Reliable Process Solutions By Terry Harris, CMRP cant get there from here.pdf · Reliable Process...

By Terry Harris, CMRP

Reliable Process Solutions

Reliable Process SolutionsReliable Process SolutionsReliable Process SolutionsReliable Process Solutions

It Can Operate Forever

Terry Harris, CMRP656 Ridgeway Dr.

Sidney, Ohio 45365937-371-1644

[email protected]

Terry Harris, CMRPTerry Harris, CMRP

Certified RCM Facilitator for BlitzCertified RCM Facilitator for Blitz™™ process.process.Equipment Life Extension Program.Equipment Life Extension Program.Predictive/Proactive Maintenance Training.Predictive/Proactive Maintenance Training.Lubrication Audits.Lubrication Audits.Lubrication Excellence Training ProgramsLubrication Excellence Training ProgramsDetailed Equipment Component training.Detailed Equipment Component training.Training Programs for Oilseeds Industry.Training Programs for Oilseeds Industry.Asset Criticality software and assessmentAsset Criticality software and assessmentMaintenance Management Rating ProgramsMaintenance Management Rating ProgramsProject Management ServicesProject Management ServicesCost Effective Training articles/power pointsCost Effective Training articles/power points

What have I been up to?What have I been up to?

In the last two years:In the last two years:Have performed reliability training programs Have performed reliability training programs

in 8 different countries.in 8 different countries.China, Thailand, Singapore, Korea, Ireland, China, Thailand, Singapore, Korea, Ireland,

Canada, Egypt, and the US.Canada, Egypt, and the US.Have training Bids for India, Malawi, and Have training Bids for India, Malawi, and

Dubai.Dubai.

WhatWhat’’s going on in the world today?s going on in the world today?

The growth of The growth of ChinaChina4000 + US businesses operating4000 + US businesses operatingHuge Increases in petroleum useHuge Increases in petroleum use

Natural resources acquired, AustraliaNatural resources acquired, Australia30% of mineral needed by 201030% of mineral needed by 2010

More interstate miles than US in 4 yearsMore interstate miles than US in 4 yearsWhat will they become?What will they become?

The Future of ManufacturingThe Future of Manufacturing

What in the World is going on?What in the World is going on?

China is growing at a very fast pace.China is growing at a very fast pace.Product quality and reliability are high Product quality and reliability are high

on there list.on there list.India is spending $180 Billion to improve India is spending $180 Billion to improve

infrastructure to attract businesses.infrastructure to attract businesses.South Korea is spending 80 billion to South Korea is spending 80 billion to

improve and attract businesses.improve and attract businesses.Egypt is building large industrial sites for Egypt is building large industrial sites for

business development.business development.

What in the World is going on?What in the World is going on?

Australia is advertising the highest employee Australia is advertising the highest employee productivity in the world.productivity in the world.

The Far East has regular meetings on how to The Far East has regular meetings on how to attract more businesses and gain market share.attract more businesses and gain market share.

Singapore and Thailand continue to work towards Singapore and Thailand continue to work towards developing and adjusting to world demand for developing and adjusting to world demand for goods and services.goods and services.

Brazil is near petroleum independence and have Brazil is near petroleum independence and have paid off their national debt!paid off their national debt!

Which One are You????

What about Today?What about Today?

I canI can’’t get there from here!t get there from here!

I have heard this comment many times I have heard this comment many times in the last year from large US companies in the last year from large US companies when they listen to my reliability when they listen to my reliability improvements overview.improvements overview.

What about Today?What about Today?

Where are you on the PF curve?Where are you on the PF curve?

Reactive MaintenanceReactive Maintenance

Predictive MaintenancePredictive Maintenance

Proactive MaintenanceProactive Maintenance

Preventive MaintenancePreventive Maintenance

Equipment Perform

ance

Time UF

S

FF

PF IntervalPP

Potential Failure Curve

Equipment Perform

ance

Time

Noise

Heat

Smell

Smoke

FF

Reactive10-15

Feel

PP

Reactive MaintenanceReactive Maintenance

Reactive MaintenanceReactive MaintenanceMaintenance is there Maintenance is there

to fix things when they to fix things when they break!!!break!!!

