Improving Equipment Reliability Using a CMMS-EAM com

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www.ipamc.orgBen Stevens OMDEC Inc –

Improving Equipment Reliability using a CMMS/EAM

Improving Equipment

Reliability using a CMMS/EAM

Ben Stevens, OMDEC Inc -

IPAMC 2006





CMMS/EAM EvolutionPhase 0 – Manual

operation, no

CMMS

Phase 1:

Automate Forms:

Work OrdersPurchase Orders

Issue slips

Time cards

Specifications

Project led by IT;

KPI’s are IT

efficiency,database type

35%

Phase 2:

Automate Processes:

Work Request/Work

Order

Work Order/

Material Issue

Work Order/

Purchasing

Project led by IT;

KPI’s are IT

efficiency,

database type,

degree of

integration

40%

Phase 3:

Use of Workflow,

Work Management

Emergence of EAMMerge and

eliminate tasks

Streamline

functions

Project led by

Business Unit;

KPI’s are cost

reduction,materials usage

employee

productivity

20%

Phase 4:

Analysis,

Information,

Knowledge Base,

Integration with

intelligent agents

to improve the

quality of the

Maintenance Plan

Project led by

Maintenance;

KPI’s are equipment

reliability, number of failures, quality of

maintenance, use of

best practices

5%





Cost of Failure

Cost of Failure =

Cost of Repair +

Cost of Lost Revenue +Penalty Costs





Failure Costs





470,000

193,000

Run Risk

470:361 =1.3:1

193:40 =

5:1

Risk

Ratio

60 days

28 days

Failure

time

15%

25%

Failure

Probab

30 days

250,00061,000,000week20,000ukoTurbine

100,0000,000,0005 hours5,000iigata

Diesel

Failure

Cost

Repair

Risk

Outage

cost per

Hour

Repair

Time

Repair

Cost

Unit

The Risks of Equipment Failure





Cost

Time

Run

Risk

Run

Risk

Repair

Risk

Repair

Risk

Next Scheduled

Outage

Risk versus Time in Equipment

Failure





Aug 1 Sep 1 Oct 1 Nov 1

20

15

10

5

Maximum Acceptable

Level of risk

Next Planned

shutdown date

Predicted Risk

Ratio level

Risk Ratio

Equipment Failure Risk Ratio

Improving Equipment Reliability Using a CMMS-EAM com

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