Vous êtes sur la page 1sur 295

WORLD CLASS MAINTENANCE MANAGEMENT

WORLD CLASS MAINTENANCE WORLD CLASS MAINTENANCE MANAGEMENT STRATEGIES MANAGEMENT STRATEGIES
THE 12 DISCIPLINES
2010 All Rights Reserve 2010 All Rights Reserve

Revision 4: June 25, 2010

RSA Maintenance Excellence


2006

Rolly Angeles

HOUSERULES :: HOUSERULES

WORLD CLASS MAINTENANCE MANAGEMENT

1. Lets be punctual so we can begin & end on time. Let us respect the time of others. 2. Refrain from going to your place of work during break to avoid being called 3. Members are requested to turn off or put on silent mode their cell phones during the training session 4. Anyone can feel free to raise questions, provide feedback, & sharing, we all learn from one another 5. Time for coffee break and lunch will be as follows :
Morning Break - 9:30 to 9:45 am Lunch Break - 12:00 to 1:00 pm Afternoon Break - 3 to 3:15 pm

If you agree then,

6. Certificates will be issued only to those who will complete the duration of the seminar on World Class Maintenance Management 7. Exercises will be issue from time to time while handouts will be provided through CD Format 8. We all learn from one another, listen, participate actively, provide sharing and most of all enjoy this seminar RSA Maintenance Excellence Rolly Angeles
2006

WORLD CLASS MAINTENANCE MANAGEMENT

Objective Of this Course :


Understand the diversity of failures and the need for an effective World Class Maintenance Management Understand when to effectively use each of the different maintenance strategies in order to fully improve equipments reliability Develop a Corporate Strategy for the maintenance function Provide a basic understanding on the 12 Disciplines of Maintenance Management Understand the real focus of a true & meaningful Maintenance Management Structure
RSA Maintenance Excellence
2006

Maintenance Management Maintenance Management


Rolly Angeles

World Class Maintenance Management Modules :: World Class Maintenance Management Modules
Module 1 : Understanding Equipment Failures
The Truth About Machinery & Equipment The Truth About Machinery & Equipment Changing the way we think about failures Changing the way we think about failures 3 Types Of Failure Zones 3 Types Of Failure Zones Understanding the Six Failure Patterns Understanding the Six Failure Patterns

WORLD CLASS MAINTENANCE MANAGEMENT Continue Module 4 : Basic Discipline Continue Module 4 : Basic Discipline
Discipline 4 : Basic Equipment Condition Discipline 5 : Preventive Maintenance Workshop on Basic Discipline

Module 2 : Changing our Maintenance Module 2 : Changing our Maintenance Culture from Reactive To Culture from Reactive To Proactive Mode Proactive Mode
How To Break The Reactive Chain of Mind How To Break The Reactive Chain of Mind

Module 5 : Maintenance Management Module 5 : Maintenance Management Strategies Strategies


Discipline 6 : Lubrication Management Discipline 6 : Lubrication Management Discipline 7 : Life Cycle Management Discipline 7 : Life Cycle Management Discipline 8 : Spare Parts Management Discipline 8 : Spare Parts Management

Module 3 : Understanding World Class Module 3 : Understanding World Class Maintenance Management Maintenance Management
Maintenance Management Defined Maintenance Management Defined 12 Maintenance Management Discipline 12 Maintenance Management Discipline

Module 6 : Maintenance Management Module 6 : Maintenance Management Advance Discipline Advance Discipline

Module 4 : Maintenance Management Module 4 : Maintenance Management Basic Discipline Basic Discipline
Discipline 1 : Training, Skills & Education Discipline 1 : Training, Skills & Education Discipline 2 : Measure Performance & KPIs Discipline 2 : Measure Performance & KPIs Discipline 3 : Autonomous Maintenance Discipline 3 : Autonomous Maintenance

RSA Maintenance Excellence


2006

Module 7 : Applying These Disciplines Module 7 : Applying These Disciplines Module 8 : Learning from these Module 8 : Learning from these Maintenance Disciplines Maintenance Disciplines Closing Remarks Closing Remarks
Rolly Angeles

Discipline 9 : Root Cause Failure Analysis Discipline 9 : Root Cause Failure Analysis Discipline 10 : Reliability Improvements Discipline 10 : Reliability Improvements Discipline 11 : Condition-Based Mtce Discipline 11 : Condition-Based Mtce Discipline 12 : Computerized Maintenance Discipline 12 : Computerized Maintenance Management Software Management Software

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 1

UNDERSTANDING EQUIPMENT FAILURES

RSA Maintenance Excellence


2006

Rolly Angeles

The Challenges facing maintenance . . .

WORLD CLASS MAINTENANCE MANAGEMENT

In a NUTSHELL, the key challenges facing modern maintenance managers are : To select the most appropriate technique and maintenance methodology system To deal with each type of failure process In order to fulfill all the expectations of the owners, users of the asset and of the society as a whole In the most cost effective and enduring fashion With the active support and cooperation of all the people involved
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT


Every industry have one thing in common, they have assets & equipments industry have one thing in common, they have assets to maintain but the difference is how they approach maintenance and but the difference is how they approach maintenance and reliability as a focal point of strategy . . . . . reliability as a

But despite our very best efforts, equipment still fails, and plants are best efforts, equipment still fails, and plants are vulnerable to failures. Hence, before adopting any Maintenance Manageto failures. Hence, before adopting any ment strategy, we must change the way we think about failures and ment strategy, we must change the way we think about understand its diversity . . . understand
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT

Unexpected breakdowns Unexpected breakdowns and failures on our assets and failures on our assets

High cost of doing High cost of doing maintenance maintenance

Day to day pressure Day to day pressure of doing maintenance of doing maintenance

Lack of skills and Lack of skills and training. Maintenance training. Maintenance Is left with no option Is left with no option but to put-out fires but to put-out fires all the time all the time

Not to mention the Not to mention the relationship we have relationship we have on operations. Feud on operations. Feud is pretty much alive is pretty much alive RSA Maintenance Excellence
2006

When production When production for the day is met for the day is met all credit goes to all credit goes to operations if not operations if not then all fingers then all fingers point to the point to the maintenance maintenance
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT

BUT CAN WE REALLY ELIMINATE FAILURES ? An equipment will compose of the following Electronic parts Electrical parts Mechanical parts
(30,000 pcs) (30,000 pcs) ( 10,000 pcs) ( 10,000 pcs) (5000 pcs) (5000 pcs)

2 important questions to raise for the maintenance will be

1) What exact part will fail ? 2) When will that part fail ?
RSA Maintenance Excellence
2006

These are questions that probably have no direct and easy answers
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT


Our equipment just like our car and Our like our car and is made up of numerous parts operating together as a system to deliver together as system to deliver a specific function we want function we want A car has thousand of parts in it A making up several systems, such as engine, transmission, fuel supengine, transmission, fuel supply, braking system, chassis, body, yet our primary function we want is to take us from one place to another take us from one place to another A computer is made up of thousand A computer is of parts divided into several systems such as the CPU, modem, memory storage, keyboard, mouse, CD drive monitor etc, yet we use them to type letters, read mails and reports, anaread mails and reports, analyze data and get information or sent data and get information or sent information, research etc.
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT

We have around 100 similar machines & 10 types of equipment similar machines 10 types of Each equipment have around more than 5000 components in it equipment have around more than 5000 components in it We only have 10 maintenance craftspeople for all equipment We only have 10 How do we know which parts will fail, what machine and when ? do we know which parts will fail, what machine and when ? Can we accept the fact that failures are really meant to happen at all ? we accept the fact that failures are really meant to happen at all
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT

TO ADDRESS THIS ISSUE :


Some people are deployed to perform maintenance work We have some form of Preventive Maintenance that sort of schedule these equipments for some form of maintenance work There are some overhauling and replacement that are being done There are some inspections that we perform on our equipment from time to time We even deploy a group called the sustaining or other names to perform repairs and troubleshooting
II guess thats guess thats the way it is the way it is boss ! boss !

Despite our very best efforts machine still fails ? RIGHT ?


RSA Maintenance Excellence
2006
Rolly Angeles

What Maintenance Can Actually Do

WORLD CLASS MAINTENANCE MANAGEMENT

Prevent the Failure Preventive Maintenance Predict the Failure Predictive Maintenance Anticipate the Failure Run to Fail Control and Prolong the Failure Redesign / Modify Performing maintenance is all about understanding that it is more important to reduce or eliminate the consequences of failure rather than eliminating the failure itself

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT


We use machinery and equipment use machinery and equipment to perform a particular function, if it to perform cannot provide that function we say cannot that our equipment have failed or a that our equipment have failed or a breakdown occurs breakdown

FACT 1
All equipment will eventually fail, All equipment will eventually parts do not last forever. In some forever. In some cases other parts will only last for days others even hours of use others even hours

FACT 2
Although we might be using some statistics & history records as a baseAlthough line, the fact still remains, we do not know exactly which parts are going line, the remains, we do not know exactly parts are going to fail and when it will fail precisely, but we certainly know that one day fail precisely, but we certainly our car will run dead, our computer will stop working and our equipment car dead, our computer will stop working and our equipment will stop working due to an event of a failure or breakdown failure or breakdown

The truth is all plants are vulnerable to failure . . .


RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT


Therefore, the aim of maintenance is to control the timing of failure so Therefore, the aim of maintenance that we can select or perform a task before failure happens perform task before failure happens The best that we can do to our equipment will be to : to our equipment will be to : 1st - Extend the length of time between failures 2nd - Prevent the failures by replacing the most worrisome component before they fail 3rd - Monitor failures by providing signs and symptoms that they are on the verge of failing, this is possible by determining the condition of the equipment

RSA Maintenance Excellence


2006

Making equipment more reliable is about extending the life & the time between failure (MTBF) as well as preventing failures by replacing of part & components. This is what maintenance is all about . . . . .
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RELIABILITY DEFINED
FAILURE simply means the inability simply means the inability of an equipment to perform its required equipment to perform its required function. The failure of a component is viewed as terminating its life. as terminating its RELIABILITY is the probability that no is the probability that no failure will occur throughout a prescribed throughout a prescribed operating period. operating period.

Maintenance is not about eliminating failures but understanding that it is more important to preserve the functions and understand each of the consequences of failure and in order to address these failures, we must thoroughly understand its diversity . . . . .

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TYPICAL CAUSES OF FAILURES

FAILURE
( TIP OF THE ICEBERG )
FRACTURE VIBRATION DIRT / DUST LEAKAGE ABRASION CONTAMINATION HUMAN ERROR LOOSENESS CORROSION DEFORMATIONTEMPERATURE LUBRICATION MISALIGNMENT LOOSE BOLTSMISALIGNMENT FATIGUE BOLTS ENVIRONMENT

RSA Maintenance Excellence


2006

Failure is just the tip of the iceberg, and when our people becomes good a fixing them, then something is definitely wrong . . . . .
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Can failures and breakdowns really be eliminated ?

Which of the following statements is true ?


1st : We can eliminate failures by analyzing them through a thorough Root Cause Failure methodologies. 2nd :We cannot eliminate the likelihood of a failure but rather we can only prevent or predict the failure from occurring on its own. 3rd : Failures cannot be eliminated and that the best that we maintenance and reliability people can do is to reduce the frequency of failure itself. 4rth : Failures cannot be eliminated, the best that we can do is to anticipate failure or control the timing of failure Which one is correct

RSA Maintenance Excellence


2006

Which one is correct and why?


Rolly Angeles

Understanding Equipment Failure :: Understanding Equipment Failure

WORLD CLASS MAINTENANCE MANAGEMENT

We need to understand the diversity of failures ?


Patterns of Failure :
Infant Mortality Failure Random Failures Age-Related Failures

Types of Failures
Function Loss Failures Function Reduction Failures

Classification of Failures
Hidden Failures Evident Failures

Occurrences of Failures
Sporadic Failures Chronic Failures

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Common Belief : Does all parts will wear out ?


Maintenance people believe that ALL parts after consistent use will reach a point of wear and tear, hence, overhauling or replacing the part before it fails on a specific fix schedule will ensure the reliability of the equipment, therefore the concept of Preventive Maintenance will solve the problem of unexpected failures, RIGHT or WRONG ?
Natural Deterioration Point that part is expected to reach failure

DETERIORATION

Failure Line
Accelerated Deterioration
Time-Based Condition-Based Failed State / Run To Fail
Point 1 Point 2 Point 3 Point 4

TIME

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Most Manufacturing Industries Experience . . . Sira na naman, OO , Kasi bagong PM

MAYROON BANG MABABASA DITO ?

Ginalaw pa kasi eh ! Malamang kung di ginalaw yan, maayos ang takbo nito ngayon !

It is also borne out by the machine operator who says that every time maintenance works on it over the weekend, it takes up to Wednesday to get it going again
RSA Maintenance Excellence
2006 Reference page 143 RCM by John Moubrey
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Most Manufacturing Industries Experience . . . Broken Again ? No , wonder they PM it

CAN SOME BOOKS EXPLAIN THIS ?

Maybe if the PM group did not touch this equipment, Im sure this will be running !

It is also borne out by the machine operator who says that every time maintenance works on it over the weekend, it takes up to Wednesday to get it going again
RSA Maintenance Excellence
2006 Reference page 143 RCM by John Moubrey
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

It is the belief that led to the idea that the more often It is the belief that led to the idea that the more often an item is overhauled, the less likely it is to fail . . . an item overhauled,
Schedule Overhauls //Preventive Schedule Overhauls Preventive Maintenance increases Overall Maintenance increases Overall failures by introducing Infant failures by introducing Infant Mortality into otherwise stable Mortality into otherwise stable system system

Resulting schedules are used for all similar assets again, without considering that different consequences apply in different operating context. This results in large number of schedules which are wasted , not because they are wrong in the technical sense, but in reality, they achieve nothing
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

What did Stanley Nowlan and the late Howard Heap Discovered What did Stanley Nowlan and the late Howard Heap Discovered 2 discoveries evolved which created a change in the evolution and thinking of the maintenance system worldwide . . . . .

First, scheduled maintenance has little or no effect on the reliability of a complex item unless the item has a dominant failure mode. Second, there are many items for which there is no effective form of scheduled maintenance.

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

There is a belief that all items have a life and that installing a new part before the life is reach will automatically restore it to its original basic condition = FALSE

This will lead us to the conclusion that the truth is . . . . .

MORE PM MEANS MORE PROBLEM LESS PM MEANS LESSER PROBLEM


RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT


MACHINE 1 MACHINE 2 MACHINE 3 MACHINE 4 MACHINE 5

1 Failure / Mo MACHINE 6

1 Failure / Mo MACHINE 7

No Failures MACHINE 8

No Failures MACHINE 9

1 Failure / Mo MACHINE 10

9 Failures / Mo

8 Failures / Mo 1 Failure / Mo

No Failures

No Failures

Will these 10 equipments have the same amount of PM required ? these 10 equipments have the same amount of PM required ? Which machines will require the greater amount of maintenance ? Which require the greater amount of maintenance ? Should we follow the specs or we apply common sense on maintenance ? we follow the specs or we apply common sense on maintenance ?
RSA Maintenance Excellence
2006

Maintenance must have an understanding of equipments operating context and consequences before they can define its tasks
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT CONCLUSION DONE ON CIVIL AIRCRAFT


AGE RELATED for A to C RANDOM for D to F Pattern A = 2% Pattern B = 5% Pattern C = 7%

Pattern D = 14% Pattern E = 4% Pattern F = 68 %

The traditional concept that the length of time between successive overhauls of an item or spare was an important factor in controlling its failure rate is not always applicable to the real world of maintenance
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CHANGING THE WAY WE THINK ABOUT FAILURES


INFANT FAILURES IS CAUSED BY HUMAN Poor Design Poor Quality Manufacture Incorrect Installation Incorrect Commissioning
Conditional Probability of Failure

Incorrect Operation Overhauling Unnecessary Maintenance Excessively Invasive Maintenance Bad Workmanship
INFANT MORTALITY Operating Age
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

CHANGING THE WAY WE THINK ABOUT FAILURES

UNDERSTANDING INFANT MORTALITY FAILURES


Infant Mortality Failures are failures that occur at the beginning or these are failures that occur when the equipment is new or overhauled Other terms includes start-up failure, commissioning failures, debugging. Infant Failures usually occurs after performing a major overhaul or when an equipment is totally new & have not yet proven itself. Failures are at a much higher risk of occurring at the beginning of its life rather than they have been operated for sometime

Infant Mortality are the main reason why manufacturers and vendors are forced to have a warranty period on their equipment and machinery . . . . .
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PATTERNS OF FAILURE
INFANT MORTALITY FAILURES : These are failures that occur at the beginning of its life. Others call them start-up failures, commissioning failures which are likely to occur after a major overhaul or Preventive Maintenance had been initiated The infant mortality period is a time when the failure rate is dropping, but is undesirable because a significant number of failures occur in a short time, causing early customer dissatisfaction and warranty expense.
Causes : Human Error after PM & Overhauls, improper installation Strategy : Improve Maintenance Procedures. Use diagnostic instruments before overhauling or replacing them RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PATTERNS OF FAILURE
RANDOM FAILURES :
Description : Failures which occur at any period Causes : Dirt, materials related problem, human errors, environment, lack of lubrication, premature fatigue, short lifespan Strategy : Run to fail for failures with minimal : consequences. Predictive Maintenance can be applied for failures that provide signs and symptoms that it is in the verge of failing or nearing its rupture. Modification for failures that will have severe consequences and possibility of changing the failure characteristic to wear out mode

Random failures is like Random catching a lighting with catching a Polaroid camera, a Polaroid

Problem with Random Failure is that the same parts or components can fail at any given period for a variety of reasons, this is where PM overhauls and replacement would be at its weakest point
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PATTERNS OF FAILURE
CASE 1 : RANDOM FAILURES 5
1

What period do we replace the bearings ?


100 failures encountered on a ball bearing in span of 9 yrs

15
2

10
3

20
4

10
5

5
6

15
7

10
8

10
9

PERIOD OR LIFE

CONCLUSION : Failure distribution is not symmetrical, PM not applicable


CASE 2 : AGE-RELATED FAILURES 2
1

BEST PERIOD TO PERFORM REPLACEMENT

1
2

0
3

0
4

0
5

2
6

1
7

0
8

94
9

PERIOD OR LIFE

CONCLUSION : Failure distribution is almost age-related, for this case the best period to perform replacement is on the 8 month
RSA Maintenance Excellence
2006
Rolly Angeles

PATTERNS OF FAILURE
CASE 1 : RANDOM FAILURES 5
1

WORLD CLASS MAINTENANCE MANAGEMENT Ex : 100 failures encountered on a ball bearing 10


4 5

15
2

10
3

20

5
6

15
7

10
8

10
9

PERIOD OR LIFE (8760x1x5) + (8760x2x15) + (8760x3x10) + (8760x4x20) + (8760x5x10) + (8760x6x5) + (8760x7x15) + (8760x8x10) + (8760x9x10)

100 cases of bearing failure


( 43,800 + 262,800 + 262,800 + 700,800 + 438,000 + 262,800 + 919,800 + 700,800 + 788,400 )

= = =
2006

100 cases of bearing failure

4,380,000 hrs
100 cases of bearing failure

= 43,800 hrs x 1 yr / 8760 hrs Replacing the bearing on the 5th year will only result to many bearing failures before it reach the 5th year
Rolly Angeles

5 years

RSA Maintenance Excellence

WORLD CLASS MAINTENANCE MANAGEMENT

CHANGING THE WAY WE THINK ABOUT FAILURES

UNDERSTANDING RANDOM FAILURES


Random Failures are failures that occur on any given period It simply means that the probability that an item will fail in any one period is the same as it is in any other period. One characteristic of random failure is that a wear out age is not identifiable and that the failure can occur at any given time or period. When failures that are occurring is random in nature, this is when Preventive Maintenance is at its weakest point. In simple terms this is not a recommended option & other tasks to use will be to Run To Fail only when the consequences of failure is low, ConditionBased Maintenance or Modification Samples of random failures are electronic boards, bulbs, ball-bearings, seals, hydraulics
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CHANGING THE WAY WE THINK ABOUT FAILURES

UNDERSTANDING AGE-RELATED FAILURES


Age-Related Failures simply means that the failure is directly related to age and there is a clear wear out out zone Age specified may be in the form of running hours, time, number of strokes, revolutions, number of stress applied or any other form. The best maintenance strategy to use on this type of failure will be to identify when most of the parts will fail and to apply Preventive Maintenance A tire that is not aligned and properly camber can fail randomly or prematurely but a tire which is properly align and camber will most probably wear out after running for several thousand of kilometers Therefore, before reaching its desired running hours we try to replace or rethread the tire.

Uneven thread on the left portion of the tire

RSA Maintenance Excellence


2006

Take exercise on Failure Pattern !


Rolly Angeles

INFANT MORTALITY FAILURES :

WORLD CLASS MAINTENANCE MANAGEMENT

Description : Failures at the beginning of life Causes : Human Error after PM & Overhauls, improper installation Strategy : Improve Maintenance Procedures

RANDOM FAILURES :
Description : Failures which occur at any period Causes : Dirt, materials related problem, human errors, environment, lack of lubrication, premature fatigue, short lifespan Strategy : Run to fail for failures w/ minimal consequences Predictive Maintenance for failures that provide signs & symptoms that it is in the verge of failing or nearing its rupture Modification for failures that have severe consequences, possibility of changing the failure characteristic to a wear out mode

WEAR OUT FAILURES


Description : Failures will wear due to age Causes : Part had fatigue and reached its lifespan Strategy : Preventive Maintenance will be the best option RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PATTERNS OF FAILURE

We need to understand that failure occur in 3 patterns . . . . .


1st - INFANT MORTALITY : Failure can occur at the beginning 2nd - RANDOM FAILURES : Failure can occur at any period 3rd - AGE-RELATED FAILURES : Failure will wear due to age

And most maintenance only focus on the 3rd type of failure, and neglecting to understand that infant mortality failures & random failures occur more frequently than wear out failures
RANDOM FAILURES

BATHTUB CURVE
Occurrences of random and infant mortality failures are more frequent than wear out failures RSA Maintenance Excellence INFANT MORTALITY
2006

WEAR OUT FAILURES


Rolly Angeles

6 TYPES OF FAILURE PATTERN

WORLD CLASS MAINTENANCE MANAGEMENT

PATTERN A : BATHTUB CURVE It begins with a high incidence of failure ( infant mortality) followed by a constant or gradual increasing conditional probability of failure then by a wear out zone. PATTERN B : Shows constant or slowly increasing conditional probability of failure ending in a wear out zone PATTERN C : Shows slowly increasing conditional probability of failure but there is an identifiable wear out age PATTERN D : Shows low conditional probability of failure when the item is new or out of the shop, then a rapid increase to a constant level PATTERN E : Shows constant probability of failure at all ages (random failure) PATTERN F : Starts with high infant mortality which drops eventually to a constant or very slowly increasing conditional probability of failure
Rolly Angeles

RSA Maintenance Excellence


2006

6 TYPES OF FAILURE PATTERN

WORLD CLASS MAINTENANCE MANAGEMENT

AGE = DETERIORATION
Then Preventive Maintenance is a good option example, tires, brakes, clutch, punches, liners, etc., parts will wear out in direct relation to the age and usage

AGE = DETERIORATION
Preventive Maintenance is not a good option, other tasks includes Predictive Maintenance, Run to Fail, or Proactive Maintenance or simply redesigning the system out
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CLASSIFICATION OF FAILURES
An evident failure is one whose failure will on its own eventually and inevitable become evident to the operating crew under normal circumstances A hidden failure is one whose failure will not become evident to the operating crew under normal circumstances if it occurs on its own
Which pump if it fails on its own will become evident to the operating crew under normal circumstances

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CLASSIFICATION OF FAILURES
For hidden failures, its failure will only become evident if the part, component or system they are protecting had failed. This is most specially true for protective devices and redundant functions.
Triple Redundancy
Over speed Device 1

Is the failure hidden or evident ?


