11 maintenance strategy.pdf

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Revision G Page 1 of 3 28/06/2011

COMPREHENSIVE ASSET MANAGEMENT PLAN

TASK SHEET

MAINTENANCE STRATEGY

APPLICATION AND PURPOSE

Reference

Maintenance Strategy Development (MSD) is a structured and auditable process for

evaluating how best maintenance practice can be applied to a physical asset using a

variety of tools and techniques. This will help IWK to have a formal method of selecting

appropriate maintenance tasks to address equipment failure modes based upon criticality

of equipment and consequences of failure as well as to minimise unexpected equipment

failures by pre-empting equipment failure. It is also applied to maximise the availability

(uptime) of any plant for operations considering its maintenance and inspection

requirements.

A maintenance strategy allows IWK to have a suitable repair strategy with required partsavailable in the event of unexpected equipment failures.

3.13

IWK CURRENT PRACTICE

Reference

IWK currently have a maintenance strategy consisting of some Planned Preventive

Maintenance (PPM) as well as a major amount of Corrective Maintenance (fix on fail).

Maintenance activities are managed through the IFS system which has proven difficult in

application at sites. Many IWK asset management decisions are taken based upon

"external" maintenance data outside of the IFS System developed by the IWK

maintenance execution staff in separate spreadsheets.

Existing planned maintenance activities appear to be mainly based on manufacturers

recommendations and not a formal IWK strategy.

4.11

IWK RECOMMENDED PRACTICE

Reference

IFS operation is almost ineffectual at this time. IWK to consider re-engineering the IFS

system to operate as an effective Computerised Maintenance Management System

(CMMS).

This would be best carried out by using a "clean slate" approach and defining whatactivities IWK need to carry out in the CMMS and what information needs to be available

as input and outputs from the system. System functions should also be defined. From this

IWK can develop a CMMS Functional Specification, IFS should then be re-engineered to

provide the functionality required by the Asset management User groups.

CMMS functionality should include (as a minimum):

Development, storage and retrieval of asset hierarchy

Development, storage, retrieval and automatic generation of planned maintenance

activities - including work priorities when required to manage excess work or

maintenance backlog

Development, storage and planning and scheduling of corrective maintenance actions

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IWK RECOMMENDED PRACTICE

Reference

Storage of equipment work history

Equipment classification data including equipment type, operating modes, criticality,

failure and repair codes etc.

Purchasing interface for spare parts and services

Ability to produce asset management KPI's related to reliability and availability, WO

status etc.

Ability to close WO out, even when support services are outstanding (such as finance)

to enable more effective backlog management

As IWK have evolved their current maintenance strategy from long-time field practices

and Equipment Vendor recommendations they will be over-maintaining in some areas and

not carrying out the correct tasks at the required time in other areas.

In the long term it is suggest that IWK carry out a formal Maintenance Strategy Review

exercise. This can be affected using one of the internationally accepted strategy

development tools such as Reliability-centred Maintenance (RCM) or Total Productive

Maintenance (TPM).

Due to the nature of IWK's asset base, WorleyParsons would recommend an approach

utilising template-based RCM. This analysis technique realises the inherent availability of

equipment items whilst focusing on the "minimal" require maintenance tasks, based upon

equipment criticality to the process. Whilst RCM (in its true form) can be a long-term effort

for a large industrial organisation, use of basic equipment type templates would allow a

much more rapid review and provide a definite "structure" to maintenance decision

making, allowing justification of future expenditure on maintenance operations.

RCM will also provide a structured review of spare parts requirements based upon actual

equipment failure modes and failure rates, rather than vendors recommendations, which

are usually excessively in their favour.

DATA REQUIREMENTS

Currently Recordedby IWK?Item Description Required Quality Level

Y / N Quality

Not required

RELATED SECTIONS IN CAMP

Reference

Data Needs 3.14

Root Cause Failure Analysis 3.11

Failure Analysis 3.10

ITC REQUIREMENTS

CMMS must provide an effective, efficient, user friendly management system for daily execution ofmaintenance workload.


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ITC REQUIREMENTS

CMMS should be capable of providing analysis of equipment and work activities data to generate

"information" on asset management status.

CMMS should be capable of providing historical data for detailed analysis and reporting of KPI's, equipment

failure investigation and daily maintenance workload management.

CURRENT ITC CAPABILITIES

IFS is cumbersome, most maintenance and inspection work is managed outside of IFS, particularly the

ongoing data analysis for equipment status, work planning and scheduling, production of asset management

KPI's etc.

Automatic planning and scheduling is not in use, work is manually scheduled and controlled which

consumes man-hours that could be spent carry out work activities or conducting failure analyses for

continuous improvement exercises.

Unable to close maintenance and inspection work-order until financials are completed. This requires a daily

management review to try and reduce the maintenance work backlog to a minimum and does not allow truereflection of maintenance work status / performance.

IWK ACTION PLAN

Timeframe Reference

IWK to re-engineer the IFS system to better align codes, reinstate

automatic functions that have been manually carried out and improve

long-term efficiencies in asset management operations.

Mid-term 5.11

IWK to decide upon formal Maintenance Strategy and roll-out across all

assets. Aligning maintenance and inspection work activities with arecognised standard method of determining work requirements will

illustrate IWK commitment to availability and efficiency.

Mid-term 5.11

IWK TRAINING REQUIREMENTS

IWK CAMP Manual Overview Training

Future requirement if selected: Maintenance Strategy Review tools (RCM)

INITIAL CHAMPION ACTIVITIES

Reference

IWK to review options for formal Maintenance Strategy Development (as suggested

template-based RCM would be the best option for IWK).

IWK to review their basic Maintenance Philosophy and Strategy documents and policy in

light of the extensive asset base covered and its continued growth in the future.

Developing these to incorporate template-based RCM provides "off-the-shelf"

maintenance strategy for nay new developments as they are brought into service.

5.11

ADDITIONAL/SUPPORT NOTES

None

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