Reliability (Data) Based

Maintenance

The Road to Lower Costs and

Increased Reliability

W. (Wouter) Luimes

Director Business Development EMEA

Copenhagen

October 26th, 2016

ABS Group – History

Mission:

‘to be a leading global provider of technical services that better enables our clients to operate safely, reliably,

efficiently and in compliance with applicable regulations and standards. We are focused on adding value to the

industries we serve.’

Building on a Legacy of Marine Technical Services:

• Safety, risk and integrity management are at the core of everything we do.

• We began providing non-classification marine services in 1971 from our original headquarters in New York.

• Over the decades, we have worked as a strategic partner of the American Bureau of Shipping (ABS), one of

the world's leading marine and offshore classification societies founded in 1862.

• We have continued to build on ABS Group's reputation for setting standards of excellence in the marine and

offshore industries as an independent technical services provider.

• Today, the ABS Group operating subsidiaries support an even broader spectrum of highly technical industries

that power, fuel and regulate our world.

• ABS Group, which refers to one or more affiliated companies, is a subsidiary of ABS.

• Intro to ABS Group

• Reliability Based Maintenance

• Reliability Based Maintenance in a Class Environment

• Future Developments

Content

ABS Group Organizational Overview

Global Presence

Industries • Offshore &

Marine

• Oil, Gas &

Chemical

• Pharmaceutical/

Biotechnology

• Power

• Government

Regions • Americas

• Asia Pacific

• Europe

• Middle East

• Africa

ABS Group – Selected Clients

Core Solution Areas

Software THESIS BowTie

Asset Performance Optimization Services

Strategy & Process

Asset Reliability

Asset Reliability Services • Equipment / Asset Walk-Downs

• Reliability Engineering

• PM Optimization

• Predictive Maintenance

• Mechanical Integrity/PSM

• Failure Modes & Effects Analysis

• Spare Parts Program

• Planning & Scheduling

Systems & Technology Services • EAM System Source Selections

• EAM System Gap Analysis

• EAM System / CMMS (Maximo, DataStream, SAP

PM, JDE, Oracle) Implementations & Upgrades

• Calibration / Metrology Solutions

• Document Management & GIS Systems

• Hand-Held Technologies

• System Integration

• System Validation

• EAM System / CMMS Support

• ASP Hosting

Strategy & Process Services • EAM Assessment & Master Planning

• Product & Process Robustness

• ISO 55000

• EAM Strategy Planning & Process

Consulting

• KPI Development / Benchmarking

Assessments

• Reliability Program Implementation

• MRO Supply Chain Optimization

• Workflow Process Optimization

• Educational Services & Certifications

• Intro to ABS Group

• Reliability Based Maintenance

• Reliability Based Maintenance in a Class Environment

• Future Developments

Content

Modern Day Reliability Principles

Contribution of Modern Day Reliability Principles to the Economic Value of the Boeing 747

Reliability Based Maintenance

A prescriptive, standardized approach to develop and sustain a rational maintenance

program that ensures optimal asset reliability

Reliability Based Maintenance Methodology

MAL ACR PMO SPA RAM RCA

Identify Assets

Prioritize Assets

Optimize PM Program

Analyze Spare Parts

Monitor PM Program

Determine Failure Causes

RBM Workflow

True or False? Most assets become more likely to fail as they get older

Asset Failures

Traditional View Pattern A = 2%

False!

Failure Pattern Study – Age Related vs. Random

Best New Pattern D = 7%

Constant Random Pattern E = 14%

Infant Mortality Pattern F = 68%

Random Failures = 89%

Traditional View Pattern A = 2%

Bathtub Curve Pattern B = 4%

Slow Aging Pattern C = 5%

Age Related Failures = 11%

P-F Curve Considering Maintenance Types

Ass

et

Co

nd

itio

n

Time

Asset failure begins

Asset failure is detectable by

Operators

Point (F) Functional

Failure

Asset failure is detectable by

PM

Asset failure is detectable by

PdM

Point (P) Potential

Failure

Asset function

stops “Life is better at the top of the curve!”

