10/14/2016

Reliability Asset
Management

Maintenance Efficiency:
Impact on the Big Picture

Operational Efficiency
Expense
Throughput Equipment Reliability
Inventory

LEAN
Principles
Uptime Maintenance Efficiency
Support
Overall MTBF Productivity LEAN Principles
Systems
Equipment MTTR
Effectiveness
OEE

1
 10/14/2016

Reliability Financial Report

Digging into the Benchmark

MAINT $ STORES $
QUARTILE (%RAV) (% RAV)
% IR % IR % OIL % OTHER % ON
% VIB MECH ELEC ANAL NDT % ON PM BOM

Top 1st 1.2 % 0.3 % 85.7 % 73.6 % 100.0 % 42.9 % 42.2 % 25.0 % 66.0 %

Middle 1st 2.7 % 0.9 % 75.6 % 62.8 % 91.9 % 38.6 % 35.5 % 26.0 % 63.0 %

Top 2nd 3.7 % 1.3 % 64.9 % 54.3 % 87.4 % 32.6 % 30.9 % 27.0 % 58.0 %

Middle 2nd 5.1 % 2.0 % 52.7 % 44.3 % 81.9 % 26.7 % 25.3 % 30.0 % 55.0 %

Top 3rd 6.5 % 3.0 % 44.7 % 36.9 % 76.4 % 22.3 % 20.5 % 31.0 % 49.0 %

Middle 3rd 8.1 % 4.6 % 30.0 % 25.4 % 69.1 % 17.6 % 15.6 % 34.0 % 45.0 %

Top 4th 9.9 % 6.0 % 22.1 % 16.7 % 63.1 % 12.9 % 11.7 % 36.0 % 40.0 %

Middle 4th 13.2 % 8.1 % 10.3 % 4.0 % 57.0 % 6.8 % 7.5 % 38.0 % 36.0 %

Bottom 4th 17.3 % 12.3 % 3.3 % 0.0 % 47.6 % 1.6 % 3.6 % 40.0 % 30.0 %

2
 10/14/2016

C MMS
KPI

A S SET ST RATEGY &

P R OCEDURES
ISO 14224 BOM

ACR Taxonomy Data Integrity

RCM FM EA P M O

KPI
A S SET MASTER
D A TA
TRAINING

A S SET
C R ITICALITY
RELIA BILITY JOURNEY
KPI
S T ART
!

C ON D ITION
M ON IT ORING
OD R
NDT PM
L u b rication
U l t rasound
S c heduling
I n f rared
P l anning Oi l
A n alysis
M o t or PM
t e sting
V i bration

W ORK
E X E CUTION
A l ignment & P recision A n alysis
B a lancing M a intenance
F o llow up

REACTIVE

W o rk Identification
KPI

M R O Optimization

S T OR E
W OR K P rocess C o n dition
M A NAGEMENT P a rameters I n dicators
M R O & SU PPLY C HAIN
M A N AGEMENT A S SET
H E ALT H

KPI
CMMS

Parts
Catalog

3
 10/14/2016

E x ecutive Op e rational H u m an
S p onsorship E x cellence M a n agement
C a p ital
V i sion

I S O 55000

WELCOME TO APM TOWN

I n c id ents SST A v a i lab ility

M a i n tena nce
P r o fit
C o s ts
$

BAD
KPI ACTOR
RCA
D E F ECT W E I BULL MT BF
E L IMINATION

C ON TINUOUS
I M PR OVEMENT

M E ASUREMENT
& C ONTROL

Core vs Support

• Is the Reliability Organization a core or support

function?

4
 10/14/2016

How your company views failure and

where would you like it to be?
Schools of Thought

Normal Accident Institution High Reliability

Theory
- Accidents in complex and
tightly coupled systems are
inevitable (Perrow 1981)
with the risk of an accident
increasing as complexity
increases or coupling
becomes tighter.
- There is a trade-off
between safety and other
operational outcomes such
as quality or productivity.
Theory Theory
- For legitimacy, - Accidents are
compliance as signal of preventable.
commitment, e.g. Organizations are
certification described as “mindful”.
- Increase sales and - HRT suggests that high
reputation but would reliability benefits all
not alter production operational performance
processes or the outcomes, not just
production system’s safety – can prevent
reliability accidents and failures,
quality defects, late
deliveries, etc.