Over speed Device 1

Signal to main Turbine Control Panel

Over speed Device 1

This triple redundancy has no individual means of identifying when a failure had occurred to each of the over speed device. Hence, the failure of the individual device is hidden and not evident. No one knows that device 1 had been corroded and will remain undetected
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

EXERCISE ON HIDDEN AND EVIDENT FAILURES


Case 1 : An electric kettle contains a switch whose primary function is to switch off the power when the water in the kettle reaches boiling point (Function A). It also has a plug ejector (Function B) whose primary function is to eject the plug if the kettle boils dry Will the failure of the switch (Function A) on its own become evident to the user under normal circumstances ? Will the failure of the ejector (Function B) on its own become evident to the user under normal circumstances ?

Will the failure of the switch on its own become evident to the user under normal circumstances ? In the normal course of events, the plug ejector would be working if the switch failed. So if the switch failed and the kettle boiled dry, the plug would be ejected. The ejected plug and the dry kettle (and the kitchen full EVIDENT of steam) would be clearly be evident to the user, so that the functional failure is

Will the failure of the ejector on its own become evident to the user under normal circumstances ? On the other hand, if the plug ejector jammed, in the normal course of events the switch would still be worki So the switch would still shut off the power, the kettle would not boil dry and no-one would know that the plu HIDDEN (The second failure which must ejector was not functioning. So the functional failure of the ejector is . also occur before the failure of the plug ejector is of course the failure of the switch)

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

EXERCISE ON HIDDEN AND EVIDENT FAILURES


Case 2 : A water tower contains a low level float switch A which switches on the pump feeding the tower when the water level reaches it. A second switch B is located 150mm below switch A and B is design to switch on an alarm in the control room if A fails to operate. However, if both switches fail, the tank would run dry and 100 inmates from Alcatraz would be without water. Will the failure of the switch A on its own become evident to the user under normal circumstances ? Will the failure of the switch B on its own become evident to the user under normal circumstances ?

Will the failure of Switch A on its own become evident to the operator under normal circumstances ? If switch A failed, switch B would still be working in the normal course of events. As a result, the water would drop to the level of switch B which would then sound the alarm in the control room. So the failure of switch A would be EVIDENT. (This example illustrates that it is sometimes possible to have to many informations) Will the failure of Switch B on its own become evident to the operator under normal circumstances ? If switch B failed, switch A would still be working in the normal course of events. As a result, the pump would still be switched on when the water level dropped to switch A, and the level would not reach switch B. HIDDEN Consequently, the users would not know whether switch B was functional or not so the failure of B is We will only know that switch B is failed if switch A also fails

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

EXERCISE ON HIDDEN AND EVIDENT FAILURES


Case 3 : The hoisting mechanism of a 30 ton crane has an emergency brake to stop the hoist drum if the main brakes fail (Function A). A second function of the emergency brake is not to stop the hoist when nothing is wrong (Function B) Will the loss of Function A on its own become evident to the operator under normal circumstances ? Will the loss of Function B on its own become evident to the operator under normal circumstances ?
Will the loss of Function A on its own become evident to the operator under normal circumstances ? If the emergency brake were to fail in such a way that it could not stop the hoist in the normal course of events, the main braking system would still be working. In this case, no one knows whether the HIDDEN. ( The second failure w/c emergency brake is functional or not, so the functional failure is would make this failure of the emergency brake matter would be the failure of the main brake) Will the loss of Function B on its own become evident to the operator under normal circumstances ? On the other hand, if the emergency brake fails in such a way that it stops the hoist when nothing is wrong, the operator would notices it as soon as he or she tried to use the hoist again. This means that this failure EVIDENT. of the emergency brake would be

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TYPES OF FAILURES
FUNCTION-LOSS FAILURE FAILURE
Failure or breakdown in which it will result to the equipment being stopped, resulting to a total loss of function for the equipment. Ex. Steering wheel of a car had locked. Also termed as Primary Failure

FUNCTION-REDUCTION FAILURES FUNCTION-REDUCTION


A specific function had failed but the equipment is still running and capable of producing output or delivering, Although in most cases this is not listed as a breakdown, RCM states that in some instances losses in secondary functions may turn out to be more dangerous than primary function ex. A car seatbelt is defective, or left brakelight of a car is not functioning, radio is not functioning. Also termed as secondary failure RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TYPES OF FAILURES
PRIMARY FUNCTION
UNABLE TO TRAVEL
Tire blew-up, flat tire Brakes not working Engine overheat No oil in engine

SECONDARY FUNCTIONS
STILL CAPABLE OF TRAVELLING
Busted tail light No AM-FM Radio Aircon not functioning Defective seat bealt Worn out seat cover Broken side mirror Left wiper not functioning Toyota emblem missing Busted left headlight Rear door wont close Car alarm malfunction Power window defective CD player not functioning Fuel gauge meter defective Speedometer not functioning Temperature gauge defective Fuel gauge defective RPM Gauge not functioning No spare tire Wheels not aligned

RCM states that although not all secondary functions are important, still there will be cases where 2nd Functions play an important role as the Primary Function and should be treated equally
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

OCCURENCES OF FAILURES
Sporadic Failures
Indicate sudden often large deviations from the norm They result from a single cause that is relatively easy to identify Since root cause is often a single cause corrective measures are easy to formulate and easy to correct

Chronic Failures
Failures that tend to recur frequently

Why does chronic losses persist ?


Failure to understand the nature of chronic loss Using ineffective approaches in dealing with chronic losses Always a combination or series of causes Latent Causes are note being addressed properly
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE TRUTH ABOUT MACHINERY AND EQUIPMENT


Maintenance is done to keep things working the way they were meant to Maintenance is done to keep things working the way they were meant to work. When the equipment is not maintained we can guarantee that it equipment is will fail sooner than expected. than expected. The questions to asks will be :
1) How much maintenance do I need 1) How much maintenance to perform on this equipment ? equipment ? 2) What is the right maintenance tasks What is the right maintenance tasks to perform on this equipment ? 3) How frequent should the tasks be performed on this piece of equipment performed on this piece of equipment after all ? after all ?

RSA Maintenance Excellence


2006

Doing maintenance provides a means to reduce the likelihood of a failure to make the equipment reliable, but even before we can define a good maintenance manageement structure, we must change the way we think about failure itself since not all failures are created equal . . . . .
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 2

CHANGING THE MAINTENANCE CULTURE FROM REACTIVE TO PROACTIVE

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

REACTIVE MAINTENANCE
In most industries, maintenance and operations hold meetings everyday and discuss what had failed, sometimes what is done to stop it from happening. Being reactive simply means addressing a failure after it happens

PRO-ACTIVE MAINTENANCE
- Being proactive means preventing or predicting the failure before it happens - This is done by identifying all failure modes which are likely to affect the asset and determining what happens when it occurs at all
RSA Maintenance Excellence
2006
Rolly Angeles

SIMPLE FLOWCHART FOR REACTIVE ENVIRONMENT


YES NO

WORLD CLASS MAINTENANCE MANAGEMENT

Is It Working? Dont Mess With It!


YES

Did You Mess With It?

YOU BETTER WATCH OUT !!! Does Anyone Else Knows?


YES YES

NO

YOU BETTER NOT CRY !!!

Will it Blow Up In Your Hands?

NO

NO NO

Hide It now quick

Can You Blame Someone Else?

Look The Other Way

YES

RSA Maintenance Excellence


2006

NO PROBLEM!
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHAT TO EXPECT IN A REACTIVE MODE OF MAINTENANCE ...... WHAT TO EXPECT IN A REACTIVE MODE OF MAINTENANCE
Maintenance have no time for training When maintenance go home their children and even their wife is sleeping During weekends, maintenance is not at home but working same old problems When maintenance is at home, they need to turn on their cell for late calls Their regular normal time will be from 8:00 am to 8:00 or 9:00 pm Maintenance always complain of one thing, they lack manpower resources There are instances where maintenance do not change clothes since they are in the plant for more than 24 hrs Maintenance having nightmares and dreaming of their work and boss
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

HOW TO BREAK THE REACTIVE CHAIN OF MIND ? HOW TO BREAK THE REACTIVE CHAIN OF MIND ?

CASE 1 :

POINTS TO PONDER AND THINK ABOUT . . . .

How do we get technicians, supervisors, engineers, operators and even your managers to buy-in and believe us when they have been 10 and 15 yrs experience living in the same old paradigm and have been doing these same old ways over and over again? And much more if the people youre going to convince have been with the company longer that you
Most Executives & Managers in reality are not persuaded by cool technologies & the latest 3 letter buzz words such as TPM, TQM, TQC, RCM. They might find it interesting but they have other priorities, hence, most will support them but few will commit to them
Rolly Angeles

KEY IS TO HAVE THEM COMMITTED RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

HOW TO BREAK THE REACTIVE CHAIN OF MIND ? HOW TO BREAK THE REACTIVE CHAIN OF MIND ?

CASE 2 :

POINTS TO PONDER AND THINK ABOUT . . . .

How can we convince people mostly from operations to join us when they only know one word OUTPUT and whose frame of mind is, Im paid here not to think but to produce OUTPUT, thats all . . . . . FACT 1
Even if they are allowed to join SGA (Small Group Activities) meetings, expect them to be pulled out once operations lag behind on productivity

FACT 2
There will always be resistance to change specially from incumbent operators or those that have been around the plant for sometime
Rolly Angeles

KEY IS TO PILOT AND START WITH THE INCUMBENT RSA Maintenance Excellence
2006

WORLD CLASS MAINTENANCE MANAGEMENT

HOW TO BREAK THE REACTIVE CHAIN OF MIND ? HOW TO BREAK THE REACTIVE CHAIN OF MIND ?

CASE 3 :

POINTS TO PONDER AND THINK ABOUT . . . .

How can we motivate our maintenance craftspeople to improve reliability if they make more money with their salary due to overtime and other hero stuff in the plant ? FACT 1
A common paradigm exists among maintenance that improving reliability can cost our department to reduce our maintenance resources

FACT 2
KEY IS TO LET THEM KNOW THAT MAKING THIS SACRIFICE WILL OPEN DOORS TO BETTER OPPORTUNITIES RSA Maintenance Excellence
2006

If our equipment improves then common sense tell us that we need not be working on overtime no more
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNING THE CORRECT PARADIGM

FALSE :Our people are a companys biggest asset TRUE : The right people are a companys biggest asset,
the wrong people are a companys liabilities
Not all people are created equal, there are people who want to learn and there are to learn and there are people who never learn .. .. .. .. .. are learn

MGA TAONG PASAWAY


They always love to do the opposite do the opposite of what we want We should accept the fact that these people are prone to committing more are prone to committing more mistakes than the right people and much more to it, these will affect the more to it, these will affect performance of other good people This people are more contagious than A1H1 Virus (Influenza)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNING THE CORRECT PARADIGM

FALSE :Having more maintenance people to perform repair TRUE :

and deploy to reactive work will definitely reduce failures Having more maintenance people learn to analyze failures will definitely reduce failures
When maintenance become really When maintenance good at repairing & fixing failures, good then something is definitely wrong then something

WHAT IS WRONG ?
It only means that the same failures It only means that keeps on occurring again & again keeps on occurring and no effort was done to analyze and no effort was done to analyze the failure itself .. . . . . the failure itself Maintenance is not about repairs but Maintenance is not about repairs but doing things that will make sure our doing things assets continue to do what its doing assets continue to
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNING THE CORRECT PARADIGM

FALSE :We need to reduce our cost to improve reliability TRUE : We need to improve reliability to reduce cost
Reducing cost had been a focus for most maintenance managers and that perhaps, we need to learn from the lessons of history that cost must be studied not just based from its initial cost but on the entire Life Cycle Cost of the equipment . . . . .
Improve reliability & cost will go down, while improving cost is not synonymous to improving reliability & sometimes leads to its opposite

RSA Maintenance Excellence


2006

Focus must be on RELIABILITY & not cost, because if RELIABILITY starts to improve COST will definitely go down, there will be times that focusing on COST will tend to hurt RELIABILITY, it cannot be the other way around
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNING THE CORRECT PARADIGM

FALSE :What we need are people who can repair failures fast TRUE :
and those who can teach others how they do things What we need are people who can analyze failures,

RSA Maintenance Excellence


2006

When our maintenance people become really good at fixing failures, it seems to say that the failure does not seem to go away, but when we expect the failure to go away then we are asking the impossible, failures can only be eliminated when we analyze its root cause
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MANAGE MAINTENANCE AS A BUSINESS


Operations people always complain for a need to improved their Operations maintenance, while maintenance always complain about the lack maintenance, while maintenance always complain about the lack of funds, resources, access to their funds, resources, access to their equipment and an overall lack of cooequipment and an overall lack of cooperation with production. peration with production. The feud never seems to stop, when feud never seems to stop, when the production is not met for the day, the their scapegoat will be maintenance, their and when maintenance retaliates, the and equipment had not been endorsed to equipment had not been endorsed to us for PM at all. us Its a day to day battle for pressure. day to day battle for pressure. The key is to have Operations and Maintenance team up together towards The key is to have Operations and Maintenance team up together towards improving equipments performance. When maintenance is manage as a improving equipments business and is looked upon as profit rather than a cost center, the way of business and is looked upon as profit rather than a cost center, the way of doing things will definitely improve things will definitely improve
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

HOW WORLD CLASS MAINTENANCE THINK ?


MOST INDUSTRIES
Maintenance performs repair on their equipment When equipment fails, maintenance repairs it - (REACTIVE MODE) Focus more on catastrophic or sporadic breakdowns Equipment Maintenance is the sole responsibility of Maintenance No time to train, just learn everything by experience Treats their human resources as mechanics and repairman RSA Maintenance Excellence
2006

WORLD CLASS INDUSTRIES


Maintenance think of ways to anticipate failures on their equipment When equipment fails, maintenance not only perform repair but analyze the Root Cause Of The Problem (PROACTIVE MODE) Focus on both sporadic and chronic breakdown Equipment Maintenance is a shared responsibility by both Operations and Maintenance working together as one Training plays a vital and important role in upgrading their skills Treats their human resources as a true Maintenance Professional & Reliability Expert
Rolly Angeles

PRIORITY
FOR INDUSTRY

WORLD CLASS MAINTENANCE MANAGEMENT MOST INDUSTRY BEYOND WORLD CLASS FOCUSED ON WORLD CLASS COMPANIES PROFIT & REVENUE CUSTOMER COMPLIANCE HAPPY CUSTOMER

OPERATIONS

OUTPUT

QUALITY

EMPOWERMENT

MAINTENANCE

REDUCE COST

RELIABILITY

CONTINUOUS IMPROVEMENT

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 3

UNDERSTANDING WORLD CLASS MAINTENANCE MANAGEMENT

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

BEING WORLD CLASS

Manny Pacquiao World Class Boxer

Paeng Nepomuceno World Class Bowler

Efren Bata Reyes World Class 9 Ball Champion

World Class Manufacturers are those that demonstrate industries best practice. To achieve this companies should attempt to be the best in the field of each of these competitive priorities (quality, price, delivery, speed, reliability, flexibility and innovation). Organizations should therefore aim to maximize performance in these areas in order to maximize competitiveness. What makes these people truly World Class.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

DEFINITION :

MAINTENANCE
To keep in continuance To keep in existing state To preserve something

MANAGEMENT
The act, art or manner of managing or controlling something Executive ability of controlling

MAINTENANCE MANAGEMENT
The art or manner of managing to keep our physical assets in existing state of condition The art or science of managing maintenance resources
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

DEFINITIONS

WORLD CLASS DEFINED


The ability to compete anywhere in the world, to be able to meet and beat any competitor anywhere in the world with product, price, quality and on-time delivery
By Terry Wireman Author of World Class Maintenance

WORLD CLASS MAINTENANCE MANAGEMENT


The art and science of managing maintenance resources performed by best in class industries from around the world

But the question arise, is it really possible to manage maintenance or the pressure over maintenance have been managing us for a long time?
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHAT AFFECTS MAINTENANCE ?

COST

Goal is to reduce the cost of maintenance


Spare Parts Management Study of Life Cycle Cost Modification and Redesign Proactive Maintenance Analysis on Top Spare Contributors

Spare parts cost Human Resources Manpower Overtime Commissioning Cost Repair & Maintenance Cost Investment & Modification

DOWNTIME

Goal is to reduce equipment downtime


Root Cause Failure Analysis Application of SMED Techniques RCM / OER Application OEE / MTBF / MTBA Application Condition-Based Maintenance Techniques Monitor Equipment Indices & Metrics Conduct Training Needs Assessment Training & Education Coach & Educate Operators Improve procedures and MTTR Application
Rolly Angeles

Breakdown or Failure Set-Up & Conversion Minor Stoppages & Assists Design Speed Loss Start-Up Loss Defects & Reworks Repair Skills Analytical Skills Multi-skills Technology Skills RSA Maintenance Excellence
2006

SKILLS

Improve the skills of our human resources

WORLD CLASS MAINTENANCE MANAGEMENT

THE NEED FOR MAINTENANCE MANAGEMENT


The Maintenance Department is one of the greatest levers of profitability that any capital intensive organization has. An average of 40 to 50% of capital intensive industries operating budget is being consumed by maintenance expenditure

With the advances in todays technology, this figures can be dramatically reduce. As such maintenance is often an organizations largest single controllable expense
RSA Maintenance Excellence
2006
Rolly Angeles

PREDICTIVE PREDICTIVE MAINTENANCE MAINTENANCE

TRIBOLOGY TRIBOLOGY

LASER ALIGNMENT LASER ALIGNMENT

12 AREAS OF MAINTENANCE MANAGEMENT DICIPLINE


MAINTENANCE INDICES & KPIs ROOT CAUSE FAILURE ANALYSIS ADDRESSING BASIC EQUIPMENT CONDITION SPARE PARTS MANAGEMENT LUBRICATION MANAGEMENT CONDITION-BASED MANAGEMENT

WORLD CLASS MAINTENANCE MANAGEMENT

12 MAINTENANCE MANAGEMENT DICIPLINES

LIFE CYCLE MANAGEMENT

AUTONOMOUS MAINTENANCE RELIABILITY IMPROVEMENT RSA Maintenance Excellence


2006

TRAINING/SKILLS ASSESSMENT PREVENTIVE MAINTENANCE

CMMS & AUTOMATION

Rolly Angeles

12 AREAS OF MAINTENANCE MANAGEMENT DICIPLINE


These 12 Areas for Maintenance Management Discipline will affect us how well we perform maintenance on our equipment and how us how well we perform maintenance on our equipment and how reliable our equipments will be reliable our equipments will be These Maintenance Management Discipline can be categorize into 3 : Maintenance Management Discipline can be categorize into 3 :
BASIC INTERMEDIATE ADVANCE

WORLD CLASS MAINTENANCE MANAGEMENT

Addressing Basic Equipment Condition Autonomous Maintenance Training and Skills Assessment Maintenance Indices and KPIs Preventive Maintenance
RSA Maintenance Excellence
2006

Spare Parts Management Lubrication Management Life Cycle Management Root Cause Failure Analysis Reliability & Continuous Improvement

Condition-Based Maintenance CMMS & Automation

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MAINTENANCE MANAGEMENT STRATEGY


SP E ST CIA RA LI TE ZA T GI IO ES N

CMMS

Vibration Monitoring, Ultrasonic

CONDITIONBASED Thermography, Oil Analysis, MAINTENANCE

E E NC NE NC NE VA L VA PLII AD SC P AD SCII D DII


E E AT AT DII E ED NE ME LIIN RM PL ER P TE CII NT SC IIN DIIS D

BA B A CK SI TO CS

M A ST INT RA EN TE AN GI C E ES

ROOT CAUSE FAILURE FMEA, PM ANALYSIS, WHY-WHY ANALYSIS ANALYSIS RELIABILITY & CONTINUOUS RCM, IMPROVEMENT OER, PM4P, PMO, TPM SPARE PARTS LIFE CYCLE LUBRICATION MANAGEMENT MANAGEMENT MANAGEMENT

PREVENTIVE AUTONOMOUS BASIC MACHINE KPI - METRICS MAINTENANCE CONDITION MAINTENANCE

C S C NE SII IINE BA PL BA IIPL SC SC D DII

TRAINING, SKILLS AND EDUCATION

Culture, Values, Beliefs, Policies & Goals F O U N D A T I O N RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 4 MODULE 4

MAINTENANCE MANAGEMENT BASIC DISCIPLINE

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MAINTENANCE MANAGEMENT BASIC DISCIPLINE


Basic discipline would be the fundamental activities that should be performed on our equipment before going to any other advance or specialized disciplines It also serve as the foundation of any Maintenance Strategy. It should be a waste of money and time on advancing to any continuous improvement effort or Condition-Based Maintenance if the equipment is dirty Most plants have these forms of basic disciplines but often times they had not been used to its full potential. Our goal is to refine & enhance these activities to better fully serve its purpose
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MAINTENANCE MANAGEMENT BASIC DISCIPLINE

So what does a maintenance manager have to do to enter the maintenance management process with many options available at hand . . . . .

ANSWER : GO BACK TO THE BASICS


Everyone knows that big failures start from Everyone knows that big failures start from little things, yet no one takes responsibility or act on them, in reality, going back to the basics seems to be a no ones responsibility no Things gets complicated because they never Things gets complicated because they never address the simple things, and the most address things, and the most obvious reason for this is that they have obvious no time to perform it, but they will always no time to perform it, but they will always have all the time to fix the equipment even have the time to fix the equipment even if they always complain about the lack of if they always complain about the lack of manpower resources manpower resources
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

1st Discipline of Maintenance Management 1st Discipline Maintenance Management

TRAINING & SKILLS ASSESSMENT

(BACK TO BASICS)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TRAINING AND SKILLS ASSESSMENT


Essential to any industry are competent people who understand their equipment intimately. Training is the backbone of any cultural change. It is mainly the missing link ingredient in any change or continuous improvement effort

SKILL DEFINED

Skill is the ability to do ones job, to apply Skill is knowledge & their experience correctly in knowledge & their experience correctly in all kinds of events over an extended period all kinds of events over an extended period Skill is the product of personal motivation Skill is the product and thorough training. The end result is and thorough training. The end result is mastery. And to enable to achieve this, mastery. And companies must develop the most effective companies must develop the most effective training methods training methods

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TRAINING AND SKILLS ASSESSMENT


The first step in any training program is to identify the level of knowledge, technology, skill and competency of their people. Second is to assess their skills from time to time
FOUR LEVEL OF SKILLS

LEVEL 1 : Lacks both theoretical knowledge and practical ability LEVEL 2 : Has theoretical knowledge but not in practice LEVEL 3 : Has mastered practice but have no theory LEVEL 4 : Has mastered both theory & practice

Training should not be the focus of any cost reduction initiative and management must understand that it will play a vital role in improving the skills of their people

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

HOW TO DEVELOP THE SKILLS

KNOWLEDGE-BASED
Define the training curriculum to be given to the people This will be the degree of knowledge gained from classroom training

SKILL-BASED

MASTERY

RSA Maintenance Excellence


2006

This refers to the skills This is when a person is needed to perform the capable of transferring required work correctly. correctly the skills and Define the gap between knowledge to others the current and what is expected from our people This is what we want our people to achieve Provide the people w/ the tools and time to practice what they have learned from training
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TRAINING AND SKILLS ASSESSMENT Listed are steps to follow to improve your current training needs STEP 1 : Analyze your current training program and set policy, goals
and strategies to meet their needs

STEP 2 : Design a program for improving the skills of your


operator and maintenance craftspeople

STEP 3 : Implement operating and maintenance skills training.