Hire some guys in Hire some guys in maintenance that know maintenance that know how to fix things fast and how to fix things fast and keep me operating!keep me operating!

Reactive Issues affecting efficiencyReactive Issues affecting efficiency--Inability to perform precision maintenanceInability to perform precision maintenance--More spare partsMore spare parts--Expediting of spare partsExpediting of spare parts--Unplanned maintenanceUnplanned maintenance--Unplanned downtimeUnplanned downtime--Quality issuesQuality issues--E,H,&S issuesE,H,&S issues--Inefficient use of maintenance timeInefficient use of maintenance time--Inefficient use of operations timeInefficient use of operations time--Extremely short equipment lifeExtremely short equipment lifeWork practices donWork practices don’’t extend equipment lifet extend equipment life

�� 80% of all equipment failures can be 80% of all equipment failures can be predicted!predicted!

�� 90% of all bearing failures can be predicted 90% of all bearing failures can be predicted 6 months before failure!6 months before failure!

�� 90% of all motor failures can be predicted 690% of all motor failures can be predicted 6--12 months before failure!12 months before failure!

Predictive MaintenancePredictive Maintenance

Mechanical Ultrasonic DeviceMechanical Ultrasonic Device

Equipment Perform

ance

Time

Wear particle testing

Vibration analysis

Thermography

Noise

Heat

Smell

Smoke

FF

Mechanical

Ultrasound

ReactivePredictive

MCE

NDT

Feel

10-15

Oil Analysis

Equipment Perform

ance

Time


Vibration Analysis

Thermography

Noise

Heat

Smell

Smoke

FF

Mechanical

Ultrasound

ReactivePredictive

MCE

NDT

Feel

10-1530-50

Oil Analysis

Predictive MaintenancePredictive MaintenanceReduces collateral damageReduces collateral damageTime to plan the workTime to plan the workTime to do the correct maintenanceTime to do the correct maintenanceTime to have correct parts (no expediting)Time to have correct parts (no expediting)Time to do precision maintenanceTime to do precision maintenanceLess spare parts Less spare parts –– 30% less30% lessMore efficient use of maintenance timeMore efficient use of maintenance timeLess Emergency DowntimeLess Emergency DowntimeRepair work can extend equipment lifeRepair work can extend equipment lifeSafer work conditionsSafer work conditions

Collateral DamageCollateral Damage

Equipment Perform

ance

Time


Vibration analysis

Thermography

Noise

Heat

Smell

Smoke

FF

Mechanical

Ultrasound

ReactivePredictive

MCE

NDT

Feel

10-1530-50

Oil Analysis

No Failures !No Failures !

Is there a way to keep failure from ever Is there a way to keep failure from ever occurring?occurring?

Can equipment last forever?Can equipment last forever?

Failure PreventionFailure Prevention

We must find methods to keep our We must find methods to keep our equipment maintained in new condition.equipment maintained in new condition.

While its operating!!!!!While its operating!!!!!

Equipment Perform

ance

Time


Vibration analysis

Thermography

Noise

Heat

Smell

Smoke

FF

Mechanical

Ultrasound

ReactivePredictive

MCE

NDT

Feel

10-1530-50Proactive

Lubrication ExcellencePrecision MaintenanceAlignment, Balance, etc.

Select SuppliersSupplier Specifications

RCMTPM

RCA

RCA/FMEARCD

Training ProgramsProceduresJob Planning/Scheduling

Equipment Ranking

70-100

CMMS System

PPOil A

nalysis

Proactive MaintenanceProactive MaintenanceMaximizes precision work techniquesMaximizes precision work techniquesMinimum spare parts, 50% reductionMinimum spare parts, 50% reductionMaximum Runtime, Minimal downtimeMaximum Runtime, Minimal downtime80% of maintenance tasks proactive80% of maintenance tasks proactiveMinimal E, H, &S exposureMinimal E, H, &S exposureVery Low quality IssuesVery Low quality IssuesMaximum Equipment LifeMaximum Equipment LifeLower MRO costsLower MRO costsReduction of Predictive Maintenance CostsReduction of Predictive Maintenance CostsElimination of equipment failure modesElimination of equipment failure modesAllows you to perform Allows you to perform ““Lean MaintenanceLean Maintenance””

You canYou can’’t get there from here!t get there from here!So how do we make the jump from the reactive area to So how do we make the jump from the reactive area to

the proactive area?the proactive area?