High Reliability Organization (HRO)

• Main principle: “mindfulness”
• Understanding of unexpected events and emerging threats and
respond to them as soon as they appear
• Capable of tracking even the smallest of failures and ultimately
learn from them for future application
• Characteristics of HRO
1. Preoccupation with failure – reporting of errors, learn from
near-misses, articulate mistakes to be avoided
2. Reluctance to simplify
3. Sensitivity to operations – interaction with frontlines,
promote situational awareness
4. Commitment to resilience – capabilities in place to detect,
contain and bounce back to original state or better in times of
error
5. Deference to expertise – encourage expertise (group) vs
groups (singular)

5
 10/14/2016

Reliability Management

• Best view in the context of Asset Management

• ISO 55000:2014 defines:
• Asset Management as: “the coordinated activity of an
organization to realise value from assets” ; and
• An asset as an “item, thing or entity that has potential or actual
value to an organization”
• If integrated with the Operational Management
System, safety and operational efficiency are
optimized.

Asset Management

The first ISO standard for Asset Management

6
 10/14/2016

Asset Management Process

Asset Health Indices can also be referred to as:

• Equipment Health Rating(HER)

• Asset Condition Assessment (ACA)
• Asset Condition Index (ACI)

Essentially, an Asset Health Index can be defined as:

• A way of measuring the overall health of a asset
• A list of data parameters for an asset that feed into a calculated
health rating
• A way of comparing different asserts and asset classes in a
consistent manner
• An output of Big Data and asset analytics
• An input, or building block, to a broader asset management
process

Reliability
Frameworks

7
 10/14/2016

Reliability Framework

• What Reliability Management framework is suitable

for your operation?

Institute of Asset Management

8
 10/14/2016

Novelis Reliability Pyramid

Consisted of 14 Reliability Elements

Chevron’s Surface Equipment Reliability

Improvement Process (SERIP)

9
 10/14/2016

Shell’s Operation Excellence

Marshall Institute’s 8-Phase Reliability

Improvement Model

10
 10/14/2016

Reliasoft’s Asset Performance

Management

RasGas Integrated Asset Management

Model

11
10/14/2016

12
10/14/2016

13
10/14/2016

14
 10/14/2016

Integrity = Reliability

• The Integrity of the • The Reliability of the

System system
• The Integrity of the • The Reliability of the
structure structure
• The Integrity of the • The Reliability of the
brand brand
• The Integrity of the • The Reliability of the
data data
• The Integrity of the • The Reliability of the
person person

15
 10/14/2016

A Journey to Shape Reliability Excellence at

Bristol Myers-Squibb

16
10/14/2016

17
10/14/2016

18
10/14/2016

19
 10/14/2016

CRE Capabilities
 Facilitation of Uptime Elements as basis for Asset Management Plan
 Asset Health Index
 PM Optimization and Work Management
 Reliability Engineering Training with International Certifications
o SMRP Certified Maintenance & Reliability Professional (CMRP)
o AMP Certified Reliability Leader (CRL)
o ASQ Certified Reliability Engineer (CRE)
 Condition Based Maintenance Training with International Certification
o VI USA Vibration Analyst Cat. 1 & 2
o ICML Machinery Lubrication Technician I & Machinery Lubricant Analyst II
o Infrared Institute Certified Thermographer Level 1 & 2
o UE Systems Airborne Ultrasound Level 1
 Engineering and Reliability Management Training
 Maintenance & Reliability Basic Skills Training
 Customized In-House Training
 Consultancy Services
 Technical Books

Thank you!
Erwin Bernal, MLT I, MLA II
Sales Operations Manager
CRE Philippines
2f 718 Bldg. Shaw Blvd.
Mandaluyong City
Philippines 1552

Tel: +63 2 718 3480 loc. 402

Mobile: +63 917 500 8306
Email: e_Bernal@crephils.com

www.crephils.com

20