1 PMO2000™ www.reliabilityassurance.com

Improved Improved Reliability Reliability through through PM OptimisationPM Optimisation

Project Team:

Electrician

Planner

Mechanic

Operator

Reliability EngineerFacilitator: Steve Turner

PMO2000™

Why investigate the Residue Cell C’sWhy investigate the Residue Cell C’s

PM Optimisation will fall in line with the business plan for the Site.

The only cost centre in the plant consistently over budget.

Opportunity to improve reliability as Cell C’s have highest failure rate in the area.

Opportunity for more consistent performance to meet plant expansion plans.

The experience is that there is more work in the area than there are people assigned.

PMO2000™

ObjectivesObjectives

Better focus of PM schedules. Increase the quality of maintenance. Understand the rationale behind each PM task. To better manage the Cell C operation and maintenance. Exchange information and increase understanding of

each role ie mech ,elect, process.

Understand equipment failure history. Improve detection and rectification of failures. Communicate findings.

PMO2000™

Objectives…Objectives…contcont

All of the previous will result in greater abilityfor us to meet the business plan.

PMO2000™

How we went about itHow we went about it

Started with the existing PM lists Applied the process to the all schedules including:

SAP schedules Maintenance and Process task lists Check sheets

Created a new daily schedule for both operator and maintenance technicians.

Review failure modes and the PM’s which addressed these.

PMO2000™

How we went about it….How we went about it….con’tcon’t

Review operating logsheets Determined the most appropriate maintenance

strategy. What task (preventive, predictive or

corrective) Who does it How often.

Develop implementation list/plan for approval.

PMO2000™

Opportunities identifiedOpportunities identified

Numerous new PM tasks that should be done. Task frequency could be more effective

particularly in the mechanical area. Some job descriptions were not specific or

reflective of actual work. Identified a opportunities for reliability

engineering.

PMO2000™

Opportunities Identified…Opportunities Identified…contcont

Better utilisation of maintenance and operations resources by eliminating task duplication.

The maintenance strategy needs to be better documented so that it can more easily be reviewed and communicated.

There is an opportunity to transfer some of the knowledge to other processes and sites.

PMO2000™

Outcome PM Optimisation AnalysisOutcome PM Optimisation Analysis

Overall Breakdown Of 110 Maintenance Tasks

Delete13%

Extend Interval11%

New Task7%

Reduce Interval9%

Use As Is60%

PMO2000™

Outcome PM Optimisation AnalysisOutcome PM Optimisation Analysis

Analysis of Mechanical Changes

Delete19%

Extend Interval30%

New Task13%

Reduce Interval25%

Use As Is13%

PMO2000™

Table of Overall Downtime for PM on Unit

Sum of Hours Proposed Program Previous Program

Interval Total Lab D/timePer Year Total Lab D/time

Per Year Total

2 Monthly 0.3 1 0.3 6 2

Monthly 5.17 2 3 12 36Two Weeks 2.25 1 2.25 26 59 1 8 26 208

Weekly 1.92 1 2 52 104Grand Total 9.64 200 208

Downtime Analysis-MechanicalDowntime Analysis-Mechanical

PMO2000™

Downtime ScheduleDowntime Schedule

0

2

4

6

8

10

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8

Do

wn

tim

e H

ou

rs

Original Total 32hrs

Revised Total 30hrs

PMO2000™

Some interesting issuesSome interesting issues

Some valve failures could possibly be managed by condition monitoring rather than in breakdown.

Breakdown history was recorded incorrectly. This precludes any efficient analysis.

Some task were carried out too often…others not often enough.

The existing mechanical PM were difficult to complete but now broken into three PM’s.

Not all process tech inspections are recorded.

PMO2000™

Some interesting issues….Some interesting issues….contcont

Greater involvement of process tech’s in fault finding is possible for maintenance and operations problems.

The justification for each maintenance task is now documented.

The existing PMs are not all being completed. Pizza Hut do not deliver on public holidays.

PMO2000™

Other benefits... Other benefits...

More knowledgeable and empathetic workforce. More descriptive tasks with acceptable limits. Improved team work. Greater sense of ownership in the maintenance and

equipment performance. Better understanding of failure modes and objective of

tasks Planned downtime reduced (1hr per fortnight per unit).

Unplanned downtime will add to this.

PMO2000™

Benefits..con’t Benefits..con’t

Move to a less reactive environment by adopting more frequent inspections where warranted.

The PM program can now be achieved.

PMO2000™

What needs to happen nowWhat needs to happen now

Input changes to SAP (already started). Implement the Process Tech check procedure. Modify Elect Maintenance Tech check sheets. Develop Mech Maintenance Tech check sheet. Improve failure reporting in SAP. Carry out some minor plant modifications. Implement new tasks ie NDT and Structural

inspections .

18 PMO2000™ www.reliabilityassurance.com

Improved Reliability Improved Reliability through through PM OptimisationPM Optimisation

Project Team:

• Electrician

• Planner

• Mechanic

• Operator

• Reliability EngineerFacilitator: Steve Turner