Fault Tree Maintenance - WERARDT Brief Presentation on FTM.pdf · Fault Tree Maintenance A...
Transcript of Fault Tree Maintenance - WERARDT Brief Presentation on FTM.pdf · Fault Tree Maintenance A...
Werardt started its Operations over 20 years ago, Developing Customized
Management Solutions & implementing its own software Products to the
Industry …
Thus acquiring expertise in a wide range of Domain areas and then sharing
it with its clients. In the process it’s focus is on enhancing and optimizing
Business Operations.
Werardt has a team of around 40 people for Development,
Implementation & Support
ABOUT WERARDT
PLANT ENGINEERING & MAINTENANCE
Primary Goal
To see that Production is NOT affected
due to Machine
Stoppages!
To use Best Practices so
that Asset Life is Enhanced
Daily Operations
To Ensure faster
Response time in attending to
Stoppages
Resource Utilization
To ensure Optimum
utilization of Manpower,
Spares & Contract
Resources
To Stop Fire-fighting, Do the right
things – at the right time – in
the right manner!
To achieve a higher level of
planning to ensure the
Primary Goal
Costs Incurred
To achieve something
tangible, you have-to spend something … judiciously!
To see that Operations
Add Value to the Asset Life
& Performance
PLANT ENGINEERING & MAINTENANCE
Primary Goal
To see that Production is NOT affected
due to Machine
Stoppages!
To use Best Practices so
that Asset Life is Enhanced
Daily Operations
To Ensure faster
Response time in attending to
Stoppages
Resource Utilization
Includes the use of
Manpower, Spares & Contract
Resources
To Stop Fire-fighting, Do the right
things – at the right time – in
the right manner!
To achieve a higher level of
planning to ensure the
Primary Goal
Costs Incurred
To achieve something
tangible, you have-to spend something … judiciously!
To see that Operations
Add Value to the Asset Life &
Performance
KEY ASSET OPERATIONS DATA
• The Technical Asset Register consisting of all Equipment
Equipment Breakup Subsystems LRU’s (Last Repairable Units)
• The Fault-Tree or Failure Modes & Causes
• Machine Specific Spares & Repairable Spares lists
• All Information documents in one place
• A paper-less Department Log Book
• Chronological records of Work done so as to get Equipment History
• Authentic Data of – Breakdowns, PM, Miscellaneous Jobs, Repair of Spares,
Opportunity or Proactive Jobs, Service Jobs, Refurbishing of Equipment,
Planned Jobs, AMC Management, etc.
• Resources utilized – be they Manpower or Spares
APPLYING BEST PRACTICES
• Ensure Data centric decision making
• Reduce the Response time for Attending any work
• Ensure the availability of Spares when required
• Maintain Inventory levels based on the Consumption pattern of Spares
• Continuous Improvement programs based on Problem Analysis
• Ensuring value-add in Contract Management activities
• Move from Unplanned-Procurement to Planned-Procurement
• Share Knowledge across Locations!
FTM HELPS YOU TO FOCUS ON YOUR PROBLEMS
Section wise Pareto (Dn.time OR Freq) Equipment wise Pareto (Dn.time OR Freq)
Dept. wise Distribution MTBF v/s MTTR
10
EQUIPMENT LIFE & RELIABILITY
PROPER Systems & Best Practices will Increase
Equipment ROI
IMPROPER practices will Reduce
Equipment ROI
Useful Life
Extend Life of Asset
Bath Tub Curve
Asset Register
Workflow Management
Resource Utilization
Your Factory Setup
Central Knowledge
Base
Enhanced Reliability
Enhanced Asset ROI
Reduced Cost
Happy Stakeholders
FTM IN SHORT
Asset Management
Spares
Failure Modes &
Causes
Resource or Manpower
Vendors
Breakdown Maintenance
Preventive Maintenance
Document Management
System
The TPM Module
Manpower Utilization
Repairs Management
AMC Schedule Monitoring
Miscellaneous Jobs & Tasks
Inventory Management
Spares Consumption
Utility Equip Monitoring
Reports Notifications &
Alerts
FTM MODULES
One excellent feature of the system is to adapt to the needs of
the culture of the organization. This starts with using the same
terminologies being used in the plant such as,
• Equipment or Equipment or Tag No.
• Section or Workshop or Line or Channel or Cell
• Region or Building or Unit or Plant or Division
• Job Request or Work Order or Work Request
• …
So on and so forth
During Startup FTM can be configured to use your Terminologies!!!
FTM IS MULTI-LINGUAL & MULTI-TERMINOLOGY
The Offline Mode of Entry
In an Offline mode of data entry, the maintenance users do the Job
entries on their own. Then, based on the availability of time, these
Jobs will be entered in FTM say, at the end of the Shift or Day or
Week or even at the end of the Month.
The Online Mode of Entry
In an Online mode of data entry, the Stores users will Log onto FTM
and send a request to Maintenance for attending a Job.
On the Maintenance users Pending Jobs screen a Pop-up screen will
tell him that a new job has arrived which he then can see in his
Pending jobs list.
WORKFLOW MANAGEMENT IN FTM
• B/D Breakdown Jobs
• PRTL Partial Breakdowns
• OPRT Opportunity Maintenance Jobs
• SERV Service Jobs
• MISC Miscellaneous Jobs
• PM Preventive Maintenance Jobs
• ABPM Activity Based PM
• REPRS Repairs of Spares
• CB Instrument Calibration
• R/M Reconditioning & Modifications
• … and others
Jobs Directly Affecting Business (Downtime Jobs)
Jobs Not Directly Affecting Business (Zero Downtime Jobs)
VARIOUS TYPES OF WORK RECORDED IN FTM
B/D
PRTL
OPRT
SERV
PM / ABPM
REPRS
MISC (User Defined)
CB
Factory
Prod. Divn-1
Prod. Divn-2
Prod. Divn-3
Section-1 Section-2
Machine-1 Machine-2
Attached Documents
Specific Spares
Instruments & Gauges
4 Level Machine Breakup
YOUR PLANT & WORK MANAGEMENT
Man PowerSpares
Internal External
Consumable Repairable
B/D
PRTL
OPRT
SERV
PM / ABPM
REPRS
MISC (User Defined)
CB
Fault Nature
Fault Code
Cause
Cause 1
Cause 2
The Fault Tree
Machine Specific
Knowledge
WORK & RESOURCE MANAGEMENT
Phase-I Foundation Phase
This is the phase, where we will setup systems and
procedures and a data collection framework for
Maintenance to operate in,
Phase-II Sustenance Phase
This is the phase where we would wish to make use of the
data, analyze it and take right action so as to control
costs, optimize resources and increase throughput
Phase-III Achieving Excellence
This is the phase where we would want to align towards
world class management techniques such as TPM, LEAN,
Reliability, 6 Sigma, etc. to achieve a higher Plant ROI
A PHASE WISE SUCCESSFUL APPROACH
Centrally Located FTMApplication Framework
A Common Collaborative Management Dashboard
Multi-Location Maintenance Operations
MULTI-LOCATION SOLUTION FRAMEWORK