dave alexander – august 2010 developing a sustainable maintenance strategy a living program acarp...

Dave Alexander – August 2010

Developing a Sustainable Maintenance Strategy

A Living Program

ACARP

Roadway Development Operators Workshop September 2010

Slide 2Dave Alexander – August 2010

Winston Ledet 1994 Du Pont Study

Tactic Up time % Change

Uptime Downtime Reduction

Reactive 83.5% 0%

Planning Only + 0.5 %

Scheduling Only + 0.8 % Preventive /

Predictive Only - 2.4 %

All three tactics + 5.1 % 88.6 % 30.9% Plus Defect Elimination

+ 14.8 % 98.3% 89.7%

Slide 3Dave Alexander – August 2010

The Vicious Cycle of Reactive Maintenance

Backlog grows

PM is missed

Temporary Repairs

More repeat work

Resources taken by Breakdowns

Head / Budget Reduction

Standards Drop

Slide 4Dave Alexander – August 2010

Holistic Approach

• The Right People

• The Right Time

• The Right Stuff

• Continually Improve

Slide 5Dave Alexander – August 2010

Road Map Example

Slide 6Dave Alexander – August 2010

A Fundamental Question

As equipment gets older, is it more likely to fail?

Slide 7Dave Alexander – August 2010

Founders of RCM - Nowlan & Heap found that failures could be grouped into 6 patterns

Co

nd

itio

nal

Pro

bab

ilit

y o

f F

ailu

re

Age

CC 5%

A 4%

B 2%

F 68%

D 7%

E 14%

Slide 8Dave Alexander – August 2010

Failure Mode Driven Strategy

Slide 9Dave Alexander – August 2010

Optimising The Maintenance Plans

PMO is a process which uses principles of Reliability Centred Maintenance (Failure Mode Analysis) to to rationalise existing maintenance strategies

Using the structure of the RCM, fitters, electricians and engineers review all of the PM tasks that are currently utilised in the CMMS and also analysed the failure history

Tasks not addressing a failure mode are removedTasks are rewritten to be descriptiveSpecifications are providedCorrective Actions are writtenIllustrations are inserted

Slide 10Dave Alexander – August 2010

Maintenance Tasks

Slide 11Dave Alexander – August 2010

PMO Analysis

Slide 12Dave Alexander – August 2010

Optimising The Maintenance Plans

Slide 13Dave Alexander – August 2010

Group Task Libraries

Shuttle Car

- Frame- Wheel End- Hydraulics- Electrics- Cable Reel- Drive System

Slide 14Dave Alexander – August 2010

Strategy Change Control

Slide 15Dave Alexander – August 2010

Governance

• Schedule Compliance

• PM Effectiveness

• Routine Order Start Date

Slide 16Dave Alexander – August 2010

Living System (DDA)

Downtime Data Analytics

Major Delay Minor Delay Detail Delay Equipment Level 2 Equipment Level 3 Equipment Level 4 Failure ModeContinuous Miner 01 - Air/Water 02 - Water Filter Assembly Element   BlockageContinuous Miner 06 - Hydraulics 05 - Hoses Wing Extension Retraction Hose JIC Fitting Cross ThreadedContinuous Miner 04 - Electrical System 12 - Electrical System Control Solenoid Coil Insulation Fractured

Slide 17Dave Alexander – August 2010

Living System (DDA)

Downtime Data AnalyticsEquipment Level 2 Equipment Level 3 Equipment Level 4 Failure Mode

Filter Assembly Element   Blockage

Wing Extension Retraction Hose JIC Fitting Cross Threaded

Control Solenoid Coil Insulation Fractured

Group Library

Slide 18Dave Alexander – August 2010

Living System (RCA)

Slide 19Dave Alexander – August 2010

Questions&

Answers