Qurayyah Sea Water Maintenance Div
May 3, 2009
“Safety is a Measure of Success”

Safety is a Measure of Success

Outline
Our Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
•
Deployment of Enhanced Business Processes
•
Developed Forms for the use of Reliability Engineers
Challenges
Rapid Improvement Teams
Way Forward
Safety is a Measure of Success

Achieve and Sustain Best-In-Class Performance
Expand
Improvement
Opportunities
SUSTAIN
Continuous
Awareness &
Team Building
Monitor Results
IMPROVE
Max Systems
& Resources
Utilization
Deploy Predictive
Maint Tools
Optimize
Preventive Maint
Optimize Support
Services
STABALIZE
Eliminate
‘Bad Actors’
Enhance
Business
Processes
Capture
Knowledge
Improve SAP
Data Quality
Journey Towards Maintenance & Reliability Excellence

Outline
Our Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
•
Deployment of Enhanced Business Processes
•
Developed Forms for the use of Reliability Engineers
Challenges
Rapid Improvement Teams
Way Forward
Safety is a Measure of Success

Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
• Shipping Pumps G-7101 – G-7801
• SO
2
Gas Fan
• Column Bottom Pumps
Safety is a Measure of Success

st
Data Source: SWED Trip Report & Operations Logbook (Period: Jan 2008 – March 2009)
Current MTBF :
1.5 Months
Mean Time Between Failure: (MTBF)
Desired MTBF:
60 Months
Safety is a Measure of Success

Safety is a Measure of Success

2
Recommendations :
• Short-term - Change Preventive Maintenance interval from 12 to 3 Months.
• Long-term - Implement engineering design package (under development) to eliminate the process upset
Status: ETC: TBD
Safety is a Measure of Success

Root Cause:
•
Premature Failure of Pump Wear Rings and Anti-
Rotation pin due to inappropriate “Material”
(Nitronic -60) causing “High Vibration”
Short Term Plan:
•
Sent old wear rings to CSD Metallurgy Specialist for Analysis. –
Waiting for recommendations
•
Overhaul five (5) pumps module 15 – 19 and replace the wear rings and anti rotation pins, fabricated from correct material
Long Term Plan:
•
Inspect other nine (9) pumps module 20 – 28 and replace wear rings
•
Inform MS to contact the vendor for correct material wear rings and stocking action
Safety is a Measure of Success

Deployment of Enhanced Business Processes
Reporting PM finding – Early detection of problems
Supervisor
Report Notification
No Tracking & Feedback
PM QA /QC
Safety is a Measure of Success

Deployment of Enhanced Business Processes
Equipment Trips Reporting and Tracking
Operations Plant Foreman Plant Engineer
No E- Process, Trip Sheets are manually filled and Tracked .
Staff
Maintenance
SAP M2
Notification
Comments Comments Findings
Root Cause
Evaluation
Reliability Engineer’s Evaluation and Tracking
Safety is a Measure of Success

Deployment of Enhanced Business Processes
Maintenance Rework Tracking
Operations Plant Foreman Reliability
Any maintenance work repeated due to same
Staff three (3) months from last completion
Rework
Notification
Comments
Engineer
Comments
Maintenance within
Findings
Current Process
Issues Finding &
Recommendations available
Reliability Engineer Evaluates and Tracks through KPI
Safety is a Measure of Success

Developed Forms for the use of Reliability Engineers
Preventive Maintenance
Deviation
To track the PM delays due to Operational requirement
Maintenance Rework
To record the findings and corrective action taken for any maintenance rework
Bad Actor – Root Cause
Analysis and
Recommendations
To track frequently failing equipment – coordination for Root Cause Analysis and recommendations tracking
Safety is a Measure of Success

Outline
Our Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
•
Deployment of Enhanced Business Processes
•
Developed Forms for the use of Reliability Engineers
Challenges
Rapid Improvement Teams
Way Forward
Safety is a Measure of Success

• Firefighting – Reactive Maintenance Culture – Low Schedule
Compliance
• Historical data for ‘Failure Analysis’ is not available
• Lack of Quality Assurance
• Incomplete Equipment SAP Database and Bill of Materials
• Equipment without PM program
• Lack of Condition Monitoring Tools and Skills
• No defined Maintenance Strategy to transform from PM to PdM
• Non availability of Standard Job Plans
• No Reliability KPIs deployed
Safety is a Measure of Success