How long will it take and what will it cost?How long will it take and what will it cost?

Can you really get there?Can you really get there?

Equipment Perform

ance

Time


Vibration analysis

Thermography

Noise

Heat

Smell

Smoke

FF

Mechanical

Ultrasound

ReactivePredictive

MCE

NDT

Feel

10-1530-50Proactive

Lubrication Excellence

Precision MaintenanceAlignment, Balance, etc.

Select Suppliers

Supplier Specifications

RCMTPM

RCA

RCA/FMEARCDTraining ProgramsProceduresJob Planning/Scheduling

Equipment Ranking

70-100

CMMS

PPOil A

nalysis

Plant Comments:Plant Comments:““I have 3000 I have 3000 –– 5000 hours of backlog work in 5000 hours of backlog work in

reactive and preventive.reactive and preventive.””

““I only have 6 or 8 Maintenance staff and they are I only have 6 or 8 Maintenance staff and they are all doing reactive work. How can I do any all doing reactive work. How can I do any proactive?proactive?””

““I donI don’’t even have time to react to my Predictive t even have time to react to my Predictive list!list!””

““My staff is not trained to do this precision work!My staff is not trained to do this precision work!””

Fundamentals to get startedFundamentals to get startedManagement BuyManagement Buy--in:in:

The benefits in $$$$$$:The benefits in $$$$$$:Increased uptimeIncreased uptimeBetter Quality, Less to no quality issuesBetter Quality, Less to no quality issuesLess E, H, &S riskLess E, H, &S riskLess spare partsLess spare partsLess unplanned downtimeLess unplanned downtimeLower maintenance costsLower maintenance costsMotivated work forceMotivated work forceMore plant cohesionMore plant cohesion

Production BuyProduction Buy--in:in:The benefits ####:The benefits ####:

More productionMore productionHigher efficiencyHigher efficiencyBetter qualityBetter qualityMore uptimeMore uptime

Production and Maintenance must share the Production and Maintenance must share the same goals.same goals.

Fundamentals to get startedFundamentals to get started

The Plan:The Plan:

How to get there from here!How to get there from here!

It wonIt won’’t be easy and it wont be easy and it won’’t be free. The t be free. The payback is 100 times the investment.payback is 100 times the investment.

Develop a 2Develop a 2--3 year plan on how to get 3 year plan on how to get there. Find the resources to help you there. Find the resources to help you accomplish your goals.accomplish your goals.


Awareness Training:Awareness Training:

This process involves everyone from This process involves everyone from upper management, engineering, all the way upper management, engineering, all the way down to the operators and maintenance staff.down to the operators and maintenance staff.

They all must understand and support the They all must understand and support the plan and goals.plan and goals.


Programs to guide the effort:Programs to guide the effort:

Use proven processes like equipment asset Use proven processes like equipment asset ranking and the RCM Blitzranking and the RCM Blitz™™ process to guide process to guide your efforts.your efforts.


Training Programs:Training Programs:Increase and develop your knowledge!Increase and develop your knowledge!

What is Lubrication Excellence?What is Lubrication Excellence?What is precision maintenance?What is precision maintenance?What is RCM?What is RCM?

Example:Example:Buying a laser alignment tool does not Buying a laser alignment tool does not

mean you are doing precision alignment!mean you are doing precision alignment!


How do I get there from here?How do I get there from here?

3000 3000 –– 5000 hours of backlog work:5000 hours of backlog work:

Hire outside services/contractors to:Hire outside services/contractors to:

*Perform preventive maintenance backlog*Perform preventive maintenance backlog*Perform reactive work assignments*Perform reactive work assignments*Develop Predictive program*Develop Predictive program*Conduct Predictive tasks*Conduct Predictive tasks

*After proper training on tasks*After proper training on tasks

Move some of the manpower:Move some of the manpower:

Immediately move a small percentage of Immediately move a small percentage of maintenance staff to perform Proactive tasks.maintenance staff to perform Proactive tasks.

