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Improving Equipment Reliability using a CMMS/EAM
Improving Equipment
Reliability using a CMMS/EAM
Ben Stevens, OMDEC Inc -
IPAMC 2006
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Improving Equipment Reliability using a CMMS/EAM
CMMS/EAM EvolutionPhase 0 – Manual
operation, no
CMMS
Phase 1:
Automate Forms:
Work OrdersPurchase Orders
Issue slips
Time cards
Specifications
Project led by IT;
KPI’s are IT
efficiency,database type
35%
Phase 2:
Automate Processes:
Work Request/Work
Order
Work Order/
Material Issue
Work Order/
Purchasing
Project led by IT;
KPI’s are IT
efficiency,
database type,
degree of
integration
40%
Phase 3:
Use of Workflow,
Work Management
Emergence of EAMMerge and
eliminate tasks
Streamline
functions
Project led by
Business Unit;
KPI’s are cost
reduction,materials usage
employee
productivity
20%
Phase 4:
Analysis,
Information,
Knowledge Base,
Integration with
intelligent agents
to improve the
quality of the
Maintenance Plan
Project led by
Maintenance;
KPI’s are equipment
reliability, number of failures, quality of
maintenance, use of
best practices
5%
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Improving Equipment Reliability using a CMMS/EAM
Cost of Failure
Cost of Failure =
Cost of Repair +
Cost of Lost Revenue +Penalty Costs
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Improving Equipment Reliability using a CMMS/EAM
Failure Costs
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Improving Equipment Reliability using a CMMS/EAM
470,000
193,000
Run Risk
470:361 =1.3:1
193:40 =
5:1
Risk
Ratio
60 days
28 days
Failure
time
15%
25%
Failure
Probab
30 days
250,00061,000,000week20,000ukoTurbine
100,0000,000,0005 hours5,000iigata
Diesel
Failure
Cost
Repair
Risk
Outage
cost per
Hour
Repair
Time
Repair
Cost
Unit
The Risks of Equipment Failure
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Improving Equipment Reliability using a CMMS/EAM
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Improving Equipment Reliability using a CMMS/EAM
Cost
Time
Run
Risk
Run
Risk
Repair
Risk
Repair
Risk
Next Scheduled
Outage
Risk versus Time in Equipment
Failure
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Improving Equipment Reliability using a CMMS/EAM
Aug 1 Sep 1 Oct 1 Nov 1
20
15
10
5
Maximum Acceptable
Level of risk
Next Planned
shutdown date
Predicted Risk
Ratio level
Risk Ratio
Equipment Failure Risk Ratio