Provide both classroom and On The Job Training

STEP 4 : Design and develop a skill development system STEP 5 : Evaluate your yearly training activities & continuously improve

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

STEP 1 : Assess Your Current Training Program


TRAINING ASSESSMENT
1) Are the courses offered by your training department based on the needs of your people ? 2) Does management provide expectation on training ? 3) Does the company allocate budget for their peoples training ? 4) Does training regularly update the skills & competency of their people ? 5) Are the courses offered updated regularly and have training provided new courses on their list based on their needs ? 6) For classroom training, Are the participants allowed to practice what they have learn in their place of work ? Is there a regular evaluation 7) Is there a problem on scheduling people to attend training mostly operations & mtce ? 8) Does training have a regular assessment on the needs of their people ?

REMARKS

Where 1 being the lowest and 5 the highest RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

STEP 2 : Design a program for improving the skills of your people


MAINTENANCE CURRICULUM
Lubrication Strategy & Tribology Condition-Based Maintenance Life Cycle Management Reliability-Centred Maintenance

Specialized Curriculum - 2 to 3 years Specialized Curriculum - 2 to 3 years


2 units 2 units 2 units 2 units 1 unit 2 units 2 units 2 units 2 units 1 unit 2 units 2 units 2 units 2 units 3 units 2 units 2 units
Rolly Angeles

Root Cause Failure Analysis Maintenance Indices and KPIs Preventive Maintenance Strategy Predictive Maintenance Overview Spare Parts Management

Intermediate Curriculum - 1 to 2 years Intermediate Curriculum - 1 to 2 years

Elementary Curriculum - 6 mo to 1 year Elementary Curriculum - 6 mo to 1 year


Interpreting Mechanical Drawings Basic Hydraulic & Pneumatics Basic Gears, Coupling, Seals Lubrication Basics Failure Analysis & Bearing Failure Basic Machine Function Auxiliary & Ancillary Equipment Dies, Jigs, Fixtures and Toolings

Introductory Curriculum - 3 to 6 months Introductory Curriculum - 3 to 6 months

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

STEP 3 : Implement and execute the training program


Tailor fit the training based on your company needs Provide training aids and materials for the participants Provide workshops where the participants can actually practice what they have learned Once the material and modules are ready, schedule the training to your target participants in advance Provide evaluation and feedback on every training to determine what points can be improve most

RSA Maintenance Excellence


2006

Training should be taken as a long term and not as a short term initiative in improving peoples skills
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

STEP 4 : Design and develop a Skill-Development Program


Each supervisor should determine the amount and degree of training their people need A scoring will be helpful in assessing the skills of their people and can be use as one of the focal criteria in their performance appraisal At the end of the financial year, this individual training program is being evaluated & the results are used to draft next years plan

RSA Maintenance Excellence


2006

Rolly Angeles

Planned Maintenance Skills Evaluation


Gearing Towards A Pro-Active Maintenance System
Leader : C L A SS C Sam Milby C L A SS B

Division : Central Equipment Engineering Station : PLCC Department C L A SS D

WORLD CLASS MAINTENANCE MANAGEMENT Teamname : The Untouchables Equipment type handled : All Types
C L A SS A

Legend :
Knowledge & Skill not Satisfactory (0points ) Knowledge Satisfactory ( 000 . points) Skill Satisfactory ( 000 . points ) Knowledge and Skill both Satisfactory

(0Point) SA Y UM A NENE FRA NZIN JB

Classification

No.

Knowledge / Skill Item

Training Atended t Yes No

PLANNED MAINTENANCE MEMBERS


SA M BO B RICO RA UEL CA CQ S

0 Bas ic Machine Function

BASIC M ACH E IN FUN CTION

0 Machine Specs, Parts and Function 0 Knowledge in Actual Set-up and Conversion 0 Bas ic Lubrication Knowledge 0 Bas ic Repair and Troubleshooting 0 Failure Mode and Effect Analysis

AN ALYTICAL SKILLS 0 Root Cause Failure Analysis EN AN H CEM T 0 P-M Analysis EN 0


0 MTBA Snapshot and Analysis 0 0 Sequence Of Events Analysis 0 0 Knowledge and use on FRL's 0 0 Knowledge and use on Pipings and Connectors 0

PN EUM ATICS & H RAULICS YD

0 Knowledge and use of Cylinders 0 0 Knowledge and use on Filtration 0 0 Knowledge and use on Speed Controllers 0 0 Leaks and Seals 0 0 Bearing Failures and Caus es 0 0 Sensors Technology 0 0 Motors and Pum ps 0

OTH ERS

0 Screws and Fasteners 0 0 Spare Parts Managem ent 0 0 RCM and OER Strategy 0 0 Maintenance Indices and Measurem ents 0 0 Knowledge on Vibration Monitoring 0

PRED ICTIV E M TEN CE AIN AN (Specializat ion)

0 Principles of Heat and Thermography 0 0 Oil Analysis and Tribology 0


Rolly Angeles

0 Ultras onic Monitoring 0 RSA Maintenance Excellence 0 CMMS Structure and Sys tem 0

S000 -

2006

Total Points

WORLD CLASS MAINTENANCE MANAGEMENT

HOW TO MAKE TRAINING WORK : Write a letter to students ahead of time letting them know
1. The nature of the training 2. The time and location 3. Management's expectations for returns 4. The time line to realize returns Once they know what is expected of them they will know what the target looks like. They know the "rules of the game" and can now play. Expectations also provide a basis of measurement on how well will the students perform against the performance expectations outlined? When expectations are set, students tend to pay more attention in class and focus on the implementation. If we really want to grab their attention, we can tie their performance as a result of their training to an accomplishment in their performance evaluations.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 1st DISCIPLINE . . . . .


Training is a venue for acquiring knowledge in order to perform their for acquiring knowledge in order to perform their job better. When we put these knowledge into the workplace, we then are building the skills of our people building the skills of our people Technology is travelling at warp speed Technology at warp speed yet our knowledge on how we maintain our asset remain the same as to the day asset remain the same as to the day the caveman invented fire, FIREFIGHTING caveman invented fire, FIREFIGHTING Training must not be considered as a venue for relieving work. Training a venue for relieving Training is much much more than having a free is much much more than having a free sandwich, donut & coffee. sandwich, donut And lastly, when we think that having our people attend training is expensive, our people let us look at the cost of ignorance. It is let us look at the cost much more expensive than the cost of much more expensive training training
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 1st DISCIPLINE . . . . .


Training & education will always be the foundation on any change or improvement initiative improvement initiative Every industry should consider Training as one of the most important industry should consider Training as one and strongest areas in any organization. It must never be the subject strongest areas in any organization. It must never be the subject of any cost reduction efforts any cost reduction efforts Training is where we acquire knowledge knowledge and these knowledge is used to allow these knowledge is used to allow us to do our job better, and when we do our jobs better we become skilled and we become skilled and this skills will be used to further improve to further improve our assets and equipments. Remember it is our people that will improve our equipments and not the other way around equipments and not the other way around

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

2nd Discipline of Maintenance Management 2nd Discipline of Maintenance

MEASURE PERFORMANCE & KPI

(BACK TO BASICS)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RIGHT REASONS WHY WE NEED TO MEASURE PERFORMANCE Performance measurement is one of the methods at the heart of propelling an organization towards breakthrough performance. This generally takes the form of performance indicators, key performance indicators, & measurement programs all designed to focus the attention on various areas of performance.
The old adage is if you can measure it, you can manage it. Before you think about how to measure it, first work out what it is you want to manage! What is important is to understand what is it that we want to measure so that we can determine where we are currently headed.
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

COMMON MEAN TIME INDICATORS

MTBF - Mean Time Between Failure MTBA - Mean Time Between Assists MTTR - Mean Time To Repair, Recover or Restore MTBI - Mean Time Between Interrupt MTTC - Mean Time To Correct MTTS - Mean Time To Set-Up MTTF - Mean Time To Failure
Mean Time Between Failure (MTBF) and Mean Time Between Assists (MTBA) are crucial in an industry that typically produces in excess of one million parts a month such as Semiconductor Industries . . . . .
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

MTBF

MODULE 5

MEAN TIME BETWEEN FAILURE


TIME BETWEEN FAILURE
OPERATING TIME / UPTIME FAILURE FAILURE
Rolly Angeles

RSA Maintenance Excellence


2006

MEAN TIME BETWEEN FAILURE

WORLD CLASS MAINTENANCE MANAGEMENT

MTBF is an average measure of reliability is an average measure of reliability a device will run without failing. Common a device will run without failing. Common units used is hours. It originated from the units used is hours. It originated from the US Military Standards (MIL-STD-217) and US Military Standards (MIL-STD-217) and has been widely used to other applications has been widely used in industries in industries MTBF also defined as the average time also defined as the average time between two failures and therefore is a between two failures and therefore is a measure of the trouble free time. measure By empirical testing or allowing By a part to fail (Destructive Testing) the length of performance or the functional life of a population of items can be divided by the total number of failures to achieve the failures to achieve the MTBF of a part or component
RSA Maintenance Excellence
2006
Rolly Angeles

MEAN TIME BETWEEN FAILURE


MTBF is a reliability engineering term MTBF is a reliability engineering term that means the average amount of that means the average amount of operating time between the occurrence operating of breakdowns that requires repair of breakdowns that requires repair MTBF simply means the average time simply means the average time between failures. It is based on historical between failures. is based on historical data or estimated by vendors and is use data or estimated by vendors as a benchmark for reliability as

WORLD CLASS MAINTENANCE MANAGEMENT

MTBF =

OPERATING TIME NUMBER OF FAILURE

WHERE : OPERATING TIME = LOADING TIME - MACHINE RELATED DOWNTIME LOADING TIME = AVAILABLE TIME - NON-MACHINE RELATED DOWNTIME
AVAILABLE TIME = 168 hrs

NMDT
40 hrs 2006

MDT
72 hrs (6x)

OPERATING TIME

RSA Maintenance Excellence

COMPUTE FOR THE MTBF IF BDO IS 6 ?


Rolly Angeles

MEAN TIME BETWEEN FAILURE


MTBF trend will be the higher the value MTBF trend will be the higher the value the more reliable the machine or part the more reliable the machine In case where there is no breakdown In case or failure, an MTBF of infinity will be an infinity will be obtained. This simply indicates that obtained. This simply there is nothing wrong w/ the equation nothing either prolong the duration of MTBF or MTBF or when there is no failure, assume a failure, assume a denominator of 1 to obtain a value denominator of 1 to obtain If we buy a component with 30,000 MTBF, buy a component with 30,000 MTBF, it means that on an average the part it means that on an average will run for 3.42 years without failure will for

WORLD CLASS MAINTENANCE MANAGEMENT

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TRENDING MEAN TIME BETWEEN FAILURE


00 0 00 0 00 0 00 0 MTBF 0 0 0 0 0 0 0 0 0
DY-00 DY-00 DY-00 DY-00 DY-00 DY-00 DY-00 00 0 00 0 00 0 0 0 0 0 0 0 0 0

TOTAL MTBF FOR THE 7 DONGYANG MACHINES

Graph indicates that the Total MTBF is 660 hours or on average MTBF is at 94.28 hrs. Which means that on the average the 7 DY machines is running at 94.28 hours a week without failure

MTBF (TOTAL) = 134 + 130 + 120 + 96 + 80 + 60 + 40 = 660 hrs MTBF (PERCENT) = 134 + 130 + 120 + 96 + 80 + 60 + 40 = 56.12% 7 x 168 MTBF (AVERAGE) = 134 + 130 + 120 + 96 + 80 + 60 + 40 = 94.28 hrs 7 RSA Maintenance Excellence
2006
Rolly Angeles

DEVELOPING AN MTBF IMPROVEMENT STRATEGY


AVERAGE MTBF
00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 0 0 0 Jan-00 Feb-00 Mar-00 Apr-00 May-00 Jun-00 0 Jan-00 Feb-00 Mar-00 Apr-00 May-00 Jun-00 0 0 0 0 0 0 0 0 00 0

WORLD CLASS MAINTENANCE MANAGEMENT

AVERAGE MTBF BY PERCENT

OVERALL TOTAL MTBF


0000 000 0000 000 0000 000 000 000 000 000 000 000 000 000 0 Jan-00 Feb-00 Mar-00 Apr-00 May-00 Jun-00

Following data will represent the Overall MTBF for all equipments upward trend shows theres an improvement in the reliability of the department.

RSA Maintenance Excellence


2006

Rolly Angeles

EXTRACTING JANUARY DATA FOR LEVEL 1 ANALYSIS


MTBF CATEGORY BY EQUIPMENT
00 0 00 0 00 0 00 0 00 0 00 0 0
00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0

WORLD CLASS MAINTENANCE MANAGEMENT

LEGEND :
1. 2. 3. 4. 5. 6. 7.
0 0 0 0 0 0 0 0 0

Chiller - 14 Substations - 5 AHU - 45 Cooling Towers - 6 Genset -8 Compressor - 6 Elevators - 10

BREAKDOWNS ENCOUNTERED
1. 2. 3. 4. Fuse melts due to overload Defective / drained battery Circuit faults and power failure Multiple failure of protective protected device

RSA Maintenance Excellence


2006

SUB-A

SUB-B

SUB-C

SUB-D

SUB-E
Rolly Angeles

MTBF and MTTF Explained

WORLD CLASS MAINTENANCE MANAGEMENT

If the Time To Fail for this bulb is 3 yrs


What is the MTTF or Time To Fail ? Answer :

3 years 3 years Different

What is the MTBF of this bulb ?


INCANDESCENT BULB Case Study : The life of this bulb reached a lifespan of 3 years. Hence, this bulb was used for 3 years before it was declared fail and incapable of providing illumination RSA Maintenance Excellence
2006

Answer :

Therefore, is MTBF and MTTF the same or different ? Answer :

Then what is the difference between the two ?

Rolly Angeles

MTBF and MTTF Explained

WORLD CLASS MAINTENANCE MANAGEMENT

MTBF is a key reliability metric for systems that can be repaired or that can be restored. MTTF is the expected time to failure of a system. Nonrepairable systems can fail only once, hence for non-repairable items, MTTF is equivalent to its mean of its failure time distribution. Repairable system can fail several times, while non-repairable can fail only once.

MTBF MTTF

A MTTR

B MTTR

Point where a new part is installed Time to repair Point where the 1st failure occurs

Total time it will take for the part to fail

Point where the new part will fail again Point where the 2nd failure occurs

HENCE : MTBF = MTTR + MTTF

RSA Maintenance Excellence


2006

Rolly Angeles

MEAN TIME TO FAILURE

WORLD CLASS MAINTENANCE MANAGEMENT

MTTF is a basic measure of reliability for non-repairable systems. It is the mean time expected until the first failure of a piece of equipment. MTTF is a statistical value and is meant to be the mean over a long period of time and large number of units. For constant failure rate systems, like MTBF, MTTF is also the inverse of failure rate. If failure rate is in failures/million hours, MTTF = 1,000,000 / Failure Rate for components with exponential distributions.

Technically MTBF should be used only in reference to repairable items, while MTTF should be used for non-repairable items. However, the MTBF is commonly used for both repairable and non-repairable items.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MOST COMMON MAINTENANCE INDICATORS


MEAN INDICATORS
MTBF MEAN TIME BETWEEN FAILURES =

FORMULA

TREND

OPERATING TIME HIGHER THE BETTER BREAKDOWN OCCURENCE

MEAN TIME TO REPAIR MEAN TIME TO SET-UP

REPAIR TIME MTTR = LOWER THE BETTER BREAKDOWN OCCURENCE SET-UP TIME MTTS = LOWER THE BETTER FREQUENCY OF SET-UP FREQUENCY OF ASSISTS

TOTAL SNAPSHOT TIME MEAN TIME BETWEEN ASSISTS HIGHER THE BETTER MTBA =

MEAN TIME TO FAIL OTHER INDICATORS

SAME AS MTBF (NON-REPAIRABLE) HIGHER THE BETTER

FORMULA

TREND

OEE = OVERALL EQUIP. EFFECTIVENESSUTILZATION x EFF. x YIELD HIGHER THE BETTER

FAILURE RATE RSA Maintenance Excellence


2006

FAILURE RATE = 1 / MTBF

LOWER THE BETTER


Rolly Angeles

SET GOALS ON MEANINGFUL MEAURES


INDICATOR Reduce Breakdown Improve MTBF Reduce MTTR Reduce Maintenance Cost Increase Utilization Improve Set-Up Time Improve Maintenance Skill Reduce Spare Parts

WORLD CLASS MAINTENANCE MANAGEMENT GOAL WE WANT TO ACHIEVE

Rank A Equipment = Zero Rank B Equipment = 100% of Rank B Improve MTBF by 60 - 70 % Reduce Time To Repair to less than 0.15 hrs Reduce Maintenance Cost to 50 % Increase Utilization to 98 % Set-up Time to be less than 15 minutes 48 hours of Technical Training per year for every maintenance Reduce cost of inventory to 40 %

Measuring Maintenance activities are geared towards challenging these Maintenance activities are geared towards challenging these goals and as these goals start to improve, skills also improve .. .. .. .. and as these goals start to improve, skills also improve
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Case STUDY : Applying PM PHASE 2


(LENGTHENING EQUIPMENT LIFETIME)
Hermetics Analog Equipment KNS1474 - Wirebond

THE PM TEAM : YEAR 2000

ARNEL SOLO

JOEL TUMALA

JOEL ALCANTARA

ALLAN NEOMES

LEANDRO ENANO

ERIK ENDAYA

Before doing Planned Maintenance on their Wirebond machine KNS 1474, the team encounter many breakdowns on each sub-assembly and as the team perform Phase 1 Breakdown occurrences were reduced, the group decided to pursue Phase 2 of Planned Maintenance by identifying parts with inherent design weaknesses and challenge to improve the lifespan of spare parts with recurring Breakdowns
BREAKDOWN OCCURENCE

BONDHEAD = 23x X-Y TABLE = 15x WORKHOLDER = 52x ELEVATOR = 22x RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT IDENTIFICATION OF PARTS WITH DESIGN WEAKNESSES BEFORE AFTER

PROBLEM : Corroded wire path contact pin sensor which tend to cut wire, Short lifespan of pin sensor encountered and easy for dust to accumulate

MODIFICATION : Provide continuous path for sensor by replacing with stainless contact pin sensor

IMPACT OF IMPROVEMENT : Eliminate non-stop feed motor Cut wire good sensing activity to wirepath Improve yield and lessen cut wire defect and damages

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT IDENTIFICATION OF PARTS WITH DESIGN WEAKNESSES BEFORE AFTER

STAINLESS LEADSCREW & NUT SUPPORT

ELEVATOR ASSEMBLY
PROBLEM : Broken lead screw nut Frequent worn out of lead screw & nut Frequent elevator jamming Worn out lead screw inner thread IMPACT OF IMPROVEMENT : Improve lifespan of elevator lead screw and nut Eliminate elevator frequent jamming

MODIFICATION : Provide aluminum spacer support on top to support and withstand heavy weight compartmentalized magazine

RSA Maintenance Excellence


2006

Rolly Angeles

REDUCTION IN BREAKDOWN OCCURENCES

WORLD CLASS MAINTENANCE MANAGEMENT

The PM group realized a dramatic reduction of their breakdown occurrences after modification of design weakness in their pilot equipment. The group Passed Phase 2 Certification

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 2nd DISCIPLINE . . . . .


Measuring Meaningful Measures of Performance is important for any organization as downtime translates to loss productivity, loss revenue and loss of customers confidence. Downtime in one business segment can easily have a direct impact on our customers business
These meaningful measures helps us improve the way we do things around from the traditional way of doing things by applying a fix and never get to the root cause of the problem, which is the essence of a reactive environment. A simple message will be when a failure occurs dont just fix it, analyze it . . .

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 2nd DISCIPLINE . . . . .


Measuring performance should be done at the beginning of any performance should be done at the beginning of any reliability improvement initiative. Key Performance Indicators are reliability improvement initiative. Key Performance necessary to track maintenance performance. Summarizing : necessary 1) Have the right reasons to measure equipment performance 2) Identify the losses your equipment is suffering and determine the correct Meaningful Measurements. Know what maintenance indices do we want to measure 3) Set goals on what we want to achieve on these indices & challenge it 4) Determine what strategies should be implemented and executed them to ensure that the goal is achieved 5) Consistently review the goals and continuously improve

RSA Maintenance Excellence


2006

Rolly Angeles

REMEMBERING ATP PLANNED MAINTENANCE 1998 - 2001


Sa Planned Maintenance, Isang Misyon, Isang Direksyon pa rin . . . . . Graph below shows actual results on the number of breakdowns after thorough implementation of Planned Maintenance 4 Phases To Zero Breakdown

WORLD CLASS MAINTENANCE MANAGEMENT

1st PILOT BDO TRENDING FOR PM PILOT MACHINES


300 250

22 MACHINES
STEP 1

200 150 100 50 0 Sep-00 Oct-00 Nov-00 Dec-00 Jan-01 Feb-01 Mar-01 Apr-01 May-01 Jun-01 Jul-01 Aug-01 Sep-01

STEP 2-3 STEP 4

Sep-00

Oct-00

Nov-00 Dec-00 Jan-01 Feb-01 Mar-01 Apr-01 May-01

Jun-01

Jul-01

Aug-01

Sep-01

BDO

PLAN

ACTUAL

259 259

200 237

150 151

100 117

85 80

50 33

25 28

10 13

0 12

0 15

0 6

0 4

0 0

LEGEND : BDO - Number of Breakdown Occurrences RSA Maintenance Excellence


2006
Rolly Angeles

REMEMBERING THE ATP PLANNED MAINTENANCE 1998 - 2001


Sa Planned Maintenance, Isang Misyon, Isang Direksyon pa rin . . . . .

