Reliability (Data) Based Maintenance The Road to Lower ...The Road to Lower Costs and Increased...
Transcript of Reliability (Data) Based Maintenance The Road to Lower ...The Road to Lower Costs and Increased...
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