Organized by:

Show me the Value!

Felix M Laboy, CMRP, CRL

Jesus M Laboy, MBA, CMRP

What is Condition Based Maintenance?

• Condition Based Maintenance (CBM) is a maintenance strategy that uses the actual condition of the asset to indicate what maintenance needs to be done.

• CBM dictates that maintenance should only be performed when certain indicators show signs of decreasing performance or upcoming failure.

Welcome to the 90’s

Dramatization: 1990

Situation: Meeting Room

• We need less failures

• What can we do?

Dramatization: 2015

Situation: Meeting Room

• We need to increase availability and decrease our maintenance costs!

• We need to do MORE with LESS.

• What can we do?

Objectives

Strategy

Value

• Asset Management Policy

• EHS Policy

• Quality Policy

• Mission / Vision

Objective

• High Quality Products

• Low Production / Maintenance Cost

• On Time Delivery

• Zero Loss Time

Strategy

• Reliability Centered Maintenance

• Total Productive Maintenance (TPM)

• Lean Manufacturing

• Risk Management

Objectives“Got it:

• Objective 1: increase equipment availability

• Solution: Buy more systems. A redundant system, is a reliable system!

• Objective 2: reduce maintenance cost

• Solution: Predictive Maintenance!”

Increase Availability

+ =

Reduce Maintenance Cost

=

Equipment

+Training

+Calibration

Pray to the Reliability Gods

W. Edwards Deming

To Achieve Success

Focus on Improving

the System Not On

Individual

Performance

Felix Laboy

іMi Santo,

No Seas Abusador!

Proactive Workflow ModelAsset Catalog

Criticality Analysis

Failure Modes Analysis

Equipment Maintenance Plans (EMP)

PM/PdMInspections

Results of PdM

Preventive & Predictive Work 80%

of Total Work

MOC Procedures Planning MOC Procedures

Scheduling

Daily Coordination

Work Performed

Requested Work 20% of Total Work

Job Plan Improvement

Equipment Reliability

Improvements

MOC Procedures

Failures Breakdowns

Ass

et H

ealt

h A

ssu

ran

ce

Failure Modes Analysis

Failure Codes Creation

Work Order History Analyis

Root Cause Analysis

Strategy Adjustment

F.R.A.C.A.SKaizen Loop

Pro

acti

ve W

ork

flo

w M

od

el

Source: AlliedReliabilityGroup

Method / Process

• Proactive Workflow Model

– Focused on failure elimination

– Reduces maintenance costs and increases availability

– Implementing CBM is a tool necessary to realize the company's value objectives

– No need to justify CBM technologies if the right process is used!

Real World Results: Utilities

Real World Results: Packaging Line

0

50

100

150

200

250

300

350

400

450

Actual New

70% Reduction in

Scheduled Maintenance

Downtime Hours

Eliminate: No added value

10% Reassign to operators

26%

Replace with PdM11%

Redesign22%

No change31%