WORLD CLASS MAINTENANCE MANAGEMENT

As we achieve near to ZERO breakdown on our 22 PM Pilot Machines, we also improve in our MTBF or Mean to Between failures, hence, we have a good trend on our MTBF Indices, (Actual data from ATP JIPM Book)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

3rd Discipline of Maintenance Management 3rd Discipline Maintenance Management

AUTONOMOUS MAINTENANCE

(BACK TO BASICS)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

AUTONOMOUS MAINTENANCE BASIC CONCEPT : Why Autonomous Maintenance is important :


1st It is believe that operators are the first line of defense on any It is believe that operators are the first line of defense on failure that occur in our equipment since they are the people failure that occur in our equipment since they are the people closest to the asset. They will be the once who will encounter closest to the asset. They the failure first before the maintenance the failure first before

2nd - Maintenance can only advance to Maintenance advance any continuous improvement effort any continuous improvement effort & advancement if operator accept & accept the responsibility that they should the responsibility that they should play a major part in establishing play a major part in Basic Equipment Condition Basic Equipment

RSA Maintenance Excellence


2006

It will be a very hard tasks for the maintenance to overcome the vicious cycle of reactive maintenance if the operators wont be involved with it . . .
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

AUTONOMOUS MAINTENANCE BASIC CONCEPT :


Maintenance people train and educate operators to perform basic repairs and maintenance, they also perform specialized skills on inspection, disassembly and MP design improvement

By teaching operators about their equipments and the need to perform basic equipment condition, Maintenance people can focus on higher

forms of maintenance and equipment improvements


RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PM GUIDANCE AND SUPPORT FOR OPERATORS


Equipments are a shared responsibility by Autonomous Maintenance Equipments are a shared responsibility by Autonomous Maintenance and Planned Maintenance. Planned Maintenance must teach operators and Planned Maintenance. Planned Maintenance must teach operators basic equipment maintenance so that they can perform specialized basic equipment maintenance so that they can perform specialized maintenance and focus on addressing the Root Causes of failures. maintenance and focus Maintenance must teach Autonomous Maintenance regarding Maintenance must Autonomous Maintenance regarding
Basic Machine Function & Operation Importance of Cleaning Basic Inspection Standards Lubricating Standards & Techniques How to perform minor repairs How to perform minor set-up & adjustment on the machine How to inspect using their senses How to pinpoint abnormalities Proper use of gauges Importance of addressing sources of contamination Machine Safety Procedures How to generate One Point Lesson Importance of performing Basic Equipment Condition on their Machine

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PM GUIDANCE AND SUPPORT FOR OPERATORS

Worn out critical spare parts are not thrown away, instead they are being mounted on this whiteboard which are later used by the maintenance people as a teaching aid to their partners which are the operators, a brief description of why the part had worn out and its criticality to the equipment, & possible signs of potential failure to detect that it is already wearing out.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PM GUIDANCE AND SUPPORT FOR OPERATORS

Operators find it hard to communicate with maintenance simply because they do not know the name of the part that fail,
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PM GUIDANCE AND SUPPORT FOR JISHU-HOZEN

We generate this Good to Find form in order to provide useful information and teach our operators the importance of locating fuguia, because if the fuguia were not found, these will be the effect of such a problem on our equipment. The operators acknowledge these learning's by signing on the GTF form portion below - as student
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

AUTONOMOUS MAINTENANCE BASIC CONCEPT :

Autonomous Maintenance is the activities in which each worker


performs daily inspection, lubrication and parts replacement, minor repair and troubleshooting, accuracy checks and so forth on one owns equipment w/c aims to keeping ones own equipment in good condition

I OPERATE (Operator)

YOU FIX (Maintenance)

If the operators change, the equipment will improve, if the equipments improve, the productions capability can will be improve . . . .
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

AUTONOMOUS MAINTENANCE BASIC CONCEPT :

Autonomous Maintenance is considered by many people to be the


transfer of maintenance tasks to operators. But in reality this means more than a simple transfer of responsibilities

Key elements are on the following

Improving equipment cleanliness Developing cleaning & lubricating standards Developing inspection procedures Organizing work areas Continuously improving the workplace Developing skilled operators

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

ACTIVITIES PERFORMED BY AUTONOMOUS MAINTENANCE


ACTIVITIES TO PREVENT DETERIORATION
Proper operation & preventing human errors Establishing Basic Equipment Condition Minor set-up adjustments Detecting abnormality and recording Understanding Basic Machine Function Kaizen activities

ACTIVITIES TO MEASURE DETERIORATION


Daily inspection Ability to sense problems through their senses

ACTIVITIES TO RESTORE DETERIORATION


Minor checking & minor repairs Proper reporting of failure & other malfunction Assistance in sporadic repairs

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PURPOSE OF AUTONOMOUS MAINTENANCE


FIRST

It brings production and maintenance to work together to accomplish a common goal which is to establish basic equipment condition and to prevent accelerated deterioration Operators learn to carry out important daily tasks such as cleaning, proper lubrication, inspections, and other light maintenance tasks including simple repairs and replacements
CURRENT MINDSET CORRECT MINDSET

I Operate, You Fix I Fix, You Design I Design, You Manage


RSA Maintenance Excellence
2006

We are All responsible for Our Equipment We take good care of Our Equipment
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PURPOSE OF AUTONOMOUS MAINTENANCE


SECOND

Autonomous Maintenance is designed to help operators learn more about how their equipment functions, what common problems can occur and how to prevent it by early detection and treatment of abnormal conditions
THIRD

Autonomous Maintenance prepares operators to be active partners with the maintenance and engineering in improving the overall performance & reliability of their equipment

Operators can prevent breakdowns and quality problems by learning how to recognize abnormal conditions . . . . .
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

AUTONOMOUS MAINTENANCE SURVEY


AUTONOMOUS MAINTENANCE
1) Does maintenance teach operators about their equipment functions & performing minor repairs and adjustments ? 2) Is there a strategy for Autonomous Maintenance for operators of the equipment ? 3) Does operators understand their role in establishing basic equipment condition on their equipments ? 4) Does your operator knows how to detect and pinpoint abnormalities and irregularities on your equipment ? 5) Does operators perform regular checking on cleaning and lubrication on their equipment ? 6) Are operator familiar with the part that fails frequently and can they communicate them properly with the maintenance ? 7) Is their a program or training to improve the skills of your operator ?

REMARKS

Where 1 being the lowest and 5 the highest RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 3rd DISCIPLINE . . . . .


Our equipments are a shared responsibility for both operators responsibility both & maintenance working together. & Start by educating operators educating operators about their equipments. about Once operators learn & accept Once accept their responsibility, only can responsibility, only maintenance advance to any reliability improvement efforts and escape from a fire fighting escape from a fire fighting or reactive mode of maintenance

Remember when a failure occurs it is the operator who encountered them first and not the maintenance since they are the people closest to the asset most of the time
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 3rd DISCIPLINE . . . . .


Oftentimes operators dont perform inspection in their equipment. We inspection in their equipment. We develop the checklist, but they dont develop perform the checks. This seems to perform the checks. This seems to be the main complaint of the mainbe main complaint tenance people, operators do not tenance people, operators do not resist change, they just do not want resist to be dictated by anyone. to The secret is to let the maintenance to let the maintenance guide them into understanding their guide them into understanding their own equipment, once they learn, they own equipment, once they learn, they will take care of their own equipment. will own equipment.

The key is to let the maintenance understand that operators are capable of developing their own checklist. And if operators develop their own checklist, it is guaranteed that they will perform it themselves
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

4rth Discipline of Maintenance Management 4rth Discipline

ADDRESSING BASIC EQUIPMENT CONDITION

(BACK TO BASICS)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LACK OF DISCIPLINE OFTEN LEADS TO HARD DOWN FAILURES


Simple RCFA case on the photo Simple caused worn out screw since worn out screw since technician do not have the right do not have the right tools at hand to tighten Insufficient knowledge on lubriInsufficient knowledge on lubrication caused a technician to caused a technician to pour a gear oil into the hydraulic gear oil into the hydraulic system of a press a press Using a coin instead of a positive Using a coin of a positive screwdriver to unlock a screw screwdriver Using a hammer to install a newly Using a hammer newly replaced bearing on the motor 200 mm
Set screw (M3) tip used

So many reasons can be Loose thread on the bolt caused by Loose written, yet everything boils too much force exerted not to mention to mention down to one exact word the head which is hexagonal slowly head which is hexagonal slowly
becoming rounded becoming

RSA Maintenance Excellence


2006

DISCIPLINE

150 mm

Due limited space set screws are prone to insufficient tightening

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

ESTABLISHING BASIC EQUIPMENT CONDITION Best In Class performers understand the essence of establishing Basic Equipment Condition in their equipment, while others often overlooked them yet almost all understand its importance
BASIC EQUIPMENT CONDITION INCLUDES

CLEANING LUBRICATION TIGHTENING OF BOLT ADDRESSING LEAKS ABILITY TO USE SENSES TO DETECT PROBLEMS
The major difference between the best performers

& others is that the best performers implement what others only talk about . . . . .
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

ESTABLISHING BASIC EQUIPMENT CONDITION


Establishing Basic Equipment Establishing Basic Equipment Condition means eliminating the Condition means eliminating the causes of accelerated deterioracauses tion or when the machine or part tion does not reach its natural life does not It means cleaning to remove dirt It means cleaning to remove dirt and sources of contamination, and sources of contamination, proper lubrication to prevent proper lubrication to prevent early wear and understanding early wear and understanding that bolts needs to be secure that bolts needs to be secure

When operators helps in establiWhen operators helps in establishing these Basic Equipment shing these Basic Equipment Condition, equipments reliability Condition, equipments reliability starts to improve, maintenance can starts to improve, maintenance can focus more on specialized activities focus more on specialized activities and start performing improvements and start performing improvements in their equipments in their equipments
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

ESTABLISHING BASIC EQUIPMENT CONDITION


CLEANING OF COMPONENTS Detailed cleaning of components and equipment is often a no mans island because everybody agrees that it is important but nobody wants to do them actually World Class Companies perform these activities. Components and equipment are clean in detail. Such an organization realizes that good inspections cannot be done without this level of cleaning and cleaning extends the life of components For example, life of electric motors varies between 5 months for a dirty motor to 20 years for a clean motor
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

ESTABLISHING BASIC EQUIPMENT CONDITION


PROPER LUBRICATION Good Lubrication Strategy Includes : Improving the choice of lubricants Improving the Addressing Oil Leaks Addressing Oil Leaks Proper method of lubrication Proper Understanding Cooling System Understanding Proper storage and handling Proper handling Lubrication Standards & Procedures Basic Filtration Principles Principles Oil Contamination Control Understanding the relationship Understanding between wear and contamination Understanding the different types of contaminants present in oil of contaminants present in oil
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

ESTABLISHING BASIC EQUIPMENT CONDITION


TIGHTENING OF BOLTS All machinery contain nuts, bolts and screw as essential elements of their construction. Equipment functions properly only if fasteners are securely tightened. It only takes one loose bolt to start a chain reaction of wear and vibration. As the other bolts become loose vibration increase All machine vibrates but excessive vibration is destructive as this will surely induce secondary damages on parts and components affected by the vibration. Vibration should be controlled, cracks, fractures propagate as a result of excessive vibration
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

ESTABLISHING BASIC EQUIPMENT CONDITION


TIGHTENING OF BOLTS
Matchmarks Matchmarks are placed on bolts and nuts so that operator can easily detect if bolts have been loosen due to excessive vibrations. These are being placed on critical bolts after each bolt had received their correct torque. Blue line for bolts which loosened for the 1st time Brown line for bolts which loosened for the 2nd time Red line for bolts which loosened for the 3x and more

Secure tighten loose nuts & bolts Secure tighten loose nuts & bolts Replace missing nuts and bolts Replace missing nuts and bolts Replace damage or worn out nuts & bolts Replace damage or worn out nuts Replace unsuitable wing nuts & washers Use locking devices on critical bolts Use locking devices
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TYPES OF CONTAMINATION
TAG LEAKS

One of the most common forms of One of the most common forms contamination is process leaks contamination is process leaks The simplest method of identifying The simplest method of identifying and correcting leaks is to TAG them and correcting leaks is to TAG them Locate the leak & identify its source, identify its type of leak and severity of the leak type

LEAK TAG
Found by : Type of leak : Equip. No.: Description of leak : Date : Priority : Area :

Implementation of a simple, easy Implementation to use system such as this can to use system such as this can save hundreds to thousands of save hundreds dollars for a plant dollars for plant

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 4rth DISCIPLINE


Establishing Basic Equipment Condition Establishing Basic Equipment Condition is a shared responsibility by both operations is shared responsibility by both operations and maintenance, and should be performed and maintenance, and should be performed regularly on the equipment regularly on the equipment Catastrophic breakdowns can greatly be Catastrophic breakdowns can greatly be reduced if Basic Equipment Condition is reduced if Basic in place. Lacking and loose bolts often place. Lacking and loose bolts often lead to excessive vibration which produce excessive vibration which produce secondary damages on parts affected by the vibration itself

Most maintenance find it hard to advance to any continuous improvement, some had advanced to Predictive Maintenance stage yet they find it hard to control the failures & parts lifespan had not been reached, why ?

RSA Maintenance Excellence


2006

BASIC EQUIPMENT CONDITION HAD NOT BEEN ESTABLISHED


Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 4rth DISCIPLINE


Big failures often started from very little failures often started from very little things that are often times neglected. things One of the major reasons why maintenance maintenance remain reactive and oftentimes trapped remain reactive and oftentimes trapped into the repair business is that basic equipinto the repair business is that equipment condition had not been established & ment condition had if asked why it had not been established, if asked not they really have no time for it since maintethey really nance is always undermanned and when we nance asked why they are undermanned, operators asked why they simply dont take part of its responsibility simply dont Let us not estimate the capabilities of Let us not of operators which is just to operate, once operators which is just to operate, they understand and take part in the resthey understand and ponsibility of addressing basic equipment ponsibility of addressing condition, maintenance can perform their condition, true job. true job.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RSA PUBLIC SEMINAR AND WORKSHOP FOR 2009


CODE RSA TRAINING WORKSHOP WHEN SPEAKER VENUE

RCM TPM

Reliability-Centred Maintenance Total Productive Maintenance

Jun 17, 18 & 19 Jul 15, 16 & 17

Rolly Angeles Rolly Angeles

Great Eastern Hotel Great Eastern Hotel

WCM World Class Maintenance Management The 12 Disciplines Sept 23, 24 & 25 Rolly Angeles LCA LUB Latent Cause Analysis Experience Oct 21 to 24 Lubrication Strategy and Oil Contamination Control C. Robert Nelms

Great Eastern Hotel To be announce

Nov 5 & 6

Rolly Angeles

To be announce

To reserve simply fill out the form at www.rsareliability.com/benefits.htm To have a copy of the invitation, download it at ww.rsareliability.com/benefits.htm RCM Invitation: http://www.rsareliability.com/RCM%20Brochure%20(3%20days).pdf RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

5fth Discipline of Maintenance Management

PREVENTIVE MAINTENANCE

(BACK TO BASICS)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREVENTIVE MAINTENANCE PRINCIPLE PREVENTIVE MAINTENANCE PRINCIPLE


Stress cause an asset to deteriorate by lowering its resistance, exposure to stress includes output, distance traveled, operating cycles, calendar time and running time
Trademark for Patterns A, B, and C

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREVENTIVE MAINTENANCE DEFINED: PREVENTIVE MAINTENANCE DEFINED:


PM is a basic maintenance performed on the equipment & facilities. The main goal of performing task on a scheduled basis is to extend the equipments life and to assure its capacity in support of plants goals and targets. In Preventive Maintenance, the basic law to consider is that the cost of performing PM must always have to be lower than the cost of not doing it which eventually will result to a failure. PM is also a series of tasks performed at a defined frequency dictated by the passage of time, the amount of machine hours, mileage that either extend the life of the asset or detect that an asset had a critical wear

and is about to fail or break in operation.


RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREVENTIVE MAINTENANCE OBJECTIVE PREVENTIVE MAINTENANCE OBJECTIVE


The most important objective of a Preventive Maintenance program is to reduced cost Better conservation and increase life expectancy of assets, thereby eliminating crisis work on machinery To improve safety & quality condition of assets and equipment

RSA Maintenance Excellence


2006

To reduce overtime costs & more economical use of maintenance workers due to working on a schedule basis instead of a crash basis to repair equipment failures
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREVENTIVE MAINTENANCE :: PREVENTIVE MAINTENANCE


Also known as Time-Based or Calendar

Based Maintenance
Maintenance activities are performed on

a calendar or fix operating schedule in order to extend the life of the equipment and prevent failures
Maintenance is performed without regard

to equipment condition
Assumes that the condition of the machine

and the need for maintenance is correlated with time which means that the item can be expected to operate reliably for an amount of time and is expected to wear out
A failure rate and history records are used

to established the best frequency


RSA Maintenance Excellence
2006
Rolly Angeles

PREVENTIVE MAINTENANCE ACTIVIES :: PREVENTIVE MAINTENANCE ACTIVIES


Regular Checking, and Inspecting Scheduled Parts Replacement and Overhauling

WORLD CLASS MAINTENANCE MANAGEMENT

Routine Cleaning and Lubrication

Managing Spares and Inventory

Preparing Work orders

Planning & Scheduling

PdM Maintenance Monitoring

CMMS and Computerization

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LIMITATIONS OF PREVENTIVE MAINTENANCE LIMITATIONS OF PREVENTIVE MAINTENANCE Can all failures be captured by Preventive Maintenance ?
ANSWER : Despite the best efforts & structure on Preventive Maintenance Failures are still inevitable & will not be captured solely by PM. Zeroing out all breakdowns is like catching a lighting with a Polaroid Camera . . .

Why wont PM capture all failures ?


ANSWER : Typically only around 20% of component failures will wear out or are directly related to the age of the equipment, and around 80% or all failures will fit the random and infant mortality failures. And when the failure is random in nature, there is no amount of PM that can address this issue. This is where PM is at its weakest, hence, let us not misuse this strategy.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LIMITATIONS OF PREVENTIVE MAINTENANCE LIMITATIONS OF PREVENTIVE MAINTENANCE


Preventive Maintenance include risks. Preventive Maintenance include risks.

There is always an assumption that There is always everything will be put back in place everything well together after a PM initiative. well together after a PM initiative.

Likewise is the possibility of Human Errors which leaves to infant Mortality of newly installed components which installed components eventually leads to additional failures after endorsing back the equipment endorsing back the equipment to production It is important to conduct a important to conduct a thorough review regarding the thorough regarding the activities that are being peractivities performed on the equipment during formed on the equipment during a Preventive Maintenance shuta Preventive down & that understanding that down most failures are not related to most failures are not related to the operating age of equipment the operating
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREVENTIVE MAINTENANCE :: PREVENTIVE MAINTENANCE


When the part or component wears out directly with respect to its operating age These parts will survive this defined age Ex. 98 % of impellers were replaced after the end of 2 years The part or component will have a normal rate of wear, TPM term will be natural deterioration. A more technical term will be normal fatigue Fatigue happens when the stress exceeds the strength of the material of the spare part or component Application of Preventive Maintenance tasks will only be worth doing and feasible to parts that will have a normal wear or deterioration
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Why Most Preventive Maintenance Efforts Fail ? Why Most Preventive Maintenance Efforts Fail ?
Every industry have their own way of doing Preventive Maintenance, yet most of them are not satisfied with the outcome of their PM. Here are just some of the failures they realize in their PM program : PM is most of the time deferred by operations to cope up with schedule Unplanned breakdown is high even with PM in place and almost everyone have their own excuses Paperwork is incomplete or either the information is being faked PM is costly due to replacement of parts which are still in good condition The worst part on PM failure is that management might not even know the system had failed. It is analogous to having a patient die on a hospital and the hospital continue to send you bills for their new services:
RSA Maintenance Excellence
2006
Rolly Angeles

Survey On Top Problems on PM (as of September 2010) Survey On Top Problems on PM (as of September 2010)
1) Add on PM Checklists Syndrome - where PM checklists and activities seems to grow 2) Infant Mortality Failures - where problems arises after a PM replacement and overhaul 3) Replacement of good parts to conform with PM specs and procedures 4) The Case of Random Failures - where random failures are included in the PM checklists 5) Ageing workforce - nearing retirement 6) Lack of training on the maintenance function 7) Still Reactive and lot of corrective maintenance even with a sound PM Program 8) Frequent reorganization in the plant - where new boss makes a new system 9) Lack or poor documentation in PM 10) PM is waived - Operations wont give equipment for PM to cope with production

WORLD CLASS MAINTENANCE MANAGEMENT

76 94 56 78 44 98 99 36 113 117

76 94 56 78 44 98 99 36 113 117
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

Why Most Preventive Maintenance Efforts Fail ? Why Most Preventive Maintenance Efforts Fail ?
The traditional approach to Preventive Maintenance is that all breakdowns are the same and all are bad. Maintenance must realize that all failures are not created equal. Every single failure have their own set of consequences Maintenance must understand that their

job is not about eliminating failures but rather it has more to do on reducing or eliminating the consequences of failure

Money spend must be justifiable in the light of the consequences of failure. Failure that result in death, accident, environmental damage & safety are simply not acceptable
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

IS PREVENTIVE MAINTENANCE FEASIBLE ? IS PREVENTIVE MAINTENANCE FEASIBLE ?


1) In a study conducted 95 out of 100 impellers will reach a life span of 3 years, maintenance decide to replace all 100 impellers before the 3rd year.

Answer : Preventive Maintenance is Feasible


2) In mining industry hydraulic pumps wears out prematurely due to abrasion therefore the maintenance prepare an MTBF study and found out that the average failure is every 3 months.

Answer : Preventive Maintenance is not Feasible


3) A ball bearing is calculated to have a life of 5 yrs however, in our experience, similar bearings seems to fail randomly, others even reach a life of 3 months. Maintenance decides to replace all ball bearings every 3 years, Answer : PM is not Feasible 4) All parts wear, others gradually and others will wear out with respect to the age of the part. If majority of the same parts will wear at a specific age then can Maintenance declare that Preventive Maintenance is feasible to use ? Answer : PM is Feasible RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 5fth DISCIPLINE LEARNINGS FROM THE 5fth DISCIPLINE
Preventive Maintenance activities are

most effective on Age-Related or Wear effective on Age-Related or Wear Out Failures, however, we still need to we still need to address the most frequent failures w/c are random & infant mortality failures & infant mortality failures

Not all similar parts will fail on the same the same

period, Preventive Maintenance are well justified when the probability of failure when the probability of failure of parts will survive a specific age specific age Mortality failures are introduce during Mortality failures are introduce during overhauls when the equipment is not properly put back together. Overhauls put back together. Overhauls and replacement should be done by replacement should be by skilled craftspeople with the right tools with the right tools

Maintenance must understand that Infant

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 5fth DISCIPLINE LEARNINGS FROM THE 5fth DISCIPLINE
Learn that the most effective way of using PM is to understand when and when not to use it, so that you can derive the most benefit from it That PdM is not an isolated program and must be part of the Preventive Maintenance Strategy The best way to perform Preventive Maintenance is to understand that failure have 6 patterns which means that not all parts will wear with age MTBF if not applicable in determining the frequency of replacement for PM since MTBF is just a probability and average Application of Preventive Maintenance tasks will only be worth doing and feasible to parts that will have a normal wear or deterioration Frequency of inspection will depend upon the pattern of failure and not just assigning a routine daily, weekly, monthly or quarterly monitoring. Likewise, understand the importance of adopting a functionality check and inspection for protective devices
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WORKSHOP ON BASIC MAINTENANCE DISCIPLINE WORKSHOP ON BASIC MAINTENANCE DISCIPLINE


On a rate of 1 to 5, where 5 is the highest On rate your area on these Basic Disciplines on these Basic Disciplines
Training, Skills & Education Measuring Maintenance Indices & KPIs Establishing Autonomous Maintenance Addressing Basic Equipment Condition Preventive Maintenance Structure

Choose 1 Basic Discipline that Choose Discipline that you think your industry needs to think your industry needs to improve most and state at least three important learnings from this discipline important learnings from this discipline State the problems mostly encountered on State the problems mostly encountered the Basic discipline you have mentioned discipline you have mentioned What do you think should be improved from the Basic Discipline What do you you have mentioned in your industry ? you have mentioned in your
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 5

MAINTENANCE MANAGEMENT STRATEGIES INTERMEDIATE DISCIPLINE

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MAINTENANCE MANAGEMENT INTERMEDIATE DISCIPLINE


Intermediate discipline refers to the different strategies on maintenance that are applied to improve equipments reliability. Once the basics have been well established, we can now develop these strategies : LIFE CYCLE MANAGEMENT LUBRICATION MANAGEMENT
MAINTENANCE MANAGEMENT INTERMEDIATE DISCIPLINE
(STRATEGIES)

SPARE PARTS MANAGEMENT

RELIABILITY IMPROVEMENTS
RSA Maintenance Excellence
2006

ROOT CAUSE FAILURE ANALYSIS

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

6th Discipline of Maintenance Management 6th Discipline of Maintenance Management

LUBRICATION MANAGEMENT

(INTERMEDIATE DISCIPLINE)
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

A BROADER STUDY OF OIL INCLUDES :


Wear, Friction and Wear, Friction and Lubrication Lubrication

Tribology Tribology

Contamination Contamination Control Control Environmental Environmental Regulations Regulations

Different test applied Different test applied

Oil Analysis Oil Analysis

STUDY OF OIL

Lubrication Lubrication Management Management Oil Recycling Oil Recycling

Filtration Filtration Synthetics Synthetics

Electro hydraulic Control Electro hydraulic Control Centrifuge Centrifuge

RSA Maintenance Excellence


2006

Rolly Angeles

DEFINITION OF OIL :

WORLD CLASS MAINTENANCE MANAGEMENT

A slippery or viscous liquid or liquefiable substance not miscible with water A greasy, unctuous liquid of vegetable, animal, mineral or synthetic origin. Any number of viscous liquids with a smooth sticky feel Usually flammable, insoluble in water, soluble in organic solvents, obtained from plants and animals, from mineral deposits, & synthetics

THE NEED FOR OIL :

Lubricants are specifically designed to reduce friction and wear of contacting surfaces in machine components
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TRIBOLOGY: FRICTION, WEAR AND LUBRICATION :


Friction is a force that is created when Friction is a force that is created when two surfaces move across each other two surfaces move across each other So long as there is friction there is wear So long as there is friction there is wear Area of Contact is the point of wear Area of Contact is the point of wear Wear occurs due to friction Wear occurs due to friction Purpose of lubrication is to separate Purpose of lubrication is to separate these contacting surfaces and reduce these contacting surfaces and reduce friction and wear friction and wear

(W) Weight (fs) Static Friction BLOCK

(F) Force (F)


Surface

Where : Fn = W

(FN ) Normal Force

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

THE NEED FOR OIL :

Lubricants are specifically designed to reduce the friction and wear of contacting surfaces in machine components Thats why our PM states that oil should be changed regularly to prolong the life of our equipment, right ?
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

FUNCTION OF OIL
To lubricate all moving internal parts To to minimize friction and wear To dissipate heat To dissipate heat For contamination and corrosion control For To seal the piston rings & mating surfaces To seal the piston rings & mating surfaces

Lubricating oil is made up of baseLubricating oil is made basestocks and additives and additives Base-stocks can be made from : Base-stocks can be made from :
Petroleum, Petroleum, Synthetic Synthetic Para-Synthetic Para-Synthetic

The base oils are then treated with chemicals and additives to form different grades of lubricating oils for a variety of applications.
RSA Maintenance Excellence
2006
Rolly Angeles

BIG ISSUE ON LUBRICATION

WORLD CLASS MAINTENANCE MANAGEMENT

Every single PM Checklists has a form of lubrication activity that is being performed in a timely fashion which states something like this :

What : Apply lubrication on bearing When : Monthly Who : Preventive Maintenance


If this is the case with you then, this is where CHAOS & CONFUSION starts As to what specific lubricant to be used is unknown. Grease or Oil ? If grease, what corresponding NLGI number must be used ? What specific brand and type of grease is to be used ? What specific temperature of grease is required for this application ? How many shots or pump is needed or when do I know when to stop ? How many grams of grease is required for this application and how do you know when to stop pumping grease ?

