Proactive Versus Reactive Maintenance Measurement/Improvement

Successful maintenance improvement projects in large organisations require a systematic and well-founded approach to ensure tangible technical outcomes. A structured maintenance data analysis has been developed to address key maintenance objectives known as proactive maintenance, backlog management and failure mode analysis.

Maintenance data (i.e. work orders) for one fiscal year 2002/2003 in a large Alumina refinery is investigated in an attempt to established short, medium and long-term maintenance improvement strategies. Data set included more than 61,000 individual work orders with a total amount of actual cost recorded as high as $63m with more than 330,000 hours of actual work registered in the CMMS.

Such a structured analysis has led to specific set of recommendations for improvements in planning and scheduling of works, PM strategies for number of critical assets, new backlog management strategy and engineering investigations into major failure modes. Since delivering the full report, several of these improvement initiatives have been successfully implemented, and few others are being considered for implementation.

 

proactive_versus_reactive_maintenance_measurement_improvement.pdf

Maintenance Engineering Bureau Using Maintenance Data To Drive Improvement

This paper presents an objective methodology for maintenance data analysis. The purposes of these analyses are to identify strengths and weaknesses in the maintenance management system, opportunities for improvements, and benchmark maintenance key elements against maintenance best practice. A wide range of reports can be provided from analysing the data from computerised maintenance management systems. These reports can be categorised as Performance Reports, Benchmarking Reports, Optimisation Reports, and Data Integrity Reports.

Failure Modes and Effect Analysis is one of the main outcomes of the maintenance engineering bureau services. This analysis is an easy to use and yet powerful, proactive maintenance engineering method, which can identify potential failure modes, determine their effect on the maintenance costs, and identify actions to mitigate the failures. The results of the analyses of the various maintenance system data sets based on the developed methodology are presented.

 

maintenance_engineering_bureau_using_maintenance_data_to_drive_improvement.pdf

Strategy — Maintenance, Capital and Risk

This paper presents various methodologies and issues associated with a total asset management process that embraces the use of capital and maintenance expenditure to ensure assets meet the full spectrum of operational requirements, including safety, performance and return on investment. The broad range of issues associated with implementing asset management mean that the work must be conducted within a cohesive framework, even though different elements may have little in common with each other. Pervading the entire process is a risk management process that is a function of the condition of the asset base and the responsiveness to identified needs.

 

strategy_-_maintenance_capital_and_risk.pdf

Strategic Asset Management

This paper presents various methodologies and issues associated with a total asset management process that embraces the use of capital and maintenance expenditure to ensure assets meet the full spectrum of operational requirements, including safety, performance and return on investment. Pervading the entire process is a risk management process that is a function of the condition of the asset base and the responsiveness to identified needs. The tangibles of the asset management plan are physical documents and systems that make up the individual elements within the framework. In this case, they are the outward signs of a business process, which is comprised of many business rules. A mixture of Oracle, intranet and Office-based documents will be described, including how these are interleaved.

Output from the asset management plan described in the paper includes distribution of costs across systems and areas, efficiency of the expenditure (including reactive versus proactive maintenance plus anecdotal notes on known problems), and effectiveness of the expenditure – management of the reliability and capability of the systems, where capability represents ability of an asset to provide its intended function with expected levels of flexibility, efficiency and quality. In conclusion this work has achieved interpretation of the broad overall business targets in terms of operational requirements for specific assets and groups of assets, planning ahead to check likelihood of asset capability being able to meet operational requirements, and gap analysis between operational requirements and operational performance.

 

strategic_asset_management.pdf

Safety Engineering Management – SafetyPoint

The Covaris Safety Engineering Management is an established system based on the Australian and International Standards and engineering best practice in safety engineering. It enables the systematic examination of the hazards associated with plant and machinery, leading to a documented safety improvement scheme and an ultimately safer workplace.

 

safety_engineering_management_-_safetypoint.pdf