PowerPoint Presentation

Deploying Criticality Analysis in Multi-Plant Reliability Improvement ProgramsMichel Cote & Serge MathieuProsygma Reliability and Maintenance Professional Services1

What is Criticality ?Work PrioritizationTo better prioritize work out of the maintenance backlogTo ensure that reliability improvements are made based on risk rather than perceptionReliability Improvement InitiativesA tool used to evaluate how equipment failures impact organizational performance in order to systematically rank plant assets for the purpose of :To support MRO initiatives to identify critical sparesMaterial ClassificationPM /PdM DevelopmentTo prioritize activities dedicated to PM / PdM development or optimization2

Impact on safety(0 to 4)Impact on environment(0 to 4)0 to 256=xImpact on quality(0 to 4)Impact on cost or production(0 to 4)xxCross-functional analysis and input from Operations and Maintenance, and as required, input from Engineering, Material Management, Environment and Health and Safety representativesWeigh the impact of a failure on each asset across all 4 criteriaThe Process3

Impact on SafetyPotential to cause death or permanent injuriesPotential to cause non-permanent bodily injuriesPotential to cause significant inconvenience to personnelPotential to cause minor inconvenience to personnelWill have no significant impact on personnel012344

5Deploying Criticality Analysis in a Multi-Plant Reliability Program

Quebec (4) Ontario (2) Wisconsin (1) Pennsylvania (2) North Carolina (1) New York (2) Oregon (1) Arizona (1) Tennessee (1)Mills located in the United StatesMills located in Canada

One of the Major Tissue Producers in North America

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The ObjectiveFor all of the 15 mills, associate a criticality ranking to each asset in the CMMS. The ChallengeHave the criticality ranking done for all of the 15 mills within a schedule of 8 to 12 weeks. A total of 45,000 assets, ranging from 600 to 16,000 per mill.7

Criticality RankingThe criticality ranking is calculated by multiplying each of the scores (from 0 to 4) obtained for each of the 4 criteria.The total is then converted into one of the following 4 criticality rankings, namely A,B,C or D.

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9Lessons LearnedPrevent mill personnel from taking shortcuts this is an objective and quantitative process

Avoid entering rankings one by one - work with IT to import the criticality rankings in the CMMS

Take the time to explain the advantages of a criticality ranking system

Make sure equipment hierarchy is adequate before you start

10Keys to SuccessThere is a wide variety of criticality tools and methods out there, Keep it simple!

Make sure to adapt the matrix with the operational context of each facility

It is OK to use the copy/paste method for identical or very similar equipment in a facility

Make sure you arrive prepared and organized

Questions ?Michel Cote: mcote@prosygma.caSerge Mathieu: smathieu@prosygma.ca

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