Most of the time we blame it on the lubricant and not on the way we actually perform our lubrication . . . . .
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHAT CAUSED OIL BREAKDOWN ?


Increase in temperature Heat is the no. 1 reason that destroy oil Heat is the no. 1 reason that destroy oil An indicator of heat tolerance is Flash Point An indicator of heat tolerance is Flash Point Lower the Flash Point ,, greater chance of Lower the Flash Point greater chance of vaporization loss at high temperature and vaporization loss at high temperature and oil to burn off on hot cylinder walls & pistons oil to burn off on hot cylinder walls & pistons Leads to oil thickening and deposit build-up Leads to oil thickening and deposit build-up on critical engine components on critical engine components Depletion of Additives Minimum Flash point is at 400 degree F Minimum Flash point is at 400 degree F The lifespan and protective ability of your oils additives package is primarily dependent upon the amount of contamination present in your oil, NOT the number of miles or hours the oil has been in service Contamination of Oil Contamination comes in the form of solid, liquid and air which should not be present in the oil in the first place
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

UNDERSTANDING HOW CONTAMINATION OCCURS

TYPICAL OIL FILTER


(Nominal Rating)
A conventional oil filter is design to will trap particles 30 to 40 microns in size but those smaller will remain in the oil and some will be abrasive and cause parts to wear

CONTAMINATION REMAINS IN THE SYSTEM


The fine particles that cause abrasive wear are usually not visible to the eye. Oil containing particles of this size can actually look clean while having enough abrasive particles to cause pump failure.

MOISTURE IN OIL
In most cases moisture penetrates into the filter and goes back again into the providing more serious damage into the system

MORE FAILURES OCCURS RSA Maintenance Excellence


2006

FAILURE OCCURS AS CONTAMINATION RISE

ABRAISIVE PARTICLES RUB


Rolly Angeles

OIL OXIDATION CHART


Catalyst None Iron Copper None Iron Copper Water No No No Yes Yes Yes

WORLD CLASS MAINTENANCE MANAGEMENT

Hours 3500+ 3500+ 3000 3500+ 400 100

10

12

Acid Number Change


Ref: Weinschelbaum M:, Proceedings of the National Conference Fluid Power, VXXIII:269

RSA Maintenance Excellence


2006

Rolly Angeles

TYPES OF WATER IN OIL


x

WORLD CLASS MAINTENANCE MANAGEMENT

Entrained
Free gas or water suspended in the oil in the form of small bubbles or droplets

Emulsified
Microscopic droplets of water distributed in the form of an emulsion - may separate

Dissolved
Gas / water dispersed in the oil in the form of an homogeneous molecular solution. Gas / water cannot be removed from a solution with a conventional filter

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

OUR BELIEF ON CONTAMINATION


We believe that oil should be replace regularly by changing oil If we dont change oil more parts will fail Oil change must be done on a time dominated frequency (running hrs)

Contamination is also the reason for oil degradation, hence, the need to change oil on a time-dominated (running hrs) frequency is essential. More contamination means more failures and frequent change oil, therefore it is important to analyze oil on the amount of contaminants as well as what elements are present and not by the frequency of changing oil itself. By knowing this information, maintenance can strategize measures to improve fluid cleanliness and lengthen its drain interval.

If oil can be maintained clean, then there is no reason to change it


RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

DOES OIL WEAR OUT ?


The US Air Force says :
Despite the popular notion that oil breaks down or wears out and is unfit for further use. Its permanent value has been known to the U.S.A.F since World War 1

Lubrication Engineering, Vol. 17


Oil does not wear out, Standard Oil of New York, Many times the question has been asked does lubricating oil wear out ? The question should be answer in negative

Mobile Oil Technical Bulletin # 863


Oil does not wear out, breakdown or otherwise deteriorate to such an extent that it needs to be changed, it becomes contaminated with water, acids, carbon particles and sludge. Average Oil Filter can remove solid particles above a certain size. It cannot remove water, acids, carbon particles all of which pass through the oil filter just as readily is the oil

U.S. Standard Bulletin # 86


Oil does not wear out, but only gets dirty

Theory and Practice of Lubrication for Engineers, 2nd edition P590-591


Oil like any mineral and cannot wear out. Oil become dirty and contaminated but like copper, iron or silver, when they are reprocessed they are as good as new RSA Maintenance Excellence Rolly Angeles
2006

WORLD CLASS MAINTENANCE MANAGEMENT

CASE STUDIES ON CONTAMINATION :


Test done by GM Corporation shows that 82% of internal wear comes from particle less than 40 microns SKF states that improper lubrication accounted to 54% of bearing failures Ford states that 80% of hydraulic system failures can be treated to particulate contamination Cummins Technical Center indicate that wear can be reduced by 91% using a by-pass filter in combination with a full-flow filter SAE states that contamination in lubricant of engines, transmissions & hydraulic systems cause 70% of equipment failures In a study by the Canadian National Research Council, contamination was found out to be the leading cause of wear in a variety of industries investigated. In fact 82% of all wear was found to be particle induced Nippon Steel reduced bearing failures by 50% through aggressive contamination control International Papers Pine Bluff Mill reported a 90% reduction in bearing failures again through aggressive contamination control program According to Caterpillar, dirt and contamination are the no. 1 cause of hydraulic system failures. J.I. Case states that with regards to hydraulic systems it must be kept clean SHOW VIDEO RSA Maintenance Excellence Rolly Angeles
2006

CONTAMINATION CONTROL AWARENESS CAMPAIGN


CORRECT PRACTICES ON OIL HANDLING

WORLD CLASS MAINTENANCE MANAGEMENT

Proper oil dispensing preventing contamination from the surroundings

Having a lubricating room or a refilling room. Each container having different types of oil

Closed top labeled containers for different types of oils used

When transporting oil use sealed type dispensing

BAD AND WRONG PRACTICES ON OIL HANDLING

This types of oil handling practices are very prone to contamination RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WORLD CLASS LUBE ROOMS : CONTAMINATION CONTROL

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MICRON UNIT OF MEASUREMENT :


A micron is also known as a micrometer, and exhibited as A unit of length. One Micron or 39 millionths of an inch (0.000039") Contaminant size is usually described in microns. A grain of salt is about 60 microns The eye can see particles to about 40 microns. (0.00156 inch) Average oil filters can trapped particles from 30 to 40 microns Many hydraulic filters are required to be efficient in capturing a substantial percentage of contaminant particles as small as 5 microns.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

FUNCTION OF A FILTER :
The function of a filter is to remove contamination from a fluid (liquid or gas) in order to achieve a required level of fluid cleanliness. The FUNCTION of a filter is to clean the oil, but the PURPOSE is to reduce operating cost by reducing abrasive and fatigue wear on components FILTRATION DEFINED :

The removal of contaminant from a fluid (liquid or gas) stream through the use of a porous medium
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

ABSOLUTE AND NOMINAL RATINGS OF FILTERS :


The absolute rating of a filter refers to smallest size particle that will be removed during filtration while nominal ratings refer to the average particle size that will remain in the fluid after filtration. A nominal five-micron filter will trap particles around 5 microns in size. An absolute 5 mic filter will guarantee to trap all particle 5 microns in size & larger.

Tests have shown that particles as large as 200 microns will pass through a nominal rating of 10 micron filter. An absolute rating gives the size of the largest particle that will pass through the filter or screen. This is the size of the largest opening in the filter. Therefore, when buying filters always speak of absolute and not nominal. RSA Maintenance Excellence Rolly Angeles
2006

WORLD CLASS MAINTENANCE MANAGEMENT

ABSOLUTE AND NOMINAL RATINGS OF FILTERS :


ABSOLUTE
FLOW

NOMINAL
FLOW

Tapered Pore Structure


Upstream Downstream

Uniform Pore Structure


Upstream Downstream

Magnified 500x RSA Maintenance Excellence


2006

Magnified 500x
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

BETA RATING OF FILTERS :

100,000 B3 = 50,000

100,000 B3 = 500

= 200

Nominal or Mean Efficiency Rating :


(BETA) ratio = 2.0 (50% efficiency).

Absolute Efficiency Rating :


(BETA) ratio = 75 to 200 (98.5% efficiency)

Beta Efficiency

Beta Efficiency

= (1 - 1/2) x 100% = 50 %

= (1 - 1/200) x 100% = 99.50 %

Particle counts greater than or equal to a given size upstream are divided by the particle counts greater than or equal to the same size downstream. This produces a Beta ratio, denoted by the Greek letter Beta, . The subscript on the letter denotes the micron size that was tested. RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHICH OIL FILTER WILL REALLY SAVE YOU COST ? WHICH OIL FILTER WILL REALLY SAVE YOU COST ?
NOMINAL RATING BETA 10 @ 50% Efficiency ABSOLUTE RATING BETA 1000 @ 99.9% Efficiency

FILTER COST : 490.00 RUP

FILTER COST : 490.00 USD

REPLACEMENT COST LABOR COST LUBRICANT COST DISPOSAL COST DOWNTIME COST SPARE PARTS COST OVERTIME COST

= $ 8.00 = $ 75.00 = $ 8.00 = $ 5.00 = $ 7,200.00 = $ 1,500.00 = $ 25.00

REPLACEMENT COST LABOR COST DISPOSAL COST LUBRICANT COST DOWNTIME COST SPARE PARTS COST OVERHEAD COST

= $ 490.00 = $ 5.00 = $ 5.00 =$ =$ =$ =$ 0.00 0.00 0.00 125.00


Rolly Angeles

RSA Maintenance Excellence


2006

OVERALL COST = $ 8,821.00

OVERALL COST

= $ 625.00

BREAKING THE CHAIN REACTION OF WEAR


Typical Ineffective Filter (x = 2)

WORLD CLASS MAINTENANCE MANAGEMENT


High Performance Filter ( x = 200) (x

1st Pass
Gear Pump Solenoid Activated Valve Spool Bearings

2nd Pass
Gear Pump Solenoid Activated Valve Spool

Bearings

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHAT IS OIL ANALYSIS ? WHAT IS OIL ANALYSIS ? When we are examined, our doctor may draw a blood sample and send it to a laboratory. Upon receiving the blood test result he then renders a medical opinion or advisory which we are free to accept or reject
Oil inside the equipment equipment can dictate its condition can dictate its condition through an Oil Analysis through an Oil Analysis Program Like blood, oil Program Like blood, oil contains a great deal of contains a great deal of information about the information about the envelope in which it envelope in which it circulates circulates
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT LEVEL 1 : CHECK OILs HEALTH AND CLEANLINESS PARTICLE COUNTER

The most recognized & widely used oil The most recognized & widely used oil analysis instrument This method aims to check the cleanliness by determining the total number of particles by particles in several different size ranges in several different Service oils used must be within the target Service be within the target cleanliness level. It can measure particles from 2 to 100 microns. An increase in the 100 microns. An increase in the no.of particles can indicate potential failure indicate potential failure 82% of wear problems are directly attributed 82% of wear problems are directly to particle-induced failures such as abrasion, failures such erosion and fatigue Particle counters also have the ability to Particle counters quantify particles in different size ranges. quantify particles in different size ranges. This quantification is often referred to as quantification is often referred to as the particle size distribution particle size distribution
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT LEVEL 1 : CHECK OILs HEALTH AND CLEANLINESS

Particle count is the procedure Particle count is the procedure recommended by the ISO for recommended by the ISO for establishing fluid cleanliness establishing fluid cleanliness standards It measures both metallic and It non metallic particles alike metallic particles alike Of all the contaminants particles Of all the contaminants particles contamination is the most destructive to the oil & machine The objective of having a particle The objective counter is to control fluid cleanliness is to control fluid level and not trending dirt levels and not trending dirt levels Best use for hydraulics and filtered oils Best Particle Counters Detect, Measure and Count the individual particles; Providing data on the number and size of particles present in a given sample. The laser beam path is blocked by the contaminant
RSA Maintenance Excellence
2006
Rolly Angeles

CONTAMINATION CLASSES ACCORDING TO ISO 4406 : 99


ISO 0000 CODE 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

WORLD CLASS MAINTENANCE MANAGEMENT


Number of Particles From To 0 00 0 0, 0 0 00 0 0, 0 0 00 0 0, 0 0 00 0 0, 0 0, 0 00 0 0 00 0 0, 0 0, 0 00 0 0, 0 00 0 0, 0 00 0 0, 0 00 0 0, 0 00 0 0, 0 00 0 00 0 , 0 0, 0 00 0 00 0 , 0 00 0 , 0 00 0 , 0 00 0 , 0 00 0 00 0 , 0 00 0 00 0 00 0 00 0 0 0 00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00 . 0 00 . 00 . 00 . 00 . 00 . 00 .
Rolly Angeles

1) Solid Contamination Code


ISO 4406 - 87 to ISO 4406 - 99
- particles > 15 mic change to 14 mic - particles > 5 mic change to 6 mic - particles > 2 mic change to 4 mic

2) Calibration of Automatic Particles


ISO 4402 to ISO 11171

3) Multi-pass Filtration Performance


ISO 4572 - ISO 16889 RSA Maintenance Excellence
2006

CONTAMINATION CLASSES ACCORDING TO ISO 4406 : 99


ISO CODE :

WORLD CLASS MAINTENANCE MANAGEMENT

4m SAMPLE 1 :

24 / 25 / 24
6m 14m

Particles Particles Particles Particles Particles Particles

> or = than 4 microns = 75,783 + 6,732 = 82,515 > or = than 4 microns 75,783 + 6,732 = 82,515 > or = than 6 microns = 98,435 + 145,089 = 243,524 > or = than 6 microns 98,435 > or = than 14 microns = 46,978 + 89,789 = 136,767 > or = than 14 microns = 46,978 + 89,789 = 136,767
Particle Conaminants : ISO Conaminants : ISO 00: 0 0 00 0 00 0 0

Particle counter test reveals presence of particle contamination as follows on a 100 ml sample what is the ISO cleanliness level of the following :
0.5 micron 2 microns 6 microns 12 microns 15 microns 18 microns - 6, 732 - 75, 783 - 98, 435 - 145, 089 - 46, 978 - 89, 789

Particle CounterTrending Particle Couter Trending


000 000 000 000 000 000 000 000 000 000 000 00 0 Sample Sample Sample Sample Sample Sample 0 0 0 0 0 0

> 0mic > 0mic > 00 mic

SAMPLE 6 :

RSA Maintenance Excellence


2006

23 / 25 / 24

Sam 0 Sam 0 Sam 0 Sam 0 Sam 0 Sam 0 ple ple ple ple ple ple
> 0mic > 0mic > 00 mic 000 00 000 000 000 000 000 00 000 000 000 000 000 00 000 0 00 000 0 00 000 00 000 000 000 000 000 00 000 000 000 000 000 00 000 000 000 000
Rolly Angeles

STANDARD BASE CLEANLINESS TARGETS


MACHINE / COMPONENT ISO RATING

WORLD CLASS MAINTENANCE MANAGEMENT Offline Filtration Equipment

Roller Bearings Journal Bearings Industrial Gearboxes Mobile Gearboxes Diesel Engines Steam Turbine Paper Machine Servo-Valve Proportional Valve Variable Volume Pump Fixed Piston Pump Vane Pump Gear Pump Ball Bearing Turbine

- 16/14/12 - 17/15/12 - 17/15/12 - 17/16/13 - 17/16/13 - 18/15/12 - 19/16/13 - 13/12/10 - 14/13/11 - 15/14/12 - 16/15/12 - 16/15/12 - 16/15/12 - 14/13/11 - 17/15/12

CCS2 Particle Counter

Determine fluid cleanliness of oil in ISO and NAS Standards Best used for hydraulic oil applications Determine particles in different size distribution
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

TYPICAL CLEANLINESS LEVELS


New Oil From Barrel 22/20/18

FILTRATION FACT New Fluid is not necessarily clean fluid. Typically, new fluid right out of the drum is not fit for use in hydraulic and engine systems and should be filtered out prior to using it. Clean and New are not the same

New System w/ Built-in Contaminants 23/22/20

System With Typical Hydraulic Filtration 20/18/16

System with 3 >200 Clearance 3 Protection Filtration 14/13/11

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CASE 1 : DETERMINE THE PROBLEM


Hydraulic Motor

HYDRAULIC CYLINDER 270 ppm

VALVE BLOCK Hydraulic Pump 250 ppm Breather


x x

Downstream 260 ppm

262 ppm

Determine what is the problem from this system that is generating excessive contamination and wear

10 ppm

10 ppm
Drain Plug 30 ppm

s
RSA Maintenance Excellence
2006

200 ppm

Rolly Angeles

ADOPTING A LUBRICATION STRATEGY STEP 1 : Maintenance and Operations people

WORLD CLASS MAINTENANCE MANAGEMENT

must be trained on lubrication strategy and contamination control

STEP 2 : Determine the cost of lubrication and

spare parts that fail due to lubrication for the past 3 to 5 years and make this as your baseline data for improvement

STEP 3 : Adopt Contamination Control Awareness

as a strategy and not as a program of the month. Understand proper Oil Handling procedures and Storage Handling lubrication complete with proper lighting, ventilation and adopt color coding when necessary if your using different types of lubrication in your plant

STEP 4 : Set up proper storage system for all your

RSA Maintenance Excellence


2006

Rolly Angeles

ADOPTING A LUBRICATION STRATEGY


persists, adopt Root Cause Failure Analysis

WORLD CLASS MAINTENANCE MANAGEMENT

STEP 5 : Address leaks in your equipment. If leaks

STEP 6 : When Contamination Control is in place

expect some savings in your lubrication. Adopt an Oil Analysis Laboratory and analyze the condition of your oil to determine the types of contamination present in your system

STEP 7 : Understand filtration system and adopt

high-beta rating on selected applications. Use offline-filtration system and have them part of your regular PM schedule such as bearings, hydraulic pumps, seals and assess the effectiveness of your strategy If goals had been achieved, aim for more. Provide simple recognition system and celebrate the success with your people
Rolly Angeles

STEP 8 : Monitor your lubrication and spare parts

STEP 9:

RSA Maintenance Excellence


2006

LEARNINGs FROM THE 6th DISCIPLINE :: LEARNINGs FROM THE 6th DISCIPLINE

WORLD CLASS MAINTENANCE MANAGEMENT

Oil is the lifeblood of any equipment and provide useful information on the condition of parts inside our equipment on the condition of parts inside our equipment Oil is change not based on the kilometers or running hours that the change not based on running equipment had run but based upon the amount of contaminants equipment had run but based upon the amount of contaminants present in the oil itself present in the oil itself Rate of wear inside an equipment is inside an equipment is directly proportional to the amount directly proportional to the amount of contaminants present in the oil. If of contaminants present in the oil. If oil can be maintained clean, then oil can be maintained clean, then wear of oil & parts can be controlled wear of

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

7th Discipline of Maintenance Management 7th Discipline of Maintenance Management

LIFE CYCLE MANAGEMENT

(INTERMEDIATE DISCIPLINE)
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LIFE CYCLE MANAGEMENT LIFE CYCLE MANAGEMENT


Life Cycle Cost refers to the total cost of equipment throughout its life. The US Management and Budget defines LCC as the sum of the direct, indirect, recurring, non-recurring and other related cost of a large-scale system during its period of effectiveness. In terms of production equipment, LCC can be describe more simply as design and fabrication cost which is the initial or acquisition cost plus the operation and maintenance cost which is the running costs. The initial cost will always be easy to see, but the running cost are not. Failure to consider the running cost can lead to many problems. At least 80% of an equipments LCC can be conceptualized at the design stage. Hence,

LCC = INITIAL COST + RUNNING COST


RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LIFE CYCLE MANAGEMENT LIFE CYCLE MANAGEMENT

ATP MECO CLF PLATING MACHINE


MACHINE TYPE : EDF + EPL 2400S AUTOMATIC LOAD & UNLOAD STRIP TO STRIP DEFLASH + PLATING MACHINE WITH THE CAPABILITY TO PROCESS 2400 STRIPS / HOUR

DESIGN FABRICATION COST COMMISSIONING COST OPERATION COST DECOMMISIONING DESIGN FABRICATION COST COMMISSIONING COST OPERATION COST DECOMMISIONING

Disposal Cost Evaluation Quality Test Installation Cost Maintenance Cost Procurement Cost Transportation Cost Spare Parts Cost Transportation Cos Design Cost Modification Cost Warranty Cost Downtime Cost Labor Cost Quality Test Debugging Cost Energy Cost Spare Inventory Revisions Contractors Cost Facilities Cost Labor Cost Modification Cost Engineering Training Cost Labor Cost RSA Maintenance Excellence Rolly Angeles
2006

WORLD CLASS MAINTENANCE MANAGEMENT

LIFE CYCLE MANAGEMENT LIFE CYCLE MANAGEMENT


Sometimes a higher performance product costs less than a commoditytype product, even though the price is higher. To gage whether this will be the case we should look at the product life cycle cost, rather than the purchase price or initial cost of the product. Life Cycle Costing is a way of analyzing equipment purchase choices. If the decision was based on several factors rather than its initial costs, we will make our selection based on the least amount to own over its entire life. This is all about Life Cycle Management

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LIFE CYCLE MANAGEMENT LIFE CYCLE MANAGEMENT


Equipment must not only be inexpensive in terms of its initial cost (also termed as procurement cost, fabrication cost ) but also in terms of its running cost. This brings us to the key concept of Life Cycle Cost and Management. Our goal is therefore to develop and design equipment with the lowest possible Life Cycle Costs LCC must not only be looked upon entirely on purchasing new equipments but rather it should also be used in selecting the right spare or component to use

Most equipment designers emphasize equipments initial cost over its running cost, but today more designers are now thinking in terms of LCC. They have now learned that the surest path to profitability lies in minimizing equipments LCC
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

UNDERSTANDING LIFE CYCLE COST


Beneath the initial procurement cost lies a much more greater cost which is all about LCC

EQUIPMENT COST
( TIP OF THE ICEBERG )

CONSUMABLESMAINTENANCE ENERGY COST PERATING COST OPERATING O LABORS COST SPARE COST BREAKDOWNS CONVERSION

COMMISSIONING REPAIR COST MODIFICATION TRAINING COST FACILITY COSTVENDOR COST DISPOSAL LOGISTIC COST

RUNNING COST OR LIFE CYCLE COST


RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHICH OIL FILTER WILL REALLY SAVE YOU COST ? WHICH OIL FILTER WILL REALLY SAVE YOU COST ?
NOMINAL RATING BETA 10 @ 50% Efficiency ABSOLUTE RATING BETA 1000 @ 99.9% Efficiency

FILTER COST : 490.00 PESO

FILTER COST : 490.00 USD

REPLACEMENT COST LABOR COST LUBRICANT COST DISPOSAL COST DOWNTIME COST SPARE PARTS COST OVERTIME COST

= $ 8.00 = $ 75.00 = $ 8.00 = $ 5.00 = $ 7,200.00 = $ 1,500.00 = $ 25.00

REPLACEMENT COST LABOR COST DISPOSAL COST LUBRICANT COST DOWNTIME COST SPARE PARTS COST OVERHEAD COST

= $ 490.00 = $ 5.00 = $ 5.00 =$ =$ =$ =$ 0.00 0.00 0.00 125.00


Rolly Angeles

RSA Maintenance Excellence


2006

OVERALL COST = $ 8,821.00

OVERALL COST

= $ 625.00

BREAKING THE CHAIN REACTION OF WEAR


Typical Ineffective Filter (x = 2)

WORLD CLASS MAINTENANCE MANAGEMENT


High Performance Filter (x = 200)

1st Pass
Gear Pump Solenoid Activated Valve Spool Bearings

2nd Pass
Gear Pump Solenoid Activated Valve Spool

Bearings

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 7th DISCIPLINE LEARNINGS FROM THE 7th DISCIPLINE

There is a tendency to reduce costs by replacing parts with the lowest possible cost. Reducing costs and improving reliability are not the same, in fact there are cases when reducing costs will affect the reliability of the machine
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 7th DISCIPLINE LEARNINGS FROM THE 7th DISCIPLINE

If we want to improve on cost, we should focus not on the Initial cost but on the Life Cycle Cost of the component. This is where a true and meaningful savings can be realize on maintenance
Every maintenance should focus on improving reliability and not on reducing cost WHY? because if reliability starts to improve then cost will definitely go down, it cannot be the other way around. Remember that there will be times that focusing on reducing cost will affect reliability, a lesson we should reflect upon. Having a low maintenance cost is always a consequence of good maintenance practice . . . .
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

8th Discipline of Maintenance Management 8th Discipline of Maintenance Management

SPARE PARTS MANAGEMENT

(INTERMEDIATE DISCIPLINE)
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

SPARE PARTS MANAGEMENT SPARE PARTS MANAGEMENT


When a machine fails, it is mostly caused by a part that fails to fulfill its function. Mechanical parts wear and needs to be replaced and what is important is to keep the downtime to a minimum. A storeroom is a place to store parts that we need to keep our equipments running.

