Maintenance

Four principles of operation risk management

1. Accept risk when benefits outweigh the cost. 2. Accept no unnecessary risk. 3. Anticipate and manage risk by planning. 4. Make risk decisions at the right level.

Risk Mitigation Techniques (ACAT)

1. Avoidance (eliminate, or not do that activity) 2. Control (optimize, mitigate or reduce risk) 3. Accept (accept and budget-plan) 4. Transfer (risk share or outsource)

Reasons why a Safety Culture fails..

1. Lack of commitment from leadership and management 2. Inconsistency in how and where safety is applied. 3. Loss of focus

4 Problem Solving Tools

1. Maintenance Root Cause Analysis Tools, 2. Six Sigma and Quality Maintenance Tools, 3. Lean Maintenance Tools, 4. Other Analysis and Improvement Tools

6 Ways to Make a Big Difference in Sustainibility

1. Reduce what we buy and what we use 2. Save on electricity-energy 3. Generate less waste 4. Reduce water resources 5. Minimize or eliminate need of hazardous material 6. Choose greener transportation anytime it is feasible

Six Spheres of Risk associated with Projects (SPCSTP)

1. Safety risk 2. Performance 3. Cost 4. Schedule 5. Technology 6. Product data access and protection risk

When should we use the Fishbone diagram?

1. To stimulate thinking during a brainstorming session 2. When there are many possible causes for a problem 3. To investigate why an asset or process is not performing properly or producing the desired results 4. To analyze and find the root causes of a complicated problem and to understand relationships between potential causes. 5. To dissect problems into smaller pieces.

5 Whys Analysis

1. Why is our customer unhappy? 2. Why we were unable to meet the agreed-upon schedule for delivery? 3. Why did it take so much longer? 4. Why did we underestimate the work? 5. Why didn't we do planning - detailed analysis - for this job?

Six Sigma Defects

3.4 parts per million or 0.00034%

What is TPM?

A maintenance strategy that originated in Japan emphasizing operations and maintenance cooperation.

What is a Best Practice?

A method or technique that has been found to be the most effective and has consistently achieved superior results compared to results achieve with other means becoming a benchmark.

What is a standard?

A prescribed set of rules, conditions, or requirements concerning definitions of terms; classification of components; specification of materials, performance, or operations; dilineation of procedures; or measurement of quantity and quality in describing materials, products, systems, services, or practices.

5 Whys

A problem solving technique for discovering the root cause of a problem. Ask why until you get to the root of the problem.

2 TPM Objectives

Achieve zero defects, zero rbeakdowns, and zero accidents in all functional areas of the organization and involve people at all levels of the organization.

Root Cause Analysis (RCA)

Aka Root Cause Failure Analysis is a step by step methodology that leads to the discovery of the prime cause of the failure.

Risk Management in Safety field

All risks are hazard is generally recognized that consequences are only negative and therefore the management of safety risk is focused on prevention and mitigation of these hazards.

Cause and effect analysis

Also called an Ishikawa or Fishbone chart. It identifies many possible causes for an effect or problem, and then sorts ideas into useful categories to help in developing appropriate corrective actions.

What does APQC stand for regrading benchmarking?

American Productivity and Quality Council

The percentage of actual time that an asset has operated (uptime) compared to how long it was scheduled to operate

Availibility (OEE related)

Pareto Analysis

Bar graph displaying variances by the number of their occurrences. Variances are shown in descending order to idetnfiy the largest opportunities for imrpovement. Concept also known as the 80/20 rule

Specific (SMART 4 Metric Performance)

Be clear and focused to avoid misinterpretation. Include measurement and assumptions and definitions and should be easily interpreted.

TPM ultimately..

Brings improvements in existing processes and asset availibility by reducing mistakes and accidents.

Risk Management Process

Central part of any organization's strategic management. It is the process whereby organizations methodically address the risks associated with their activities to enable the goal of achieving sustained benefit within each activity an across all activities of the organization.

Risk Management Defined

Considers both positive and negative aspects of risks.

What does DMAIC stand for?

Define, Measure, Analyze, Improve and Control

DMAIC's five phases in the Six Sigma methodology

Define, Measure, Analyze, Improve, Control

PDCA

Deming's Improvement Cycle Plan - Do - Check- Act (PDCA) is known as Deming's methodology to make improvements.

How should the DMAIC method be applied

Follow steps in sequence and don't skip a phase or it will not produce the desired result. It is a structured process to solve problems with proper implementation and follow-up.

Sustainability

Forms of progress that meet the needs of the present without compromising the ability of future generations to meet their needs.

Root Cause Analysis

Identification and evaluation of the reason for an undesirable condition or non-conformance. A methodology that leads to the discovery of the cause of a problem or root cause.

RCM Principle 2

Identify failure modes that can defeat the functions.

Diagnosis/Prognosis (CBM Phase)

Isolating the cause of the problem and developing a corrective action plan based on its condition and remaining life.

Realistic (SMART 4 Metric Performance)

It fits into the organization's constraints and is cost effective.

Timely (SMART 4 Metric Performance)

It's do-able, data is available within the time needed.

