Asset Lifecycle– Design andMaintenance

John Hunter

MAV Conference

30 May 2013

Ability to Influence

Time in the asset’s life cycle

Abi

lity

to in

fluen

ce

Concept / Preliminary Design

Maintenance

Design / Specification

Procurement / Construction

Commissioning and handover

Operations Renewal

Design for…• Maintainability• Reliability• Durability• Quality• Deconstruction• Safety• Waste prevention• Positive social and environmental impact

Design for MaintainabilityDesigning features to allow ease of maintenance.

Advantages – Low downtime, continuous LoS.

Examples:• Grass cutting and steep slopes• Co-locating into single areas• Accessibility - light poles• Bio-retention devices• Standardisation

Design for Reliability

Designing assets to minimise downtime

Advantages - Repeatable uninterrupted LoS.

Examples:• Sealed roller bearings to prevent dust ingress• Traffic signals with diagnostic capabilities• Fibre optic network with redundant paths

Design for Durability

Failure-free / maintenance-free operating.

Advantages – Long time to renewal.

Examples:• Galvanise / paint / powder coat / stainless• Add asphalt additives in plant to counter UV R• Downpipes – S/S.• External cladding on Bus Depot Buildings

Design for Quality

Totality of features to satisfy needs of users.

Advantages – Lean; negate rework and 10X rule

Examples:• QA in design, materials, construction.• No defects; no rework• Fit for purpose and meets service levels.

Design for Deconstruction

An opportunity to salvage / reuse components.

Advantages - Ease of disassembly.

Examples:• Fixing mechs, welding / bolting / adhesives• Potential for future reuse / recycling• Prefabric’n rather than permanent structures• USA – C&D represents ~ 25% landfill waste

Design for Safety

Mitigate / minimise safety risks.

Advantages – protect community and staff

Examples:• Construction, maintenance, operation• Locate cabinets away from roads• Bike-safe storm water grates• Non-slip materials

Design for Waste Prevention

Minimise waste at each asset life cycle phase

Advantages – Sustainability

Examples: • Services share same trenches if possible• Group wet areas together - save pipe lengths• Reduce, e.g. water, electricity• Reuse, e.g. Brisbane tuff kerb stones• Recycle, e.g. asphalt

Design for Positive Social, Environmental and Economic Impacts

Advantages – To contribute positive impacts to social, environmental and economic wellbeing.

Examples:• Sustainability – now and the future• Green star ratings• Meet a range of targets.

Design Collaboration

• Design• Procurement• Construction• Operations• Maintenances• Service Users

Here’s what we can do

• Think long term• Simplify• Carry a notebook• Implement practical solutions• Involve others

Here are some questions to ask

• “How can I / we make a whole-of-life difference with this design?”

• “Who do I need to involve?”• “What’s possible?”

What are the take home messages?

• Design has the single biggest impact on the assets’ WOL costs and serviceability.

• Design can impact for 10, 100 years and more.• We have the opportunity to create the future• - What can you do differently in your design?

Steve Job’s mantra

Design is not about how things look.

Design is about how things work.

The big difference - outcomes.

Internet sites (Design for…)

Maintainabilityhttp://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Maintainability.pdf

Safetyhttp://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Reliability.pdf

Manufacturinghttp://www.design1st.com/Design-Resource-Library/design_tips/Design_for_Manufacturing.pdf

Deconstructionhttp://www.deconstructioninstitute.com/files/downloads/75508728_DesignforDeconstructionPaper.pdf

Asset Lifecycle - Maintenance

Maintenance is “end of pipe”

Time in the asset’s life cycle

Abi

lity

to in

fluen

ce

Concept / Preliminary Design

Maintenance

Design / Specification

Procurement / Construction

Commissioning and handover

Operations Renewal

Maintenance

“If all you have is a hammer, every problem looks like a nail.”

Maintenance Overview

1. Detect 2. Prevent. 3. Remediate

Performance

Inherent Reliability – How the asset was designed. We cannot change reliability unless by re-designing or replacing with better parts

Operating environment – How it will be operated. ~ 40% of failures are due to Operator handling.

Maintenance – Detect, prevent, remediate

Performance Indicators

Leading Indicators

Forward looking (windscreen). Allows us to examine the process.

Lagging Indicators

Backward looking (rear-vision). Allows us to measure the output of a process.

Condition ratings

Condition Rating

Description of Condition

1 Very good condition – Only normal maintenance required

2 Minor defects only – Minor maintenance required (5%)

3Maintenance to enable an asset to provide an acceptable level of service – Significant maintenance required (10% - 20%)

4 Requires renewal – Significant renewal/upgrade required (20% - 40%)

5 Asset unserviceable – Over 50% of the asset requires replacement

P-F Curve

Planning and Scheduling

P P A A A A A

P A A P A A P A A P A A A A

Maintenance Contracts

Inspection – such as checking for wear and tear, breakage and reporting back.

Preventive – e.g. In a building or P&E, calibrating building plant or lubricating.

Full labour – 100% labour coverage, but no materials cover.

Full coverage – 100% coverage for labour, parts, materials and breakdowns.

Lean

Seven wastes

• Overproduction

• Waiting

• Transport• Motion

• Over-processing

• Spare parts

• Defects

5S Housekeeping

• Sorting – Keep only the tools essential for your job.

• Setting in Order – Arranging tools to eliminate time working with them.

• Shine – Keep workplaces clean, tidy and organised.

• Standardising – Systemise activities where possible.

• Sustaining – Maintain new standards and do not allow to lapse.

Sustainability

• Designing for maintainability• Design for reliability• Design for durability• Design for quality•  Design for safety• Design for Deconstruction• Design for Waste prevention• Design for positive social impact

Concluding

Design

Pre - acquisition

Maintenance

Post – acquisition

Opportunities

Questions?