But managing spare parts simply means how fast we can response in acquiring the right part during the time when maintenance and operations needed them most
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

SPARE PARTS MANAGEMENT SPARE PARTS MANAGEMENT

A good Spare Parts Management system ensures the right parts gets to the right place at the right time
PROBLEMS ON SPARE PARTS Out of control emergency buying Everyones access to the spare parts room during peak hours under the honor and honesty system Large amount of non-moving items Wrong parts supplied Wrong inventory of parts at hand Parts unavailability when needed Disorganized storeroom & time to get parts in the storeroom eat too much time on the maintenance ROLE OF SPARE PARTS IS TO PROVIDE PARTS QUICKLY WHEN NEEDED ROLE OF SPARE PARTS IS TO PROVIDE PARTS WHEN NEEDED
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

SPARE PARTS MANAGEMENT SPARE PARTS MANAGEMENT


A spare parts is not just a place to stock parts. It is a place for everything A not just to stock and that everything should be in place. A good spare parts management system must include the following must include the following Receipt of incoming spare parts Receipt of incoming Control of issuance to users Control of issuance to users Control of parts inventory, min-max Control of parts inventory, Control over defective parts Control over defective parts Control of parts under warranty Control of parts under warranty Quality Control of incoming parts incoming parts Proper storage & handling for fast Proper storage & handling for fast and slow moving parts and slow moving parts Parts storage lifespan (due dates) storage lifespan (due dates) Data reporting, tracking reporting, tracking Control of obsolete parts
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

SPARE PARTS MANAGEMENT SPARE PARTS MANAGEMENT


Proper planning and control of spare parts inventory is a critical component of an effective asset management program. If the right parts are not on hand when needed for routine maintenance or repairs, downtime is prolonged. If too many parts are on hand, the company absorbs excessive costs and the overhead of carrying the inventory.

Housekeeping and orderliness in the storeroom is an important part of Spare Parts Management responsibility, as this is critical to the ability to retrieve the correct item quickly to the end user

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Storeroom must be organized


Parts must be free from debri & clutter to permit personnel access to parts Locations must be labeled to reduce time to search parts Stepladders, stools & carts must be parked in an area that is out of the main flow Area needs to be separated through walls or cage to discourage theft and to enforce recording of parts receipts/issues for inventory accuracy purposes. Lighting in the area should be sufficient Strategic location of parts such as fast moving parts should be located for easy access while slow moving and big items can be located at the back side of the store
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Importance of Inventory Accuracy


One of the critical success factors for a Spare Parts Management is achieving a high level of inventory accuracy Accurate inventory is defined as the correct part and quantity physically in the storeroom and in the system Lost of confidence in the storeroom can result in maintenance stocking parts in their cabinets, toolbox, shelves which often result in excessive cost of parts If the actual inventory is lower than the system recorded, then the risk is high that physically an out of stock condition occurs, while if actual inventory is higher than the system recorded then parts are overstock even when its not needed
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Preventive Maintenance Kit Building


One of the functions of the storeroom is to provide parts, tools and supplies for the technicians to perform PM Tasks. It will be a good idea for the spare parts personnel to have access over the PM schedule. PM kits are prepared in advance before the PM schedule starts. This saves time in acquiring the parts to be used for PM activities.

When a PM is scheduled for work, the technician presents the PM work order to the storeroom. The system will show that the inventory has already been picked and is in the kitting hold area. The technician can take the PM kit to the job and the entire process of retrieving all the parts needed for PM
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

Freeing Up Of Obsolete Parts


Oftentimes, there are many parts held in storage that do not belong to any equipment in the facility since it had already been decommission. Overtime, equipment in the facility may be retired and no longer in site, yet, the parts of that equipment are still in the storeroom. And worst, storeroom personnel may still be ordering the obsolete parts When an equipment is retired, the spares associated with it must be identified so that they can be freed from the storeroom, this will free up space, storing obsolete items cost money and space in the storeroom. A plant can terminate plans to expand their storeroom by freeing up space consumed by obsolete parts
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

9th Discipline of Maintenance Management 9th Discipline of Maintenance

ROOT CAUSE FAILURE ANALYSIS

(INTERMEDIATE DISCIPLINE)

RSA Maintenance Excellence


2006

Rolly Angeles

Root Cause Analysis Defined :: Root Cause Analysis Defined

WORLD CLASS MAINTENANCE MANAGEMENT

Root Cause Failure Analysis is trying to UNDERSTAND why something went wrong . . . . . BOB NELMS
Root Cause Failure Analysis identifies the basic source or origin of the problem so that recurrence of the problem may be prevented RCFA provides a methodology for investigating, categorizing and eliminating the root cause of incidents w/ safety, quality, reliability & manufacturing process consequences . . .

Bob Nelms at Jakarta, Indonesia Teaching Latent Cause Analysis

Identifying the Root Cause Failure Analysis event allows us to explain the WHAT, HOW and WHY of the failure
RSA Maintenance Excellence
2006
Rolly Angeles

Root Cause Analysis Defined :: Root Cause Analysis Defined

WORLD CLASS MAINTENANCE MANAGEMENT

Root Cause Analysis separates the facts from hearsay. RCFA is not about trial and error and seeing what works and not
While there are many techniques in in analyzing a problem which provide a analyzing a problem which provide a quick answer, it does not mean that the quick answer, it does not mean that the answer is correct everytime. A true and answer is correct everytime. A true and meaningful Root Cause Failure Analysis takes the time to prove that what we say takes the time to prove that what we say is fact & supports our hypothesis with supports hypothesis with evidence before we spend our money to evidence before we spend our money improve the design of the equipment design of the equipment

RSA Maintenance Excellence


2006

When the facts are backed up by evidence & science and they are separated from the fiction we now have a better understanding as to the real Root cause of the problem
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RCFA CASE STUDY ::MISSING MONEY RCFA CASE STUDY MISSING MONEY
CAUSE STUDY : In the problem below a car wash manufacturer sold one of his complete, turn-key car wash systems to a client in Maryland. This includes the change machines for the people who wish to get change to wash their cars. The new owner recognizes that he is losing a significant amount of money from this change machine and insinuates that the manufacturers employees have a spare key and are stealing the money. The problem started when the new owner complained to Bill that he was losing significant amounts of money from his coin machines each week. Bill just cant believe that his people was stealing the money since he have known them for many years Bill then form a RCFA to get to the bottom of the problem The group decided to install a surveillance camera to know who was stealing the money RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RCFA CASE STUDY ::MISSING MONEY RCFA CASE STUDY MISSING MONEY Logic Tree Diagram
Missing Money
(Money from the Change Machine was missing)

Money was never there


Customers not paying

Money was stolen from the machine


(Theres a thief)

Change Machine Malfunction


Not working properly

Stolen by someone

Stolen by something

The video surveillance indicates that the customers entering the car wash hence, their hypothesis that customers was not paying was disregarded The owner try to simulate the Machine by placing some coins in them and the machine was then working properly so Change Machine Malfunction was not the problem, It is clear to them that someone is stealing the money but who . . . RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RCFA CASE STUDY ::MISSING MONEY RCFA CASE STUDY MISSING MONEY
But the RCFA group had not given up and monitor the surveillance camera and found out . . .

There goes another bird this tim Thats a bird sitting on the change slot Thats 3 quarters he has in his beak, taking of the machine and it had to go down amazing thing is that it wasonly 1 quarter another into the machine but why ? not just one bird but several of them

RSA Maintenance Excellence


2006

Once they identify the thieves, they found over $ 4,000.00 in the roof of the car wash and more under a nearby tree, therefore, the case of the stolen money was solved thanks to Root Cause Analysis . . .
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

EXERCISES ::TEST YOUR ANALYTICAL SKILLS --1 EXERCISES TEST YOUR ANALYTICAL SKILLS 1
Detective Varnike was playing golf in the hotel garden, when a shot was suddenly heard in one of the rooms. The detective appeared on the 1st floor and pushed slightly and opened the door into a room. Help, someone wanted to kill me! cried addressing to Varnike a well-known movie star stopped in the hotel's room. Just there was a man in a mask here. I was assailed by him. I protected myself as I could, then he shot. Probably, during struggle I had snatched a pistol out from him hands. After that he rushed to a door and disappeared in a corridor. Please, call police

Why did detective Varnike refuse to pursue the criminal?

RSA Maintenance Excellence


2006

Rolly Angeles

Root Cause Analysis Defined :: Root Cause Analysis Defined

WORLD CLASS MAINTENANCE MANAGEMENT

Proper Root Cause Analysis identifies the basic source or the origin of the problem . . . .
Every system, spares or components failure happens for a reason. There are specific succession of events that lead to a failure. RCFA follows the cause and effect path from the final failure back to its origin The root cause analysis methodology provides specific & solid foundation for preventing the recurrence of the problem or failure

RSA Maintenance Excellence


2006

Root cause analysis is a tool to better explain what happened, to determine how it happened and to better understand why it happen . . . . .
Rolly Angeles

Root Cause Analysis Defined :: Root Cause Analysis Defined

WORLD CLASS MAINTENANCE MANAGEMENT

Failures have a pattern, we must realize that failure is actually being looked back in reverse. The root causes are actually the point at which failure began and the event is merely the result of the root cause or how the failure manifest itself. And there is a cause and effect relationship associated with the pattern of failure Example

Does misalignment cause high vibration ?


CAUSE

OR

EFFECT

Does high vibration cause misalignment ?


Is it possible both ways that the equipment was misalign which cause the high vibration to occur or due to high vibration it then cause the equipment to be misalign
RSA Maintenance Excellence
2006
Rolly Angeles

ROOTCAUSE IS LIKE A ROADMAP

WORLD CLASS MAINTENANCE MANAGEMENT

PROBLEM

Root Cause

In performing Root Cause Failure Analysis, we are interested to know the real cause of a particular failure by verifying each hypothesis until we reach the final cause of the failure . . . . .
RSA Maintenance Excellence
2006
Rolly Angeles

Understanding Why-Why Analysis :


Level 1

WORLD CLASS MAINTENANCE MANAGEMENT

Kingdom Kingdom is Lost is Lost King is King is Killed Killed King fell of King fell of the horse the horse Horseshoe Horseshoe comes off comes off 1 nail short 1 nail short on shoe on shoe Shortage Shortage of nails of nails

If the king is not killed then If the king is not killed then the kingdom had not been Why is the kingdom lost ? the kingdom had not been captured ? captured ?

Level 2

Why is the king killed ? Why is the king killed ? Why did the king fell of Why did the king fell of the horse ? Why did the horseshoe Why did the horseshoe come off ? come off ? Why is it that one nail is Why is it that one nail is short on the horseshoe ? short Why is there shortage of Why is there shortage of nails ? nails Why prepare horses for Why prepare horses for battle ? battle ?

Level 3

If the horseshoe did not If the horseshoe did not come off the king might come off the king might not fell on the ground and not fell on the ground and might not have been killed might not have been killed The groomsman might The groomsman might have prevented the king have prevented the king from riding the horse due from riding the horse due to a missing nail and its to a missing nail and its implications implications If the kings horse shoe nail If the kings horse shoe nail was complete then it might was complete then it might not have come of at all not have come of at all If the city have been defenIf the city have been defended even if the king was ded even if the king was dead then it might not have dead then it might not have been captured ? been captured ?
Rolly Angeles

Level 4

Level 5

Level 6

Prepare horses Level Prepare horses 7 for battle for battle


2006

RSA Maintenance Excellence

Understanding Why-Why Analysis :

WORLD CLASS MAINTENANCE MANAGEMENT

The story is told that before an important battle a king sent his horse with a groomsman to the blacksmith for shoeing. But the blacksmith had used all the nails shoeing the knight's horses for battle and was one short. The groomsman tells the blacksmith to do as good a job as he can. But the blacksmith warns him that the missing nail may allow the shoe to come off. The king rides into battle not knowing of the missing horseshoe nail. In the midst of the battle he rides toward the enemy. As he approaches them the horseshoe comes off the horse's hoof causing it to stumble and the king falls to the ground. The enemy is quickly onto him and kills him. The king's troops see the death, give up the fight and retreat. The enemy surges onto the city and captures the kingdom. The kingdom is lost because of a missing horseshoe nail.

(1)
2006

(2)

(3)

(4)

(5)

(6)

(7)
Rolly Angeles

RSA Maintenance Excellence

EXERCISES : Lets Determine The Sequence Of Events Excessive Moisture Lack Lubricant Bearing Failure Leak in the seal High Acidity Level Corrosion Present Seal was damage

WORLD CLASS MAINTENANCE MANAGEMENT

Bearing Failure Lack Lubricant Corrosion Present Excessive Moisture Leak in the seal Seal was damage High Acidity Level

RSA Maintenance Excellence


2006

Determine the problem and ask why to determine the sequence of events in these sample
Rolly Angeles

Physical, Human and Latent Causes :: Physical, Human and Latent Causes Physical Cause, this is the physical the physical
reason why the parts failed. This is the reason why the parts failed. This is the technical explanation on why things technical broke or failed broke or failed

WORLD CLASS MAINTENANCE MANAGEMENT

omission or commission that resulted in the physical roots. Someone did something wrong or did the wrong did the wrong thing thing Latent Cause, the deficiencies in the the deficiencies the management systems or the management approaches that allows the approaches that allows the human errors to continue unchecked. errors to continue unchecked. Flaws in the systems & procedures in

Human Cause, the human errors of the human errors of

RSA Maintenance Excellence


2006

All physical failures are triggered by humans. But humans are negatively influenced by latent forces. The goal is to identify and improve these latent forces
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RCFA LOGIC TREE DIAGRAM

In RCFA Analysis a Logic Tree is In RCFA Analysis a Logic Tree is used to work through a failure used to work through a failure The failure event is placed on top followed by all failure modes or possible causes of breakdowns

DESCRIBE THE FAILURE EVENT DESCRIBE THE FAILURE MODE

Each of the causes are hypothesis that needs to be verified so that HYPOTHESIS VERIFY HYPOTHESIS we have an understanding on w/c of the causes actually led to the problem DETERMINE PHYSICAL ROOTS & VERIFY

DETERMINE HUMAN ROOTS & DETERMINE LATENT ROOTS &

The next step consists of determiVERIFY and verifying the physical ning roots, human roots and latent roots behind the failure. The final VERIFY will always have to do with cause the latent cause of failures

RSA Maintenance Excellence


2006

Rolly Angeles

Physical, Human and Latent Cause :

WORLD CLASS MAINTENANCE MANAGEMENT

Problem : Cylinder does not operate smoothly WHY 1 : Why is it that the cylinder dont not operate smoothly ? Strainer was clogged WHY 2 : Why is the strainer clogged ? Oil was dirty WHY 3 : Why is the oil dirty ? Dirt enter the tank WHY 4 : Why did the dirt enter the tank ? Upper plate in the tank had a hole and gap - Physical Cause WHY 5 : Why was there hole and gap in Evidence of dirt from Oil Analysis the tank ? Repair error during maintenance work - Human Cause WHY 6: Why was there repair error ? No procedure to follow - Latent Cause
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHEN DO WE USE ROOT CAUSE FAILURE ANALYSIS ? WHEN DO WE USE ROOT CAUSE FAILURE ANALYSIS ?
1) On recurring or failures that frequently fails recurring or failures that When the part or component frequently fails. component frequently fails. Or parts we replace frequently in our PM 2) When failures have environmental or nonconformance to regulatory provisions regulatory provisions 3) When the cost of failure is high, such as failure is high, such as complete shutdown of operations complete shutdown of operations 4) To improve design flaws and weaknesses in our equipment in order to further lengthen equipment in order to further lengthen the life of the component or spare parts the component or spare parts 5) When the impact of the failure is definitely When the impact of the not acceptable to the user and might cause acceptable to and might cause harm and death and death 6) When the problem definitely cannot seem problem definitely cannot seem to go away and Reactive, Preventive and go away and Reactive, Preventive and Predictive Maintenance is ineffective
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

RCFA WORKSHOP 1 :: RCFA WORKSHOP 1


CAUSE STUDY : A pump was declared failed since it was not discharging fluid at all. The pump failed due to a failure of the bearing. The maintenance decided to perform a Root Cause Analysis on the failed bearing to determine the real cause of the problem and have the failed bearing analyzed on a metallurgical laboratory. Arrange the causes in sequence to determine the real root cause of the problem INSTRUCTION : Brainstorm and analyze the case study and rearrange the set of cards and prepare a RCFA Logic Tree Diagram

Clues :
There are 6 or 7 levels in the logic tree the logic tree Metallurgical lab report indicates Metallurgical lab report indicates that the bearing failed due to fatigue w/c is a a type of wear failed due to fatigue w/c is a a type of wear The last level (Bottom part) will be the real root cause of the problem level (Bottom part) will be real root
Rolly Angeles

RSA Maintenance Excellence


2006

CASE STUDY ::BEARING FAILURE CASE STUDY BEARING FAILURE

WORLD CLASS MAINTENANCE MANAGEMENT

Pump Failure

REARRANGE THE CARDS TO FIND OUT THE ROOT CAUSE OF THE PROBLEM
Overloading Erosive Abrasive Wear Corrosive No Procedure Adhesive Fatigue

(No discharge at all)

Functional Failure

Dirt / Debris No Training

Lack of Lubrication Motor Burned Out Imbalance

Valve Is Shut Bearing Failure High Vibration Resonance

No Alignment Tools

Misalignment Clues :

a) Ask the team how can a bearing failed ? b) These typical RCFA logic tree have 3 roots, the physical, human & latent roots c) In this logic tree excessive or high vibration can be is caused by 3 things d) Also determine what will be the ultimate solution to this problem RSA Maintenance Excellence
2006
Rolly Angeles

ANALYZING THE BEARING FAILURE LOGIC TREE ANALYZING THE BEARING FAILURE LOGIC TREE
LEVEL 1

WORLD CLASS MAINTENANCE MANAGEMENT

The pump may fail for a variety of reasons, in this case it is evident to the mtce that the cause of the pump to fulfill its function of discharge fluid is bearing failure.

What the maintenance will do ?


A typical job of the maintenance is to replace the bearing with a new one

since the part had evidently failed and production is up and running again but the question is asked, Did the problem go away ? No, it will recur again on a given time

What the engineers will do ?


When we have our engineers take a look

at the failed bearing, he then takes a look on failure history and data of the pump, and conclude that a different type of bearing more heavy duty be installed. We would then get a heavy duty bearing and install it with the new design and again the question is asked, Did the problem go away ?
RSA Maintenance Excellence
2006
Rolly Angeles

ANALYZING THE BEARING FAILURE LOGIC TREE ANALYZING THE BEARING FAILURE LOGIC TREE Logic Tree Diagram
LEVEL 1

WORLD CLASS MAINTENANCE MANAGEMENT

Pump Failure
(No discharge at all)

Functional Failure

Motor Burned Out


Failure Mode

Bearing Failure
Failure Mode

Valve Is Shut
Failure Mode

Lets analyzed the failure of a pump


The pump failed since it is not discharging fluid at all All causes are hypothesis and must be proven if they exists The motor was checked and it was working, therefore, motor burned out had been disregarded The valve was open therefore, valve shut had been disregarded The bearing had been analyzed and it was evident that there was bearing failure, we now asked why the bearing had failed
RSA Maintenance Excellence
2006

Rolly Angeles

ANALYZING THE BEARING FAILURE LOGIC TREE ANALYZING THE BEARING FAILURE LOGIC TREE
LEVEL 2 : DIRT/DEBRIS and WEAR

WORLD CLASS MAINTENANCE MANAGEMENT

The bearing may fail on a variety of reasons, such as dirt entry or ingression which may have caused the accelerated wear of the bearing. All are probable causes and are still considered as hypothesis. Hence, to distinguished the facts from hearsay the bearing was sent to a metallurgical lab for further analysis to determine how did the bearing failed to fulfill its function.
LEVEL 3 : WEAR DUE TO FATIGUE

The bearing had been analyzed and reviewed by metallurgist and the report concluded that there is strong evidence of FATIGUE, now the other probable causes had been therefore eliminated we ask ourselves how can fatigue occur on the bearing ?