Life at the Bottom • Plan on the fly • Expedite Parts • Parts Not Available • Extended Outages • Hurry and Fix It Fast • No Time to Analyze Failure • High Impact on Operations • Rework

Life at the Top • Time to Plan and Schedule • Parts can be Ordered • Less Parts on Site • Less Costly Repairs • Less Impact on Operations • Data to Analyze Failure • Time to Analyze Failure • Less Rework

Benefit to Condition Based Maintenance

Preventive

Reactive

Rel

iab

ility

& A

vaila

bili

ty

Maintenance Cost

Data ~ Condition Based

Analysis ~ Reliability Based

Predictive

Proactive

Time Based

Breakdown

Maintenance Program Optimization

Two Options

The Most Critical Assets: FMEA

Most Complex approach

Most time consuming

Very systematic way of looking at

the functions of maintainable

items to determine most likely

causes of their loss of function

Ensures that crafts are engaged in

the process and revisions to PMs

Other Assets: PM Optimization

Less complex than FMEA

Contains the same process

Has some of the same same steps

(e.g. failure modes, failure effects,

revised maintenance activities

tied to failure modes)

Genesis software tool

Load Optimized program into CMMS for use across

Entire Enterprise

World Class Maintenance Labor Mix

18

• Intro to ABS Group

• Reliability Based Maintenance

• Reliability Based Maintenance in a Class Environment

• Future Developments

Content

Maintenance Planning

OEM

Condition Based

Maintenance

(CBM)

Planned

Maintenance

(PM)

FMEA

Experience

Company

Procedures

Maintenance Plan Development

Maintenance

Task Type

Run to Failure

Maintenance

Maintenance Plan

Computerized Maintenance

Management System

(CMMS)

Equipment

Criticality

High

Medium

Low

Asset Performance Management

Concept FEED Design Construction Operations Decommissioning

Machinery Systems

Assist owners/operators in adoption of reliability and performance based maintenance

programs

Technical Lead on Condition Monitoring (CM) and Condition Based Maintenance (CBM)

Help operators to leverage for Class advanced maintenance and asset health strategies

Expand traditional class tools and services, leverage data centric concepts to enable a

more efficient class approach with less operational disruptions

Asset Integrity Management - AIM

Leverage operational and class data into innovative concepts, tools and practices needed by clients to

improve their assets’ operational efficiency, simplify regulatory compliance, and improve safety

Machinery Integrity and ABS

New ABS Draft Guide for Surveys

based on Machinery Maintenance

Programs • Crediting of PM, CBM, PdM plus

maintenance plan optimization approaches

• Incorporates old ABS RCM guidance & adds

new streamlined RBM approach

• New Design for Reliability (DFR) section to

address reliability from equipment design

Complementary CM Guidance

Notes • Covers all CM methods

• Includes “big data analytics” type

approaches

Data Integrity for Marine and Offshore

Operation • Data sources

• Data integrity

• Data security

New 2016 Maintenance Guide and CM GN

(ABS CyberSafetyTM)

• Intro to ABS Group

• Reliability Based Maintenance

• Reliability Based Maintenance in a Class Environment

• Future Developments

Content

• Data Rich Environment

• Ship Network and Automated Data

• Prognostic and Diagnostic Tool Support

• Smart EAM

Available Data and the SMART Ship

Network Server

Vessel Control Room

Performance and Health Data

Propeller and Hull Performance

Shore Side office

Vessel’s Network

Marriage of Performance and Maintenance Data

26

Performance Management

•Hull / Propeller Performance

•Engine Performance

•Shaft Data

•Cargo Stowage

•Trim / Draft

•Fuel Oil / Lubricants

•Emissions

•Weather Data

•Ballast Water Management

Performance Improvement

Maintenance Management

•Condition Monitoring

Thermography

Tribology

Vibration

Ultrasonic

Operational Data

•Predictive Maintenance

Data Capture Tools

•Automation Systems

•Log Books

•Record books

•Planned Maintenance

Operational Excellence

Optimized Maintenance

Data Analysis

Data Capture Tools •Data Historian

•Instrumented Machines

•Integrated Automation Systems

Improved Reliability Improved Uptime

Improved Bottom Line Crediting to Special Survey

Company Confidential

What Does Tomorrow Look Like

27

Class Use of ASSET Data

Client Use of ASSET Data

SMART ASSET Data

● Continuous

● Condition Based

● Risk & Data Informed

Company Confidential

What is FutureClassTM ● Class is Wider and Deeper

– Cyber Safety and Security

– Energy and Environment

– Asset Integrity

● Data Centric Future

– New Inspection Technologies

– ABS Maximo and Nautical Systems

– Smart Assets

● Adaptive to Changing Business Environment

– Marriage of Asset Health, Performance and Class

– New Tools, Methods and Predictive Analytics

28

White Paper Data Analytics Frame work

29

7 key factors required to succeed in Data Analytics: • Set the Vision & Foundation

• Strategic Business Opportunities

• Select the Best Data Analytics Approach

• Secure the Data

• Extract the Insights

• Define and Execute Responses

• Continuous Improvement

For more information:

wluimes@absconsulting.com

www.abs-group.com