If you have 4If you have 4--5 people start with 1/2 5 people start with 1/2 person time. If you have 15 people then move person time. If you have 15 people then move 11--2 to performing Proactive tasks. If you have 2 to performing Proactive tasks. If you have 50 then move 5 to Proactive tasks.50 then move 5 to Proactive tasks.


Identify your assets:Identify your assets:

Which assets are critical and which assets Which assets are critical and which assets need immediate attention?need immediate attention?

You need to make a decision on which You need to make a decision on which process can help you do this task. Asset must process can help you do this task. Asset must be rated on many factors, not just maintenance be rated on many factors, not just maintenance issue related equipment.issue related equipment.


Identify Proactive Tasks priority:Identify Proactive Tasks priority:

Which Proactive tasks are most critical to Which Proactive tasks are most critical to start and when to start the remaining tasks?start and when to start the remaining tasks?

Lubrication Excellence is a easy one to Lubrication Excellence is a easy one to start and has the best start and has the best ““bang for the buckbang for the buck””..


Training:Training:

You must train everyone!You must train everyone!

Part of your plan is determining who Part of your plan is determining who needs trained and how intensive on each area needs trained and how intensive on each area of predictive and proactive.of predictive and proactive.

Management needs overviews and Management needs overviews and supervisions and hourly staff need very supervisions and hourly staff need very detailed training.detailed training.


What do you want to spend?What do you want to spend?Cost:Cost:

How fast do you want to get below 20% How fast do you want to get below 20% reactive maintenance?reactive maintenance?

If your timeline is 12If your timeline is 12--18 months it may add 18 months it may add up to 30% to your maintenance budget.up to 30% to your maintenance budget.

If your plan is 2If your plan is 2--4 years it may add 10% to 4 years it may add 10% to your maintenance budget.your maintenance budget.

PaybackPaybackWhat is the payback for the effort?What is the payback for the effort?

Is the payback just lowering maintenance Is the payback just lowering maintenance costs?costs?

Is the payback just more productivity?Is the payback just more productivity?

Is the effort worth the time and investment?Is the effort worth the time and investment?

PaybackPaybackPayback Items:Payback Items:Reduction of maintenance costs by 20Reduction of maintenance costs by 20--30%30%Reduction of emergency downtime of 30Reduction of emergency downtime of 30--50%50%Spare parts reduction of 30Spare parts reduction of 30--50%50%Quality claims reduction of 20Quality claims reduction of 20--40%40%Reduced exposure to E,H,&S issues, huge $$$Reduced exposure to E,H,&S issues, huge $$$Reduction in maintenance staffing???? (not)Reduction in maintenance staffing???? (not)Increased maintenance effectivenessIncreased maintenance effectivenessReactive maintenance less than 10%Reactive maintenance less than 10%Increase production capacityIncrease production capacity

PaybackPayback

The big payback statistic:The big payback statistic:

For every dollar saved in reducing For every dollar saved in reducing maintenance costs by improving reliability,maintenance costs by improving reliability,There is a 5There is a 5--10 dollar return to the bottom 10 dollar return to the bottom line.line.

Where do we go from here?Where do we go from here?

Do you go back to your plant and jump Do you go back to your plant and jump right back into the reactive area?right back into the reactive area?

Do you go back and start to plan and Do you go back and start to plan and implement?implement?

Do you need help making the plan and Do you need help making the plan and making the presentation?making the presentation?

StartStartToday!!!!!Today!!!!!

QuestionsQuestions

Thank YouThank You

Reliable Process SolutionsReliable Process SolutionsReliable Process SolutionsReliable Process Solutions

It Can Operate Forever

Terry Harris, CMRP656 Ridgeway Dr.

Sidney, Ohio 45365937-371-1644

[email protected]

Reliable Process Solutions By Terry Harris, CMRP cant get there from here.pdf · Reliable Process...

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