pursuing excellence in asset management. web reliability... · 05/06/2014 · maintenance...

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Pursuing Excellence in Asset Management

“Taking it to the next level”

Greg Ramon, Assistant General ManagerMaintenance Administration

June 5, 2014

Asset Management

History

• 1985 to 2003: Reactive Maintenance

Reactive “fix it when it breaks”

• 2003 to 2012: Maintenance Excellence

Proactive “fix it before it breaks”

• 2013 and beyond: Reliability Excellence

Risk Based “fix critical assets before they break

Agenda Number 4.

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14 Pump Plants, 1 Pump Generating Plant Picacho Pumping Plant

Waddell Pump/Generating PlantWaddell Dam & Lake Pleasant

Mark Wilmer Pumping Plant

109 Pumps (2000 HP to 66,000 HP)

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Electric Power Facilities

39 Check Structures, 35 Turnouts

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6 Communication and Control Facilities

Reactive Maintenance

1985 to 2003

• Start-up and operate the system

• Deliver Arizona’s full Colorado River allocation

• Reactive Maintenance “fix it when it breaks”

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Improve Asset Management Program

Objective

• Reduce accidents and injuries

• Proactive process “fix it before it breaks”

• Organization gains control of the assets

• Increase Operational Availability (capacity)

• Manage the Maintenance Budget

Maintenance Excellence 2003

• Maintenance Philosophy used in manufacturing/industry

• Spectrum of business processes, practices, and procedures

• Manage the life cycle cost, and performance of infrastructure assets

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Maintenance Excellence

Implementation:

• Perform baseline audit

• Develop a 5 year Master Plan

• Design workflow processes, roles, and responsibilities

• Reorganize to support the new processes

• Evolve the workforce “What’s in it for me?"

• Develop metrics to measure performance

• Perform follow-up assessments to gauge progress


AGMMaintenance

Planner

ElectricianMechanicMaint. Wkr

Team Lead


Team Leader

4 Electrician6 Mechanic4 Maint. Wkr

Team Leader

Supervisor

Planner


Team Leader


Team Leader


Team Leader

Supervisor

Planner

2 Electrician2 MechanicMaint. Wkr

Team Leader


Team Leader

4 Electrician2 MechanicMaint. Wkr

Team Leader

Supervisor

MaintenanceManager

MaintenanceManager

MaintenanceManager

MaintenanceManager

GeneralManager2003 Reactive Organization Structure

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AGMMaintenance


Area Supv


Area Supv

Asset OwnerWest Manager


Area Supv


Area Suprv

Asset OwnerSouth Manager

Heavy Overhaul

Heavy Overhaul

Heavy Overhaul

HVAC

Fire Systems

Electrical I&C

Protective Coating

CentralizedSupport Mgr.

Maint. Engineering

Planning

CMMS Support

Maint. ControlManager

GeneralManager2013 Proactive Organization Structure

Maintenance Excellence Assessments

Evaluating Performance

• First external assessment completed March 2003 (baseline)

• Three internal assessments, 2004, 2007 and 2009

• Last assessment (external) in 2011 by CH2M Hill

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2011 CH2M Hill Assessment

Objective a. Benchmark CAP’s maintenance program

b. Perform an organizational review

c. Validate CAP’s internal assessment process

Assessment Processa. Question based survey and employee interviews

b. Risk assessment of each audit category

c. Risk assessment of 7 CAP facilities


2011 Audit Category Scores

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

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42%

60% 65%

81% 82%

2003Life Cycle

2004Internal

2007Internal

2009Internal

2011CH2M HILL

Reactive

Emerging

Proactive

Excellence

World Class

Assessment History

2011 CH2M Hill Assessment

Water Services Association of AustraliaUsed to compare maintenance practices of water utilities

• Water utility assessment – Water utilities from North America (13)

– Global water utilities (27)

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CAP VS North America Water Utilities

The United States

Seattle Public Utilities Washington

Tacoma Water Washington

Tacoma Public Works Washington

Portland Water Bureau Oregon

Portland BES Oregon

Anchorage W/WW Alaska

Philadelphia Water Dept Pennsylvania

Cincinnati MSD Ohio

Toho Water Authority Florida

Los Angeles Water & Power California

Canada

Region of York Ontario

Region of Peel Ontario

City of Toronto Ontario

Water Services Association of Australia

CAP VS Global Water Utilities

Australia

Sydney Catchment Authority NSWSydney Water NSWHunter Water NSWGold Coast Water QueenslandSEQ Water QueenslandBrisbane City Council QueenslandGladstone Area Water QueenslandCentral Highlands Water VictoriaCity West Water VictoriaSouth East Water VictoriaMelbourne Water VictoriaColiban Water VictoriaGoulburn Valley Water Victoria Wannon Water VictoriaHobart Water TasmaniaWater Corporation Western AustraliaSA Water South Australia

New Zealand

Manukau WaterMetrowaterNorth Shore City CouncilChristchurch City CouncilDunedin City CouncilWatercare New Zealand

Hong Kong

Hong Kong Water Supplies Department

The United Arab Emirates

Abu Dhabi Distribution Company

Abu Dhabi Sewerage Services Company

Sultanate of Oman

Oman Wastewater Services Company


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2011 CH2M Hill Results

CAP Score = 72%

Global Water Utility Group

North America Group

$27.1 $27.1 $27.6

$28.8 $28.8

$26.8

$25.4 $25.0 $24.7 $25.5

$24.9

$10.0

$12.0

$14.0

$16.0

$18.0

$20.0

$22.0

$24.0

$26.0

$28.0

$30.0

2008 2009 2010 2011 2012 2013

General Fund General Fund (Adjusted for CPI)

Maintenance Costs (Actual vs. Adjusted for CPI)

Co

sts

in M

illio

ns

of

$

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Reliability Excellence

Fundamentals necessary for success

• Risk based approach

• Performance measurements

• Condition Based Monitoring (CBM)

• Sharing information

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Reliability Excellence 2013 to 2016

Objectives:

• Optimize maintenance effort (continuous improvement)

• Establish asset criticality relative to Safety and Operations

• Apply Reliability Centered Maintenance (RCM) process

• Continue to implement Condition Based Monitoring technologies

• Risk based process “fix or replace just before it breaks”

“prevent failure of critical assets and allow some non-critical assets to run to fail”

Reliability Excellence

Condition Based Monitoring

• Install technology to collect asset data

• Organize data and provide remote display

• Trend critical asset performance data

• Automate intrusive manual inspections

• Facilitate Predictive Maintenance (Pdm)

• Facilitate “Run to Failure” decisions

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Thoughts / Questions?

pursuing excellence in asset management. web reliability... · 05/06/2014 · maintenance...

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