Creator of Cause and Effects Analysis

Kauro Ishikawa, a japanese quality control statistician invented the fishbone diagram.

Benchmarking Code of Conduct

Legal, Be Open, Confidentiality, Use of Information, The Golden Rule of Benchmarking, Lack of Standardized Definitions

Lean Maintenance

Majority of maintenance activities revolve around systems and the processes that move people, material and machine together such as PM, PdM, planning, scheduling, CMMS

Is mitigating every plausible risk possible?

May not be possible and is rather impractical due to resource limitations.

What is the objective of TEEP?

Measure how well an organization creates lasting value from its assets

Standard Deviation

Measures variations of values from the mean

Surveillance (CBM Phase)

Monitoring machinery condition to detect incipient problems

How is TEEP calculated?

Multipling these four factors and is expressed as a percentage.

What does OEE stand for?

Overall Equipment Effectiveness

Remedy (CBM Phase)

Performing corrective action.

Risk Management Purpose

Prevent, reduce, or control future impacts of unfavorable events as opposed to reacting to unwanted events after they have already occurred.

RCM Principle 3

Prioritize function needs (failure modes)

The fishbone diagram purpose (CAE)

Provides a systematic way of looking at effects and the casues that create or contribute to those effects.

Six Sigma Defined

Quality improvement initiative developed directly from TQM which reduces process variation to very lwo levels.

Why CBM is popular

Recent advances in technology have made CBM a reality with inexpensive computing power, and analyzing data that makes CBM possible.

5 RCM Benefits (RCDEE)

Reliability, Cost, Documentation, Equipment/Parts Replacement, Efficiency/Productivity

ISO 9001 New Requirement

Requries continuous improvement where organizations collect and analyze data on process performance using audits, internal performance indicators, and customer feedback. Implement corrective action to prevent recurrence.

RCM Principle 4

Select applicable and effective tasks

What do with data (ISO 9000)?

Should be analyzed using various techniques and tools in order to develop and implement effective plans that can lead to improvements in assets and processes.

What does SMART Test stand for?

Specific, Measurable, Attainable, Realistic, Timely

Where should effective risk management process start?

Start from the ground up and participation being encouraged at all levels. It is especially important to encourage proactive participationby the subject matter experts and stakeholders.

Fault Tree

Starting with the final failure and progressively traces each cause that led to the previous cause. This continues till the trail can be traced back no further. Once checked for logical flow, it is determined what changes would prevent the sequence of causes with marked consequencies from occurring again.

DMAIC defined

Steps used to guide implementation of the Six Sigma process.

CBM Program characterized in three phases:

Surveillance, Diagnosis/Prognosis, Remedy

OEE is a key metric used in

TPM and Lean Manufacturing programs to measure the effectiveness of TPM and other initiatives

Energy Reduction and Process Improvement Strategies

TPM, Right-Sized Equipment, Plant Layout and Flow, Standard Work, Visual Controls, and Mistake-Proofing

What does benchmarking gather?

Tacit knowledge, the know-how, judgments and enablers

What is the benchmarking gap?

The difference in performance between the benchmark for a particular activity and the level of other organizations. AKA Measured performance advantage of the benchmark organization over other organizations

What happens if root cause is not addressed in a timely fashion?

The failure will repeat itself, usually causing unnecessary loss of production and increasing the cost of maintenance.

Measurable (SMART 4 Metric Performance)

The metric can be quantified and compared to other data. It should allow for meaningful statistical analysis and avoid yes/no measures except in startups

Attainable (SMART 4 Metric Performance)

The metric is achievable, reasonable, and credible under conditions expected.

RCM Principle 1

The primary objective of RCM is to preserve system function.

Define benchmarking

The process of identifying, learning, and adapting outstanding practices and process from any organization, anywhere in the world, to help an organization improves its performance

Six Sigma

This methodology systematically analyzes processes to reduce process variations and also to eliminate wastes. Six Sigma is also used to further drive productivity and quality improvements ni any type of organizations.

RCA is a structured way to arrive at the root cause...

Thus facilitating elimination of the cause and not just symptoms associated with it.

Why is the ISO 9000 needed?

To continually improve processes, reduce costs, and cut waste to remain competitive.

Measure of overall asset or process effectiveness.

Total Effective Equipment Performance

What does TEEP stand for?

Total Effective Equipment Performance

What does TPM stand for?

Total Productive Maintenance

Lean Maintenance focuses on these areas (TIMWOID)

Transportation, Inventory, Motion, Waiting, Overproduction, Inappropriate Processing, Defects

Barrier Analysis

Used in process industries to trace energy flows. It has a focus on barriers to those flows, and helps identify how and why the barriers did not prevent the energy flows from causing damage.

Four factors of TEEP?

Utilization, availibility, performance and quality

Who defined sustainibility

World Commission on Environment and Development in 1987

Managing Performance per Peter Drucker

You cannot manage something you cannot control, and you cannot control something you cannot measure.

What lean maintenance is not.

You need reliable assets and reliable machines. Not about performing less corrective or preventative actions and not about faciliating a poor maintenance program.

TPM Goals

Zero defects, zero accidents, zero breakdowns, and an effective workplace design to reduce overall operations and maintenance costs.