RSA Maintenance Excellence


2006

Rolly Angeles

ANALYZING THE BEARING FAILURE LOGIC TREE ANALYZING THE BEARING FAILURE LOGIC TREE Logic Tree Diagram
LEVEL 1

WORLD CLASS MAINTENANCE MANAGEMENT

Pump Failure
(No discharge at all)

Functional Failure

Motor Burned Out


Failure Mode
LEVEL 2

Bearing Failure
Failure Mode

Valve Is Shut
Failure Mode

Dirt / Debris
LEVEL 3

Lack of Lubrication Erosive

Overloading

Wear

Have the bearing analyze for its metallurgical lab on why it failed

Adhesive

Abrasive

Fatigue

Corrosive

How

Lubrication in the bearing was checked and found out it is sufficient Vibration monitoring shows there is no indication of overloading The only possibility left was Dirt/Debris and Wear and so the team decided to have the bearing test on a metallurgical laboratory
RSA Maintenance Excellence
2006

Rolly Angeles

ANALYZING THE BEARING FAILURE LOGIC TREE ANALYZING THE BEARING FAILURE LOGIC TREE
LEVEL 4 : HIGH VIBRATION

WORLD CLASS MAINTENANCE MANAGEMENT

In Level 4 of our analysis we ask ourselves How can Fatigue occur on the bearing ? We hypothesize that it can come from high vibration. We check our vibration monitoring records and we are certain that there is evidence of excessive vibration. Excessive amplitude from our vibration data supports our hypothesis that fatigue occur on the bearing due to high or excessive vibration
LEVEL 5 : MISALIGNMENT

As we dig deeper into the root cause, again we hypothesize, How can we have excessive vibration? Possibilities is that it can come from imbalance, resonance and misalignment Again the vibration analyst verifies his vibration records and find out the resonance and imbalance is not a major cause for the excessive vibration. We called the maintenance who aligned the pump to align it again and we observe his practices. From our observation we are certain that he does not know how to align the pump properly RSA Maintenance Excellence
2006

Rolly Angeles

ANALYZING THE BEARING FAILURE LOGIC TREE ANALYZING THE BEARING FAILURE LOGIC TREE
LEVEL 6 : NO PROCEDURE / NO TRAINING / IMPROPER TOOLS

WORLD CLASS MAINTENANCE MANAGEMENT

We asked the mechanic if he had been trained in the proper alignment and he said that he was never trained in how to align, there was no procedure for the alignment and how frequent it should be performed People often misalign because they were never trained in proper alignment practices, no procedure exists outlining alignment as a required practice with specification or the current alignment equipment we are using is worn our or inadequate for the application

THIS IS THE LATENT CAUSE

RSA Maintenance Excellence


2006

Rolly Angeles

ANALYZING THE BEARING FAILURE LOGIC TREE ANALYZING THE BEARING FAILURE LOGIC TREE Logic Tree Diagram
LEVEL 1

WORLD CLASS MAINTENANCE MANAGEMENT

Pump Failure
(No discharge at all)

Functional Failure

Motor Burned Out


Failure Mode
LEVEL 2

Bearing Failure
Failure Mode

Valve Is Shut
Failure Mode

Dirt / Debris
LEVEL 3

Lack of Lubrication Erosive

Overloading

Wear

Have the bearing analyze for its metallurgical lab on why it failed Physical Cause

Adhesive
LEVEL 4

Abrasive

Fatigue High Vibration


Human Cause

Corrosive How

How

LEVEL 5 LEVEL 6

Imbalance No Procedure

Misalignment No Training

Resonance

How

Real Root Cause of the Problem Real Root Cause of the Problem Latent Cause

No Alignment Tools
Rolly Angeles

RSA Maintenance Excellence


2006

WITHOUT RCFA WHAT DO THEY DO TO SOLVE THE PROBLEM WITHOUT RCFA WHAT DO THEY DO TO SOLVE THE PROBLEM
FROM A PREVENTIVE MAINTENANCE VIEWPOINT

WORLD CLASS MAINTENANCE MANAGEMENT

The maintenance will merely change or replace the bearing. When BOSS says Make sure that this does not happen again, maintenance add it up on the PM replacement
FROM A PREDICTIVE MAINTENANCE VIEWPOINT

Our CBM group can warn the operation of an impending failure to occur bought about by excessive vibration in the pump. Although the failure is predicted, the life of the bearing had not been reached
FROM AN ENGINEERING VIEWPOINT

Modify or change the bearing with a more heavy duty and put it in service. In short we conclude at once to change out the bearings with a New Design
FROM A CONTINUOUS IMPROVEMENT VIEWPOINT

Brainstorming teams gather together with past history and data performance of the pump and sees a variety of causes, however they are not certain which is the real cause so they all agreed that it was due to the change in the lubricant
FROM AN OPERATIONS VIEWPOINT

Hold countless hours of meeting blaming the maintenance for not doing their job
FROM TOP MANAGEMENT VIEWPOINT

We penalize the culprits and even threathen to cut off their bonus pay if the same problem arises in the future, or tell them Ill get another guy that can do the job better. RSA Maintenance Excellence Rolly Angeles
2006

WORLD CLASS MAINTENANCE MANAGEMENT

LESSONS FROM THE 9th DISCIPLINE LESSONS FROM THE 9th DISCIPLINE

Never ever accept failures in your plant. Trouble shooting is no longer an effective strategy. In todays competitive world, the analysts finds real solutions to the problems
Failures have a lesson to teach us and have a lesson to teach us and unless we learn from the failure and apply unless the lesson then only can we realize that the lesson then only can we realize failure wont repeat itself again failure wont repeat itself again The new paradigm is that FAILURES MUST The new paradigm is that FAILURES MUST NOT BE ACCEPTED it can be eliminated if ACCEPTED can be eliminated if we know the right tools to address them. The true job of maintenance is to eliminate failures & not fixing them all the time .. .. .. .. .. the time When we get really good at fixing failures When really it seems that the problem keeps on reapiting itself
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

10th Discipline of Maintenance Management

RELIABILITY IMPROVEMENT
(RCM, PM4P, OER)

(INTERMEDIATE DISCIPLINE)
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT 5 % and more WORLD CLASS MAINTENANCE EXCELLENCE :: WORLD CLASS MAINTENANCE EXCELLENCE 10 - 20 % Proactive Proactive Maintenance Maintenance Maintenance Maintenance Prevention Prevention Level 5 Level 5
Maintenance Free Plug and Play Longer Lifespan

40 - 50 %

can have is knowing when to use these strategies ? can have is knowing when to use these strategies ? RSA Maintenance Excellence
2006

Root Cause Failure Analysis Failure Mode & Effect Analysis Level 3 Failure Analysis Preventive Level 3 Preventive 10 - 15 % Maintenance Condition-Based Maintenance Maintenance Use of Diagnostic Tools Specialized Equipment Reactive Reactive Level 2 Predict Eminent Failure Level 2 Maintenance Maintenance Scheduled Overhauls Early Alert / Detection Schedule Discards Level 1 Outage Schedules Level 1 Time-Based Maintenance Band-Aid Maintenance Stroke-Based/Running Hrs Breakdown Maintenance Scheduled and Fix Intervals Run to Fail / Destruction The best maintenance structure a plant No Scheduled Maintenance The best maintenance structure a plant
Rolly Angeles

20 - 30 %

Level 4 Level 4 Predictive Predictive Maintenance P-M Analysis Maintenance

WORLD CLASS MAINTENANCE MANAGEMENT

RELIABILITY-CENTRED MAINTENANCE DEFINED RELIABILITY-CENTRED MAINTENANCE DEFINED


Reliability -Centred Maintenance : is a process used to determine the maintenance requirements of any physical asset in its operating context.

LIGHTER DEFENITION :
Reliability -Centred Maintenance : is a process used to determine what must be done to ensure that any physical asset continues to do whatever its users want it to do in its present operating context.

7 BASIC RCM QUESTIONS :


1. What are the functions associated performance standards of the asset in its present operating context ? 2. In what ways does it fail to fulfil its functions ? 3. What causes each functional failures ? 4. What happens when each functional failure occurs ? 5. In what ways does each failure matter ? 6. What can be done to predict or prevent each failure ? 7. What should be done if a suitable proactive task cannot be found ? RSA Maintenance Excellence
2006

Rolly Angeles

HOW IS RCM IMPLEMENTED ?


E quipment No. E quipment Type : Component / Sub Assembly : Date Start :

WORLD CLASS MAINTENANCE MANAGEMENT


PH SE : R A 0CM IN FOR TION W KSHEET MA OR
Teamname : Leader : R eviewed by : PM Committee Approved by : Rev. No. D ate Sheet of

Determine the Assets Operating Context

SaPlandM ineac ne a t nne Is n M yn Is n D kyn ag is o, ag ires o FU C N TION

Date Complete

FU C N TION L FA R A ILU E

FA R MO (C e of Failure) ILU E DE aus

FA R EFFEC (What happens when it fails ILU E T )

Determine the RCM Information Worksheet


- Functions - Functional Failure - Failure Modes - Failure Effect

PHASE 0 RCM DECISION WORKSHEET :


Equipment No. :
Equipment Type :

Date Started :

Date End :

Teamname : Leader :

Reviewed by : Approved by :

Rev. No. Date :

Sheet of Initial Interval QUALITY Can be done by

I s n Mis o , a g yn I s n Dire s o p rin. . . a g kyn a


Information Reference

Team Objective :

Consequence Evaluation

H0 H0 H0 Default Tasks S0 S0 S0 O0 O0 O0

Proposed Tasks

Maintenance Classification (Check Classification)


PM Pd M NSM FFT RED

FF FM

N0 N0 N0 H0 H0 S0

Use the RCM Decision Diagram to determine the required Maintenance tasks and include on the RCM Decision Worksheet
RSA Maintenance Excellence
2006
Ph00 LEG END : PM - Preventive Maintenance PdM - On-Condition Tasks NSM - No Scheduled Maintenance FFT - Failure Finding Tasks RED - Redesign

Rolly Angeles

RCM FMEA INFORMATION WORKSHEET


Equipment No. Equipment Type : Date Start :

Gearing Towards A Pro-Active Mtce System

Component / Sub Assembly :

Benzene Storage System

Reviewed by : PM Committee WORLD Teamname : MAINTENANCE CLASS Date Complete Leader : Approved by : MANAGEMENT

Rev. No. Sheet Date of

FUNCTION
0 To supply benzene to the process at a minimum rate of 0 0ltrs per minute 0

FUNCTIONAL FAILURE
A Fails to supply benzene at all

FAILURE MODE (Rootcause)


0 Impeller jammed by foreign object

FAILURE EFFECT (What happens when it fails)


- The pump motor trips on overload and the motor overload indicator lights up in the control room. The presence of upstream filter means that this failure mode is only likely occur if something is left in the system after maintenance of if the filter element is holed or missing. It takes 0 hrs to replace the impeller cartridge.

0 Line shaft bearing seizes due to normal wear and tear

- The pump motor trips on overload and the motor overload indicator lights up in the control room. The supply of benzene to the process stops, which sounds additional alarms. It takes 0hrs to replace the pump

0 Pump shuts down due to spurious signal from trip mechanism

- The mechanisms which could shut off the pump in this way are the motor overload circuit breaker, the dry-run mechanism and the high temperature switch. Although these failures are rare, they each take about 0hrs to diagnose and rectify

0 Large particles in benzene cause impeller bearings to sieze 0 Pump impeller wears out

- This failure is considered to be extremetly unlikely if the filter in the supply line is adequately maintained - These bearings are made from silicon carbide, so they are likely to wear very slowly indeed if the benzene is kept reasonably clean. Severe wear would allow the inner magnets to touch the can, possibly damaging it, and the pump trips out on overload. The motor overload indicator lights up in the control room and supply of benzene to the process stops. 00 to diagnose the min problems and open the valve

0 Impeller bearing seizes due to lack - If these bearing seizes, magnetic drag causes motor

RSA Maintenance Excellence


2006

of lubricant (lubricated by benzene)

overload system to shut down the motor. However, if the supply of benzene stops the dryrun unit shouldAngeles Rolly trip the motor before the bearings are damage

HIDDEN FAILURE CONSEQUENCES


H
Will the loss of function caused by this failure mode on its own become evident to the operating crew under normal circumstances ?

SAFETY & ENVIRONMENTAL CONSEQUENCES WORLD


S
Yes

OPERATIONAL NON-OPERATIONAL CONSEQUENCES CONSEQUENCES CLASS MAINTENANCE


operational capability (output, product quality, customer service or operating cost in addition to the direct cost of repair?

E Does this failure Does this failure mode cause a loss of mode cause a loss No function or other damage of function or other which could breach any damage which could known environmental injure or kill someone? standard or regulation?
Yes S0 Is an on-condition tasks technically feasible and worth doing?

O Does this MANAGEMENT failureeffect on have a direct adverse


No

No

No H0
Is an on-condition tasks technically feasible and worth doing?

O0

Is an on-condition tasks technically feasible and worth doing?

N0

Is an on-condition tasks technically feasible and worth doing?

Is there a clear potential failure Does this task secure the availability condition? W hat is it? W hat is the needed to reduce the probability of a P-F interval? Is the P-F interval long multiple failure to a tolerable level? enough to be of any use? Is it consistent? Can the task be done at intervals less than the P-F interval?

Is there a clear potential failure Does this task reduce the risks of condition? W hat is it? W hat is the Pfailure to a tolerable level? F interval? Is the P-F interval long enough to be of any use? Is it consistent? Can the task be done at intervals less than the P-F interval?

Is there a clear potential failure Over a period of time, will the tasks condition? W hat is it? W hat is the Pcost less than the costs of operational F interval? Is the P-F interval long consequences plus the repair of the enough to be of any use? Is it failure which it is meant to prevent? consistent? Can the task be done at intervals less than the P-F interval?

Is there a clear potential failure Over a period of time, will the tasks condition? W hat is it? W hat is the P- less than the costs of operational cost F interval? Is the P-F interval long consequences plus the repair of the enough to be of any use? Is it failure which it is meant to prevent? consistent? Can the task be done at intervals less than the P-F interval?

Yes

No

Yes

No

Yes

No

Yes
Do the on-condition tasks

No

Do the on-condition tasks

Do the on-condition tasks

Do the on-condition tasks

H0 Is an scheduled restoration tasks


technically feasible and worth doing ?
Is there an age at which there is a Does this task secure the availability rapid increase in the conditional needed to reduce the probability of a probability of failure? W hat is it? Domultiple failure to a tolerable level? most failures occur after this age? W ill the restoration task restore the original resistance to failure?

S0 Is an scheduled restoration tasks


technically feasible and worth doing ?
Is there an age at which there is a Does this task reduce the risks of rapid increase in the conditional failure to a tolerable level? probability of failure? W hat is it? Do most failures occur after this age? W ill the restoration task restore the original resistance to failure?

O0 Is an scheduled restoration tasks


technically feasible and worth doing ?
Is there an age at which there is a Over a period of time, will the tasks rapid increase in the conditional cost less than the costs of operational probability of failure? W hat is it? Do consequences plus the repair of the most failures occur after this age? failure which it is meant to prevent? W ill the restoration task restore the original resistance to failure?

N0 Is an scheduled restoration tasks


technically feasible and worth doing ?
Is there an age at which there is a Over a period of time, will the tasks rapid increase in the conditional cost less than the costs of operational probability of failure? W hat is it? Do consequences plus the repair of the most failures occur after this age? failure which it is meant to prevent? W ill the restoration task restore the original resistance to failure?

Yes

No

Yes

No

Yes

No

Yes

No

Do the scheduled restoration tasks

Do the scheduled restoration tasks

Do the scheduled restoration tasks

Do the scheduled restoration tasks

H0

Is a scheduled discard tasks technically feasible and worth doing ?

S0

Is a scheduled discard tasks technically feasible and worth doing ?

O0

Is a scheduled discard tasks technically feasible and worth doing ?

N0

Is a scheduled discard tasks technically feasible and worth doing ?

Is there an age at which there is a Does this task secure the availability rapid increase in the conditional needed to reduce the probability of a probability of failure? What is it? Domultiple failure to a tolerable level? most failures occur after this age?

Is there an age at which there is a Does this task reduce the risks of failure rapid increase in the conditional to a tolerable level ? probability of failure? W hat is it? Do most failures occur after this age?

Is there an age at which there is a Over a period of time, will the tasks rapid increase in the conditional cost less than the costs of operational probability of failure? W hat is it? Doconsequences plus the repair of the most failures occur after this age? failure which it is meant to prevent?

Is there an age at which there is a Over a period of time, will the tasks rapid increase in the conditional cost less than the costs of operational consequences plus the repair of the probability of failure? W hat is it? Do most failures occur after this age? failure which it is meant to prevent?

Yes

No

Yes

No

Yes

No

Yes

No

Do the scheduled discard tasks

Do the scheduled discard tasks

Do the scheduled discard tasks

Do the scheduled discard tasks

H0 Is a scheduled failure-finding tasks


technically feasible and worth doing ?
Is it possible to check if the item hasDoes this task secure the availability fail? Is it practical to do the task at needed to reduce the probability of a the required interval? multiple failure to a tolerable level?

S0 Is a combination of the above tasks


technically feasible and worth doing ?

No scheduled maintenance

No scheduled maintenance

Yes
Combination of Yes tasks

No
Redesign may be desirable

Redesign may be desirable

Yes

No H0 Could the

Redesign is compulsory

Do the scheduled multiple failure RSA tasks failure-finding affect safety Maintenance No Excellence or the Yes

Redesign is Compulsory

RCM0 DECISION DIAGRAM


(ORIGINAL RCM DIAGRAM FROM JOHN MOUBRAY) 0 Rolly Angeles

2006

environment

No scheduled Maintenance

Redesign may be desirable

RCM TASKS DECISION WORKSHEET


Equipment No. :
Team Objective : Gearing Towards A ProActive Maintenance System Information Failure H0 H0 H0 H0 Reference Consequence S0 S0 S0 S0 O0 O0 O0 O0

Equipment Type :

Date Started :

Dafault Tasks

Reviewed by : Date Teamname : Rev. WORLDEnd : CLASS MAINTENANCENo. Approved by : Leader : Date : MANAGEMENT

Sheet of Initial Interval Responsible

Proposed Tasks

Maintenance Classification

F
0 0 0 0 0 0

FF FM
A A A A A A 0 0 0 0 0 0

H
N N N N N N

S
N N N N N N

E
N N N N N N

O
Y Y Y Y Y Y

N0 N0 N0 N0 H0 H0 S0
N Y N N Y N Y N N Y Y N Y - Redunduncy or Standy unit - Check line shaft bearings for audible noise and vibration - Redunduncy or Standy unit - Redunduncy or Standy unit - Use vibration analysis to monitor condition of impeller bearings - Monitor supply of lubricant to impeller bearings

(Check Classification) PM CBM RTF RED MOD

X X X X X X

n.a. 0mo n.a. n.a. 0mo 0mo

Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance

RSA Maintenance Excellence


2006

Rolly Angeles

TPM and RCM2 Strengths :


Point of Comparison
1. Origin 2. Founder 3. Consultant Firm 4. Measure of Performance 5. Maintenance Goal 6. Approach 7. Initial Approach 8. Concept 9. What it believes 10. Implementation time 11. Can It be combined 12. Maintenance Focus 13. Aim on Maintenance Japan

WORLD CLASS MAINTENANCE MANAGEMENT

TPM
Seiichi Nakajima JIPM OEE Zero BDO Zero Failures Top-Down Approach Establish BEC Continuous Improvement Maintenance educate operators 3 months/Step per machine YES Address 6 Big Losses Maintenance Prevention

RCM2
United Kingdom John Moubray Aladon MTBF by Component Reduce Consequence of failure thats acceptable Down-Up Approach Determine all FM Maintenance first before redesign Operators educate Maintenance 3 months/case/ machine or sub-assy YES Address Primary & Secondary Functions Pro-Active Maintenance
Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

What TPM and RCM believes TPM believes that in order to advance to any other improvement program, Basic Equipment Condition must be carried out first . . . . . While RCM believes that the first step is to change the way people think and then apply this change thought to their asset . . . . .

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 10th DISCIPLINE LEARNINGS FROM THE 10th DISCIPLINE
Every failure has a specific set of consequences associated with it, and Every failure has a specific if it is very serious, efforts should be done to prevent or reduce very serious, efforts should be done prevent reduce consequences of the failure itself consequences of the failure itself RCM, TPM and OER believes that RCM, all failures behave according to the failures behave according to the 6 failure patterns, and the best way failure patterns, and the to address this will be to utilized all address this will be to utilized all the maintenance tasks simultaneously with the aid of the decision diagram & the key in determining the most approthe most appropriate maintenance tasks will depend maintenance tasks upon the consequences of failure the consequences of failure

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 6 MODULE 6

MAINTENANCE MANAGEMENT SPECIALIZED DISCIPLINE

(ADVANCE DISCIPLINE)
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

ADVANCE & SPECIALIZED DISCIPLINE ADVANCE & SPECIALIZED DISCIPLINE One of the requirements in pursuing this discipline will be investment and training. It is very difficult to advance to these discipline if the equipments basic had not been established
Savings generated through the Savings generated through application of Basic & Intermediate application of Basic & Discipline can be well spent on the Discipline can be well spent on acquisition of these technologies acquisition Most industries try to resort to these Most strategies only to be abandoned in strategies only a couple of years. Do not be misled couple of years. Do not by vendors that promises a silver vendors that promises a silver bullet solution to maintenance

RSA Maintenance Excellence


2006

There is no single SILVER BULLET solution to every maintenance challenges. Knowledge of what maintenance management strategy to use and when to use them will be the key to improve reliability
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

11th Discipline of Maintenance Management 11th Discipline of Maintenance

CONDITION-BASED MAINTENANCE

(ADVANCE DISCIPLINE)
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREDICTIVE MAINTENANCE DEFINED PREDICTIVE MAINTENANCE DEFINED

A person is gifted with 5 senses which are sense of smell, touch, taste, hear, sight. He can use these senses to detect problems on the equipment. Condition-Based Monitoring checks the condition of an equipment through the use of sophisticated measuring instruments with precision accuracy. Predictive Maintenance instruments are a higher form of the human senses
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREDICTIVE MAINTENANCE DEFINED PREDICTIVE MAINTENANCE DEFINED

These instruments allow us to see what we cannot see. It allows us to hear what we cannot hear. Simply stated it allows us to communicate better with our equipment's

A visible light picture (left) and an infrared picture (right) of two cups. One cup contains cold water, while the other contains hot water. In the visible light picture we cannot tell, just by looking, which cup is holding cold water and which is holding hot water. In the infrared image, we can clearly "see" the glow from the hot water in the cup to the left and the dark, colder water in the cup to the right. If we had infrared eyes, we could tell if an object was hot or cold without having to touch it.

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PREDICTIVE MAINTENANCE DEFINED PREDICTIVE MAINTENANCE DEFINED These instruments simply allow us to determine the problem much more than our senses can either hear or see them. It allows us to make decisions once a potential failure is visible

While INFRARED THERMOGRAPHY allows us to see the problem, ULTRASONICS allows us to hear the problem with our senses INFRASONICS
RSA Maintenance Excellence
2006

SONICS

ULTRASONICS
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

WHY USE PREDICTIVE MAINTENANCE ? WHY USE PREDICTIVE MAINTENANCE ?


Some failure fail randomly and provides Some failure randomly and provides symptoms that they are on the verge of symptoms that they failing. These failures can be captured failing. through the use of Non-destructive through the use instruments call Predictive Maintenance instruments call Predictive Maintenance

PdM allows maintenance to make PdM allows maintenance make decision by being able to peer inside to peer inside your components and replace them your just before they fail. We are not basing they fail. We are not basing our maintenance decision on the schedule time interval but rather on the actual condition of our components. condition of our components.
RSA Maintenance Excellence
2006
Rolly Angeles

PREDICTIVE MAINTENANCE :: PREDICTIVE MAINTENANCE

WORLD CLASS MAINTENANCE MANAGEMENT

Predictive Maintenance aids in detective potential failures in equipment Predictive Maintenance aids in detective potential failures in equipment with the aid of specialized instruments. Maintenance is based on the with based on the condition of the equipment which differentiate it from Preventive Mtce condition

Condition-Based Maintenance

Equipment Diagnostic Technique

Equipment Monitoring Technique

On-Condition Tasks

Just In Time Maintenance

RSA Maintenance Excellence


2006

On-Line Monitoring Equipment

Reliability-Based Maintenance
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CONDITION-BASED AND PREDICTIVE MAINTENANCE CONDITION-BASED AND PREDICTIVE MAINTENANCE Predictive Maintenance is a maintenance activity geared to indicating where a piece of equipment is on the critical wear curve and predicting its useful life or is in the verge of failing. This is done with the aid of specialized diagnostic instruments Predictive maintenance tends to be equipment oriented while CBM is systems oriented CBM deals with the entire system as an entity

RSA Maintenance Excellence


2006

Rolly Angeles

CONDITION-BASED MAINTENANCE DEFINED CONDITION-BASED MAINTENANCE DEFINED

WORLD CLASS MAINTENANCE MANAGEMENT

CBM tasks entails checking for potential failures, so that action can be taken to prevent the functional failure or to avoid the consequences of a functional failure

RSA Maintenance Excellence


2006

Rolly Angeles

When to used CBM technique ?