Outline
Our Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
•
Deployment of Enhanced Business Processes
•
Developed Forms for the use of Reliability Engineers
Challenges
Rapid Improvement Teams
Way Forward
Safety is a Measure of Success

Enhance Equipment Trip Tracking and Monitoring
Scope
• Deploy new business process and Reliability
Tracking Forms
• Conduct SAP awareness sessions
• Develop a ‘Best Practice’
• KPIs and Monitoring
• Involve Crafts in RCA
• Audit SAP M2 Notifications
Champion :
Abdul Waheed
Reliability Engineer
Safety is a Measure of Success

Improve the ‘Quality’ of Equipment Repair History and Knowledge Sharing
Scope
• Arrange training workshops
• Develop template for quality history input
• Develop ‘Quick Reference’ pocket books for crafts
• Facilitate SAP authorization for Quality data
Champion :
Salah Al-Shihri
Maintenance Foreman
Safety is a Measure of Success

Improve the Planning & Scheduling Process and Manpower Utilization
Scope
• Facilitate the Schedule
Compliance Improvement
• Measure the current manpower utilization and improve the process
• Deploy a system for Crafts daily assignment through work ticket.
• Identify the causes for
Material delays
Safety is a Measure of Success
Champion :
Khalid Al-Shehri
Reliability Engineer

Improve the SAP Equipment Data Quality and Bill of Materials
Scope
• Establish an action plan to improve the SAP Equipment data quality
• Link Bill of Materials and ecopy of equipment manuals /
URL of smart drawings
• Assign appropriate PM for the new equipment through PM
Coordinator.
Champion :
Mohammad Al-Garrash
Reliability Engineer
Safety is a Measure of Success

Lead the PM Quality Team
Scope
• Develop PM QA scope
• Tour Plant and identify deficiencies from Maintenance
Perspective
• Track and Monitor the deficiencies reported by PM
Crew
• Balance PM workload for next year
Champion :
Mohammad Al-Fadhal
Maintenance Foreman
Safety is a Measure of Success

Contracts Optimization and Effective Utilization
Scope
• Develop guidelines for stepping jobs to Contractor
• Deploy KPI to track and monitor the emergency mobilization
• Monitor repeated work on
‘Short Form Contract’ and peruse for a Long Form
Contract
Champion :
Hani S Nogaidan
Contracts Engineer
Safety is a Measure of Success

Outline
Our Strategy to Build Reliability
Current Initiatives
• Elimination of ‘Bad Actors’ (Frequently Failing Equipment)
•
Deployment of Enhanced Business Processes
•
Developed Forms for the use of Reliability Engineers
Challenges
Rapid Improvement Teams
Way Forward
Safety is a Measure of Success

• Continue on Quarterly Reward and Recognition for Maintenance
Crafts in taking the “Proactive Maintenance approach”
• Involve Maintenance Crafts in improvement projects
• Continue capitalizing on PM findings to develop appropriate
Maintenance Strategies
• Strengthen the PM QA process
• Conduct PM optimization using PMO 2000 in 2011.
• Deploy Predictive Maintenance Tools (IR Camera – Ultra sound)
• Deploy Wireless technology for Vibration Monitoring
• Purchase hand held vibration monitors
• Strengthen the OCM Program
Safety is a Measure of Success

Scattered knowledge
Inconsistent actions
Safety is a Measure of Success
What Maintenance
Work?
At What time?

business process and practices
Consistent organized way to capture and use Knowledge &
Information actionable knowledge
Information System provides easy access to a Common
Knowledge
Repository
Safety is a Measure of Success consistent action
The Right Work at
The Right Time

“We are what we repeatedly do. Excellence then, is not an act, but a habit.”
~ Aristotle, 4th century BC Greek philosopher
Safety is a Measure of Success

4,000.0 HR
3,500.0 HR
3,000.0 HR
2,500.0 HR
2,000.0 HR
1,500.0 HR
1,000.0 HR
500.0 HR
0.0 HR
Safety is a Measure of Success
QSMD