Plot these data on a time-series graph so you can see the improvement. Benchmark the data against those of other organisations. Confidential Measuring and Managing Maintenance Page 107 2. Do I understand how these results were achieved? Are the targets achievable? The graphing of a measurable improvement over time is a good way to show that your project has worked. In turn this shows that you have accurately understood the problem, defined that the project is relevant to the organisations' strategic objectives and implemented an effective improvement strategy. If you have been successful, then your improvement initiative will be repeatable and you can modify your project to attain a realistic target. Stage 4- Improvement What the user should do and what questions to ask Useful information 1. How can I review this improvement project? How can the results be further improved? Ongoing monitoring of the results of your project and further discussion of the results amongst your workgroup may produce ideas as to how you can further improve the process or outcomes. You may also choose to look further afield for opinions or undertake further benchmarking to see how other institutions perform. When you have developed a new strategy to improve the outcomes of your project, or decide to undertake a new project, it is time to start the ADRI cycle again. 2. How can the rest of the organisation learn from this quality improvement project. If you have successfully completed the ADRI cycle and have achieved the desired improvement, share your findings with other work groups in the organisation. This may be through informal discussion and staff meetings or a formal presentation or briefing paper. Other work-groups will be interested to hear of your work and they may be able to apply a similar plan to improve their areas of responsibility. The QEC and the Management & Projects Analyst will be keen to hear of the progress and outcomes of your project. Quality is often described as the degree to which a set of inherent characteristics fulfils requirements. Therefore attaining quality is the first step in the cycle. Continuous Improvement is described as recurring activity to increase the ability to fulfillment of requirements. Consequently improvement is the second step in the cycle. Confidential Measuring and Managing Maintenance Page 108