P-F INTERVAL
P-F INTERVAL : Is the interval between the emergence of the Potential Failure and its decay into a Functional Failure

WORLD CLASS MAINTENANCE MANAGEMENT

POTENTIAL FAILURE : Is defined as an identifiable physical condition which indicates that a functional failure is either about to occur or is in the process of occurring FUNCTIONAL FAILURE : Is defined as the inability of an item to meet a specific performance standard
Rolly Angeles

RSA Maintenance Excellence


2006

DETERMINING POTENTIAL FAILURES DETERMINING POTENTIAL FAILURES

WORLD CLASS MAINTENANCE MANAGEMENT

Predictive Maintenance aids us in determining the potential failure or symptoms that an equipment is in the process of failing. Changes or failing. Changes or increase in the following can denote a potential failure. Specialized the following can denote a potential failure. Specialized diagnostic instruments can aid in detecting the following : diagnostic instruments can aid in detecting the following Heat or temperature Vibration For Electrical we have

Increase in Noise Pressure change Flow rate change Lubricant contamination Wall thickness decrement Rate of corrosion Leak detection Crack detection
RSA Maintenance Excellence
2006

changes in resistance changes in conductivity changes in dielectric strength

Rolly Angeles

PREDICTIVE TASKS :: PREDICTIVE TASKS

WORLD CLASS MAINTENANCE MANAGEMENT On Condition tasks must be carried out at intervals less than the P-F interval

Longer than the P-F Curve - Failure is Missed Shorter than the P-F Curve - Waste of Time

- Warning Period or Lead time to Failure - Failure Development Period - Measured in any units - Running time, units of output, cycles etc - Most commonly measured in elapsed time

P-F INTERVAL
Rolly Angeles

RSA Maintenance Excellence


2006

PREDICTIVE TASKS :: PREDICTIVE TASKS

WORLD CLASS MAINTENANCE MANAGEMENT


Point where we can find out that it is failing (Potential Failure) PRO-ACTIVE Tasks using CBM or Predictive Mtce Technology to predict Failures Point where it has failed (Functional Failure)

Point where failure starts to occur (Not necessarily related to age)

Potential Failures is an identifiable condition which indicates that a functional failure is about to occur or in the process of occurring

Many failure modes give some sort of warning that they are to occur. The P-F curve shows how a failure starts, deteriorates to a point where it can be detected (Point P), and if it is not detected deteriorates at an accelerating rate. The P-F Interval is the interval between the occurrence of a potential failure and its decay into a functional failure. RSA Maintenance Excellence Rolly Angeles
2006

WORLD CLASS MAINTENANCE MANAGEMENT

APPLICATIONS OF CONDITION-BASED MAINTENANCE APPLICATIONS OF CONDITION-BASED MAINTENANCE

Infrared Thermography

Oil Analysis

Vibration Analysis

Noise Monitoring

Wall Thickness Decrement Ultrasonic Monitoring

Corrosion Monitoring

Crack Leak Detection Detection

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 11th DISCIPLINE LEARNINGS FROM THE 11th DISCIPLINE
Predictive Maintenance is never a replacement for Preventive Mtce. PM will always have its place in the overall improvement strategy of Maintenance Management There are instances that checking the condition of the equipment is a much better strategy than overhauling the equipment itself. And there will be times that overhauling the equipment will induce infant mortality or start-up failures A good CBM strategy is not about monitoring failures through the use of PdM instruments but rather information from Predictive Mtce can aid in determining the real cause of the problem
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

12th Discipline of Maintenance Management 12th

ADOPTING A CMMS

(ADVANCE DISCIPLINE)
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PURPOSE OF CMMS PURPOSE OF CMMS


A Computerized Maintenance Management Software(CMMS) is an essential operational and management tool for managing asset preservation, ensuring that production systems operate as required, & minimizing downtime. An effective CMMS should be able to support these functions by automating administrative tasks, as well as gathering relevant information in order to perform this processes. CMMS also needs to be able to develop and manage a strategic plan for proper maintenance, replacement and upgrade of major assets. The primary purpose of a CMMS is to manage, capture & track inspection, maintenance and repair activities of an organization. Most CMMS perform the basic function of providing work orders for repairs of equipment. They provide a scheduling facility for maintenance for planned preventive work on maintainable assets. And also collect costing details for labor and materials related to the work performed.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

PURPOSE OF CMMS PURPOSE OF CMMS


Advanced CMMS solutions can also improve many aspects of your mtce daily activities, as well as provide you with the tools to understand and analyze your maintenance and repair processes and trends. They can eliminate your manual data entry, incorporate alerts, triggers, and escalation procedures, and shift your focus from unnecessary administrative tasks to performing maintenance activities.

They can also assist you in planning and predicting future needs, prolonging the life expectancy of your assets, and managing your processes.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

APPLICATION OF CMMS APPLICATION OF CMMS Reliability Reports Calibration Schedules Training & Skills Predictive Maintenance Spareparts

PM Schedule

CMMS

Equipment 201 History Expert & Repair Procedures Repair & Mtce Cost (RNM)
Rolly Angeles

Purchase Requisition Maintenance Indices / KPI


RSA Maintenance Excellence
2006

Parts Lifespan Monitoring

ROLE OF CMMS IN MAINTENANCE MANAGEMENT ROLE OF CMMS IN MAINTENANCE MANAGEMENT


Instrumentation Instrumentation & Calibration & Calibration
Precision of Gauges

WORLD CLASS MAINTENANCE MANAGEMENT

Condition-Based Condition-Based Maintenance Maintenance


Oil Analysis Program Infra-Red Thermography Vibration Analysis Leak Detection

Maintenance Maintenance Skills Enhancement Skills Enhancement


Specialization Training Multi-skills programs Guidance to Jishu-Hozen Expert System

Spare Parts Spare Parts Management Management


Just In Time (JIT) Inventory Control

Computerized Maintenance Management Software

CMMS

Maintenance Maintenance Cost Control Cost Control


RNM Cost Reduction Spare Parts Reduction

Lubrication Lubrication Management Management


Contamination Control Oil Recycling and Filtration Wear Debris Analysis

Zero Breakdown Zero Breakdown Strategies Strategies Reliability & Continuous Reliability & Continuous Improvement Activities Improvement Activities
Reliability-Centred Maintenance Addressing Design Weaknesses Root Cause and Failure Analysis 4 Phases of Planned Maintenance Address Basic Equipment Condition Restoration Activities Activities to reduce MTBF Activities to improve MTTR Preventive and Periodic Maintenance

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CONSIDERATIONS IN SELECTING THE RIGHT CMMS CONSIDERATIONS IN SELECTING THE RIGHT CMMS

STABILITY OF THE VENDOR : It is vital to ask the vendor how long he STABILITY OF THE VENDOR : It is vital to the vendor how long had been in business. Choose a vendor that had been in business for a been in business. Choose a vendor that had been in business for a number of years. COMPONENT FEATURES : Before purchasing a CMMS, it is important COMPONENT FEATURES : Before purchasing a CMMS, for the organization to determine what are your maintenance requirewhat are your maintenance ments and how will the CMMS serve your function. Each company have a unique set of requirements and that the vendor should be the one to requirements and that the vendor should be the one to adjust to your requirements and not you adjusting to the CMMS to your requirements and not you adjusting to the CMMS
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

CONSIDERATIONS IN SELECTING THE RIGHT CMMS CONSIDERATIONS IN SELECTING THE RIGHT CMMS USER FRIENDLY: CMMS software FRIENDLY: software must be easy to use & learn. Once must be easy to use learn. Once the CMMS is installed, implementathe CMMS is installed, implementation must be quick & efficient tion must be quick & efficient TECHNICAL SUPPORT: This must TECHNICAL SUPPORT: be available specially for periodic updates to keep technology current updates to keep technology current in this fast paced digital age. Deterfast paced digital age. Determine the support is available and if available and if it satisfy your requirements COST OF CMMS : Cost will be one of the most important consideration Cost will be in the hunt for CMMS software. Even if all the features of a CMMS is in the hunt for CMMS software. Even if all the features of a CMMS is available at hand if the companys budget is way below the cost then available companys budget is way below the cost then it will be useless. Compare at least 3 vendors and evaluate which of it will be useless. Compare at least 3 vendors and evaluate which of them best fits your requirements in terms of cost, service, features them best terms
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THE 12th DISCIPLINE LEARNINGS FROM THE 12th DISCIPLINE
Savings generated from establishing the Savings generated establishing the Basics and from these reliability strategies reliability strategies being initiated can be used as an investment in acquiring Predictive and CMMS software acquiring Predictive and CMMS software What is important before acquiring these What is important before acquiring these instruments and software is to define the instruments and software is requirements needed so that maintenance can generate the greatest benefit from it These disciplines will require the heaviest investment of all & acquiring These disciplines will require the heaviest investment of all & acquiring these specialized disciplines requires investment not only in instruments specialized disciplines requires investment not only in instruments but in training and education. These disciplines require changes in the but in training and education. These disciplines require changes in the maintenance organization and Maintenance Managers must be committed maintenance organization and Maintenance to these changes. Once these factors are considered then only can we changes. Once these factors are considered then only can we derive the most benefit from its implementation derive the most benefit
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 7 MODULE 7

APPLYING THE 12 DISCIPLINES

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

APPLYING THE 12 DISCIPLINES


From the book of Stephen Covey, Principle Centered Leadership, a 4 Step approach can be applied for these disciplines
1) Where we are ? 2) Where do we want to go ? 3) How will we get there ? 4) How will we know we have arrived ? 1st : Determine where we are ? Defines our current situation and baseline on where the organization maintenance structure currently is. Make a selection of people and start with a survey or you can select a cross selection of members & have them conduct an internal audit based on these disciplines discussed
RSA Maintenance Excellence
2006

Stephen Covey is perhaps best known as the author of The 7 Habits of Highly Effective People, which is ranked as a No. 1 bestseller by the New York Times, having sold more than 13 million copies in 36 languages throughout the world.
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

APPLYING THE 12 DISCIPLINES


1st : Determine where we are ? Knowing where we are is the starting point on any continuous improvement initiative and effort Start with the basic discipline first and make an assessment on how are we doing based on the learnings provided. What is important is for us to know where we are right now and where do we plan to go. Being World Class is not about benchmarking other industries but having a thorough understanding about our own failures and how we were able to learn from it. Remember, failure are good if we can learn from it.
RSA Maintenance Excellence
2006
Rolly Angeles

HOW DO YOU RATE THESE DISCIPLINES IN YOUR INDUSTRY THE 12 DISCIPLINES


1. Training & Skills 2. Measure Performance 3. Autonomous Maintenance 4. Basic Equipment Condition 5. Preventive Maintenance 6. Lubrication Management 7. Life Cycle Management 8. Spare Parts Management 9. Root Cause Failure Anal. 10. Reliability Improvements 11. Condition-Based Mtce 12. CMMS
Rate your current industry with 1 being the lowest and 10 the highest RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT 3 4 5 6 7 8

10

WORLD CLASS MAINTENANCE MANAGEMENT 4 2 5 REMARKS 1 AUTONOMOUS MAINTENANCE 3


1) Is there a program for Autonomous Maintenance in your industry ? 2) Does maintenance teach operators about their equipment functions & can your operators perform minor repairs and adjustments ? 3) Can operators communicate effectively with the maintenance regarding what parts failed ? 4) Does operators understand their role in establishing basic equipment condition on their equipments ? 5) Does your operator knows how to detect and pinpoint abnormalities and irregularities on your equipment ? 6) Does operators perform regular checking on cleaning and lubrication on their equipment ? 7) Does operators perform visual control on their equipment to detect problems easily ? 8) Is their a program or training to improve the skills of your operator ? 9) Can operators perform basic lubrication on their equipment ?

NO ACTIVITY NO ACTIVITY NO ACTIVITY NO ACTIVITY NO ACTIVITY NO ACTIVITY NO ACTIVITY NO ACTIVITY NO ACTIVITY


Rolly Angeles

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

APPLYING THE 12 DISCIPLINES


2nd : Where do we want to go ? This will be the direction on which we are going. Its important to know our destination and letting our people know that this is where our maintenance is headed forth in the near future. Its important to know our destination and letting our people know that this is where our maintenance is headed forth. (Similar to Vision) Aim for a high or ideal vision so that people will continuously improve and set a timeframe for achieving it. It is rewarding to see what can truly happen when the talents of the entire organization are tapped in the breakthrough strategy
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

APPLYING THE 12 DISCIPLINES


3rd : How are we going to get there ? This will be the path or map and the things to be done in order to implement the disciplines. These are the activities and steps to be done in order to implement each of the 12 Disciplines Maintenance must understand that these Disciplines are long term and not short term initiatives. Generate a Master Plan for each of these Disciplines and have them review regularly This step determines how to bridge the gap between the current status and what we want to achieve on each of the 12 Disciplines
RSA Maintenance Excellence
2006
Rolly Angeles

GENERATE A MASTER PLAN OF COMPLETION


THE 12 DISCIPLINES
1. Training & Skills 2. Measure Performance 3. Autonomous Mtce 4. Basic Equipment Cond 5. Preventive Maintenance 6. Lubrication Management 7. Life Cycle Management 8. Spare Parts Management 9. Root Cause Failure Anal. 10. Reliability Improvements 11. Condition-Based Mtce 12. CMMS
RSA Maintenance Excellence
2006

WORLD CLASS MAINTENANCE MANAGEMENT

PREPARATORY IMPLEMENTATION STABILIZATION 2008 2009 2010 2011 2012 2013

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

APPLYING THE 12 DISCIPLINES


4th : How will we know we have arrived ? The first & last Step is to define & measure metrics & indices that not only tell us that we have arrived but whether or not we are headed in the right direction It is important to measure our performance on these disciplines in order to determine if we have realized our goals

Measurements should be define at the beginning of implementation and must be reviewed regularly. Success or failure of all our efforts depend entirely on these measurements
RSA Maintenance Excellence
2006
Rolly Angeles

RECOMMENDED MEASUREMENT FOR THESE DISCIPLINES THE 12 DISCIPLINES RECOMMENDED MEASUREMENTS


1. Training & Skills MTTR, NUMBER OF LEVEL 4 MAINTENANCE OEE, MTBF, MTTR, BDO, MTBA, ETC., 2. Measure Performance NUMBER OF CERTIFIED OPERATORS PER STEP 3. Autonomous Maintenance ABNORMALITIES CORRECTED 4. Basic Equipment Condition REDUCTION IN BREAKDOWN 5. Preventive Maintenance 6. Lubrication Management REDUCTION IN LUBRICATION COST & FAILURES 7. Life Cycle ManagementSAVINGS GENERATED

WORLD CLASS MAINTENANCE MANAGEMENT

REDUCTION IN SPARE PART COST & MTTR 8. Spare Parts Management 9. Root Cause Failure Anal. INCREASE IN MTBF, ELIMINATION OF RECURRENC

10. Reliability Improvements REDUCTION IN UNPLANNED BREAKDOWN & COST 12. CMMS ROI & SAVINGS GENERATED
Rolly Angeles

11. Condition-Based REDUCTION IN UNPLANNED BREAKDOWN & COST Mtce

RSA Maintenance Excellence


2006

WORLD CLASS MAINTENANCE MANAGEMENT

WORKSHOP : List down at least 5 most important learnings from this seminar that you find very relevant to your work Which of the 12 Management Disciplines will you prioritize and state the reasons why. State your plans on how to execute the disciplines you prioritize.

RSA Maintenance Excellence


2006

Rolly Angeles

COMING SOON !

WORLD CLASS MAINTENANCE MANAGEMENT

World Class Maintenance Management The 12 Disciplines, Author: Rolly Angeles Book Specs: Total Pages: 314 Total Chapters: 15 Cover: Glossy Hardbound Book Size: 8 x 11.5 inches Total Figures: 133 Foreword Messages by C.Robert Nelms and Vee Narayan Availability: Mid August 2009

RSA Maintenance Excellence


2006

Rolly Angeles

COMING SOON !

WORLD CLASS MAINTENANCE MANAGEMENT Chapter 1: Introduction to WCM Chapter 2: Discipline 1: Training and Education Chapter 3: Discipline 2: Setting-up Maintenance Indices and KPIs Chapter 4: Discipline 3: The Need for Autonomous Maintenance Chapter 5: Discipline 4: Addressing Basic Equipment Condition Chapter 6: Discipline 5: Understanding Preventive Maintenance Chapter 7: Discipline 6: Spare Parts Management Chapter 8: Discipline 7: Life Cycle Management Chapter 9: Discipline 8: Lubrication Strategy Chapter 10: Discipline 9: Reliability and Improvement Strategies Chapter 11: Discipline 10: Root Cause Failure Analysis

RSA Maintenance Excellence


2006

Rolly Angeles

COMING SOON !

WORLD CLASS MAINTENANCE MANAGEMENT Chapter 12: Discipline 11: Predictive Maintenance Chapter 13: Discipline 12: CMMS Chapter 14: Implementing the Twelve Disciplines Chapter 15: The Conclusion

To all maintenance and reliability people, this is not only a technical book about reliability and maintenance, it is a book that makes every single maintenance proud that they belong to the maintenance function, Author, Rolly Angeles

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

MODULE 8 MODULE 8

LEARNINGS FROM THESE 12 DISCIPLINES

RSA Maintenance Excellence


2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THESE 12 DISCIPLINES


1) Every maintenance must understand that focus must be on Reliability and not Cost, because if Reliability starts to improve the Cost will definitely go down & it cannot be the other way around. There will be times that focusing on Cost will hurt reliability, a lesson we all should reflect upon 2) Never accept failures in your plant. Troubleshooting & repair is no longer an effective strategy, In today's competitive world of manufacturing, the analyst find real solutions to our equipment problems. Always remember that when our people become really good at repairing failures then something is wrong, since we are doing it much too often, but when we expect a different result from the same things that we are doing, it just ain't possible, the Chinese called this insanity.
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THESE 12 DISCIPLINES


3) The best time to address a problem is when it is small, it is very hard to advance to any specialized maintenance activities & improvement efforts if equipment's Basic Condition had not been established, we should always remember our equipment is a shared responsibility for both operators and maintenance people a lesson we must all learn from the Japanese, this is the main essence of TPM . . . . . 4) A question on why industry remain reactive may lead to a thousand reasons or more & those who fear that improving reliability may lead to elimination of jobs are right only to the point where they resist change. Increasing reliability is not achieved by cutting manpower nor are they contrasting goals. Increasing reliability means slowly getting out of the repair business and opens new doors to the maintenance function
RSA Maintenance Excellence
2006
Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THESE 12 DISCIPLINES


5) The real mission of the maintenance department is to provide reliable physical assets & excellent support for its customers by reducing unecessary and intrusive maintenance. Do not confuse maintenance as synonymous to repair, these 2 are entirely different.

6) There is no silver bullet program or strategy that can transform a plants reliability overnight all will start with its basic foundation and that is by EDUCATION and this is the most most powerful weapon to change the mindset of our people
RSA Maintenance Excellence
2006

Rolly Angeles

WORLD CLASS MAINTENANCE MANAGEMENT

LEARNINGS FROM THESE 12 DISCIPLINES


7) Applicability of Preventive Maintenance is limited only to failures that will wear out and the maintenance function must accept that infant mortality & random failures exists and that the degree of maintenance requirements should always be based upon the consequences of failure itself

RSA Maintenance Excellence


2006

8) The distinction between a true blooded maintenance and a mechanic is a maintenance uses more of his brain than his hand while a mechanic uses his hand much of the time. Let us treat our people as maintenance and not as mere mechanics. Give them the respect and dignity they deserve . . .
Rolly Angeles

CLOSING :
A son asked his father, 'Dad, will you take part in a marathon with me? The father who, despite having a heart condition, says 'Yes'.

WORLD CLASS MAINTENANCE MANAGEMENT

They went on to complete the marathon together. Father and son went on to join other marathons, the father always saying 'Yes' to his son's request of going through the race together. One day, the son asked his father, 'Dad, let's join the Ironman together.' To which, his father said 'Yes' too.

For those who don't know, Ironman is the toughest triathlon ever. The race encompasses three endurance events of a 2.4 mile (3.86 kilometer) ocean swim, followed by a 112 mile (180.2 kilometer) bike ride, and ending with a 26.2 mile (42.195 kilometer) marathon along the coast of the Big Island. Father and son went on to complete the race together WATCH THE VIDEO : TEAM HOYT RSA Maintenance Excellence
2006
Rolly Angeles

Achieving WCM is like running the IRONMAN race. Many will start but only the thorough-bred will finish . . . . .

CLOSING :

WORLD CLASS MAINTENANCE MANAGEMENT

Team Hoyt Truly World Class People


RSA Maintenance Excellence
2006
Rolly Angeles

Change Must Always Come from Within . . . . . Many people wants to change something but nobody wants to change themselves, Leo Tolstoy Nobody says it better than the late King of Pop - I'm starting with the man in the mirror, I'm asking him to change his ways. And no message could have been any clearer, if you want to make the world a better place, take a look at yourself and then make that change, Michael Jackson Because Change must always start from within. To achieve World Class Maintenance is to have a plan, a team and a big heart.
RSA Maintenance Excellence
2006

WORLD CLASS MAINTENANCE MANAGEMENT

(Michael Joseph Jackson 1958 2009)


Rolly Angeles

CLOSING :

WORLD CLASS MAINTENANCE MANAGEMENT

Many say that People are our greatest assets, I would like to state this differently that the right people are our greatest asset in any industry and we can only have the right people if they are equipped with the right knowledge to perform their jobs better. Maintenance is not about eliminating failures. It has more to do about understanding the consequences of failures, and that for every consequences there is a feasible tasks at hand to manage, control, and anticipate it so we can derive the most benefit from it.

RSA Maintenance Excellence


2006

It is my hope that this 3 days training provide us some thoughts on the best way to maintain our equipments and that whatever we do with our lives, let us always remember that the learning just never stops . . . MARAMING SALAMAT PO (THANK YOU) !
Rolly Angeles

ACKNOWLEDGMENT

WORLD CLASS MAINTENANCE MANAGEMENT

This is to thank the following people that have continuously provided me knowledge and inspiration in driving my passion on reliability & maintenance . . .

RCFA Consultants and Rooticians


Bob Nelms of Failsafe Network, Vee Narayan author of Risk Analysis, Dr. Bob Nelms of Failsafe Network, Vee Narayan author of Risk Analysis, Dr. William Corcoran Saving Lives, Robert Latino of Reliability Center Inc., William Corcoran Saving Lives, Robert Latino of Reliability Center Inc., Terry Herrmann, Michael Mulligan, Bill Salot Terry Herrmann, Michael Mulligan, Bill Salot

My Friends from Reliability


Terrence O Hanlon, Steve Turner of PM Optimization, Daryl Mather, author of Terrence O Hanlon, Steve Turner of PM Optimization, Daryl Mather, author of Maintenance Scorecards, Sam Pickens, Bryan Weir CMMS Consultant ,, Joe Maintenance Scorecards, Sam Pickens, Bryan Weir CMMS Consultant Joe Peterson Maintenance Editor, Rui Assis Weibull Specialist, Dave Thompson, Peterson Maintenance Editor, Rui Assis Weibull Specialist, Dave Thompson, Neil Bloom (RCM Author), Harald van der Avoird (TPM Consultant) Neil Bloom (RCM Author), Harald van der Avoird (TPM Consultant)

And most of all to our dear God Almighty for providing me this opportunity to share this brief presentation . . . And May God Bless Us All

Maraming Salamat Po !
RSA Maintenance Excellence
2006

Thank you !
Rolly Angeles