maintenance management consulting

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Emerson Process Management - CSI

DoctorKnow Application PaperTitle: Consulting

Source/

Author:

Reliability Week 1997 Paper

Product: GeneralTechnology: Vibration

Classification:

Maintenance Management Consulting

The RBMTM Management Consulting Services group provides maintenance management

consulting and management training for the development and implementation of advanced

maintenance strategies.

Program Assessment

A world-class maintenance program consists of best methods, practices, procedures, and

technologies blended through an integrated plan of action. Our Reliability-Based

MaintenanceAssessment and information gathering process serves as a checklist of elements

vital to a successful world-class maintenance program. The assessment identifies opportunities for

improvement, and provides a specific implementation plan, with concrete measures of performance

improvement. It serves as an effective communication device between organizations and between

various levels of management. It helps to establish partnership roles for the over-all improvement

in equipment operations, reliability, and availability.

The Assessment questions are based on over 25 years of hands on experience in maintenance

consulting, coupled with direct line management experience a variety of maintenance

organizations. Topics covered in the assessment include:

r Management Support and Plant Culture

r Performance Measurements

r Program Organization and Communication

r Predictive Maintenance and Technologies

r Preventive Maintenance

r Reactive Maintenance

r Proactive Maintenance and Technologies

r Planning, Scheduling and Maintenance Management Systems

r Training Certification and Training Plans

The resulting report and needs assessment will reflect the overall state of the existing program and

will include discussions and recommendations as they apply to:

r Technologies

r Training

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r Methods, Procedures, and Practices

r Individual and Organizational Roles and Responsibilities

r Resources Required -- Personnel & Equipment

r Specific Performance Indicators

r Expected Returns on Investments

System and Equipment Prioritization SurveyCSI has developed the System/Equipment Reliability Prioritization (SERP) as an extremely

efficient streamlined RCM study to determine the appropriate (optimum) mix of maintenance

investments as applied to plant systems and the associated critical equipment. Existing machinery

histories, personnel safety, equipment criticality, established routes, and monitoring schedules are

reviewed. A detailed matrix of the plant equipment and systems is developed to ensure proper

application of available technologies based on criticality to the process. The cornerstone of an

effective Maintenance program is the SERP process which identifies and prioritizes the "Critical

Equipment" requiring the most investment attention.

Program Procedure Development

Program procedures are an important part of ensuring that consistency in work effort is maintained.

Procedures also provide the ability to implement changes in programs with consistency, as they

become necessary. Consistency and control are the main reasons that ISO 9000 requires

procedures for certification. The areas that need to be covered by procedures include:

r Control of Work,

r Systematic Problem Solving or Root Cause Failure Analysis,

r Development and Closet of Work Orders,

r Generation and Prioritization of Work Requests and Work Orders,

r Preventive Maintenance Review Cycles,

r Application of Condition Monitoring Technologies,

r Procurement Specification for New and Rebuilt Equipment,

r Procurement Specification for Spare Parts.

r Document Control

Other points of opportunity may include specific work procedures including:

r Individual Repair Tasks for Equipment,

r Conduct of Individual Predictive Maintenance Tasks,

r Conduct of Individual Preventive Maintenance Tasks,

r Calculation of Cost Savings or Avoided Costs,

r Spares Inventory Change and/or Reduction,

r Specific Specifications for New and Rebuilt Equipment,

r Specific Specifications for Spare Parts.

Review and Optimization of Preventive Maintenance Programs

The PM Optimization Process ensures that only the necessary Preventive Maintenance tasks are



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being performed. This is accomplished through two avenues. The first is the replacement of

individual preventive maintenance tasks with condition monitoring techniques whenever

appropriate. The second is ensuring that the remaining predictive maintenance tasks are being

performed on the most appropriate frequency to catch failures prior to their occurrence without

redundancy or unnecessary labor.

The replacement of preventive maintenance tasks with condition monitoring tasks is based on

experience with the condition monitoring technologies and their application to various machines.Ensuring the appropriate frequency for preventive maintenance tasks is accomplished by

determining the mean time between failures. These calculations are performed using the in-house

data on machine history or ASME and IEEE standards when machinery history is not available.

Evaluation of Computerized Maintenance Management Systems Needs, and

Recommendations for Purchases or Upgrades

The Computerized Maintenance Management System (CMMS) is an important feature of an

advance maintenance strategy. The ability to accurately plan and schedule work, to record and

store historical information on work performed, the ability to accurately analyze the storedinformation for trends, and the ability to interface with or maintain the spares inventory are

essential requirements for an acceptable CMMS. There are currently over 2000 CMMS programs

ranging in price from $500.00 to $500,000.00 with a wide variety of capabilities. In determining

which CMMS is right for your applications, it is important to first assess your specific program

needs before you begin looking. CSI has extensive experience helping clients evaluate their

CMMS needs, and in further assisting clients in selecting an appropriate package to meet their

needs.

All contents copyright 1998 - 2006, Computational Systems, Inc.All Rights Reserved.


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