identifying critical spare parts & recommending stock...
TRANSCRIPT
1
Identifying Critical Spare Parts amp Recommending Stock levels ndash JIG amp DMS Plants
Camrin Janse van Rensburg
2019-05-14
2
Agendabull Purpose of Project
bull Value Add of Project
bull 5 Steps Followed ndash ASampR Asset Criticality Tool utilised
1 System Criticality
2 Asset Criticality
3 Search for Spares - Sources of Information
4 Material Criticality
5 Service Levels amp Duplication
bull Example of the Tool used
bull Consequences amp Likelihood tables
bull Rates worked at
bull Final List - Stats
bull Assumption Decisions Inclusion amp Exclusions
bull Sources of Information
bull Learnings amp Recommendations
bull Special Thanks
3
Purpose of Project
Purpose of Project
bull Identify Critical Spares to part level(BOM) and specify the stock levels to be kept on-site
4Value Proposition of Project
Value Proposition of Project
NB Only if spares are listed and kept on stock will project add value1 1 Mean Time To Repair
12 Production losses
13 Failure Avoidance ndash Components about to fail replaced timeously jobs scheduled
12 Anglo Americanrsquos vision for asset-care(P101 target) achieved ie liners
13 Possible reduction in squirrel stores ndash Trust in stores could be rebuilt
14 Reduced Safety risk ndash Preventing temptation to bridge out ie probes
15 Reduced Non-compliance risk ndash ie trip-wires
16 Artisan Overtime Costs
5Criticality Process
Anglo American Criticality Analysis Tool utilized ndash FMECA process rarr
bull Arranged SAP follow
Ore Flow
bull Performed with
MS+Production
bull Signed off - Section
Engineer
bull Risk Matrix
bull Services added
additionally
bull Elevators
bull Overhead Cranes
bull Compressed Air
bull Electrical Distribution
System Criticality
bull ForemenMaster
Artisans
bull Signed off - Section
Engineers
Asset Criticality
bull Sources to be
discussed
Search for Spares
bullCategories
bullEquipment
Criticality
bullSHE
bullMHSAMine
Regs
bull Absence of
Spare impact on
Asset
bullSupply Lead
time
bullSensitivity
bull gt 30 = C1
bull16-29 = C2
bull0 ndash 15 = C3
Material Criticality
bullPurchase History
bullNo of unitsasset
bullNo of units
across all Critical
Assets
ServiceLevels
Hyperlink to Sheet
6
Example of Tool used
7
Consequence amp Likelihood tables
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
2
Agendabull Purpose of Project
bull Value Add of Project
bull 5 Steps Followed ndash ASampR Asset Criticality Tool utilised
1 System Criticality
2 Asset Criticality
3 Search for Spares - Sources of Information
4 Material Criticality
5 Service Levels amp Duplication
bull Example of the Tool used
bull Consequences amp Likelihood tables
bull Rates worked at
bull Final List - Stats
bull Assumption Decisions Inclusion amp Exclusions
bull Sources of Information
bull Learnings amp Recommendations
bull Special Thanks
3
Purpose of Project
Purpose of Project
bull Identify Critical Spares to part level(BOM) and specify the stock levels to be kept on-site
4Value Proposition of Project
Value Proposition of Project
NB Only if spares are listed and kept on stock will project add value1 1 Mean Time To Repair
12 Production losses
13 Failure Avoidance ndash Components about to fail replaced timeously jobs scheduled
12 Anglo Americanrsquos vision for asset-care(P101 target) achieved ie liners
13 Possible reduction in squirrel stores ndash Trust in stores could be rebuilt
14 Reduced Safety risk ndash Preventing temptation to bridge out ie probes
15 Reduced Non-compliance risk ndash ie trip-wires
16 Artisan Overtime Costs
5Criticality Process
Anglo American Criticality Analysis Tool utilized ndash FMECA process rarr
bull Arranged SAP follow
Ore Flow
bull Performed with
MS+Production
bull Signed off - Section
Engineer
bull Risk Matrix
bull Services added
additionally
bull Elevators
bull Overhead Cranes
bull Compressed Air
bull Electrical Distribution
System Criticality
bull ForemenMaster
Artisans
bull Signed off - Section
Engineers
Asset Criticality
bull Sources to be
discussed
Search for Spares
bullCategories
bullEquipment
Criticality
bullSHE
bullMHSAMine
Regs
bull Absence of
Spare impact on
Asset
bullSupply Lead
time
bullSensitivity
bull gt 30 = C1
bull16-29 = C2
bull0 ndash 15 = C3
Material Criticality
bullPurchase History
bullNo of unitsasset
bullNo of units
across all Critical
Assets
ServiceLevels
Hyperlink to Sheet
6
Example of Tool used
7
Consequence amp Likelihood tables
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
3
Purpose of Project
Purpose of Project
bull Identify Critical Spares to part level(BOM) and specify the stock levels to be kept on-site
4Value Proposition of Project
Value Proposition of Project
NB Only if spares are listed and kept on stock will project add value1 1 Mean Time To Repair
12 Production losses
13 Failure Avoidance ndash Components about to fail replaced timeously jobs scheduled
12 Anglo Americanrsquos vision for asset-care(P101 target) achieved ie liners
13 Possible reduction in squirrel stores ndash Trust in stores could be rebuilt
14 Reduced Safety risk ndash Preventing temptation to bridge out ie probes
15 Reduced Non-compliance risk ndash ie trip-wires
16 Artisan Overtime Costs
5Criticality Process
Anglo American Criticality Analysis Tool utilized ndash FMECA process rarr
bull Arranged SAP follow
Ore Flow
bull Performed with
MS+Production
bull Signed off - Section
Engineer
bull Risk Matrix
bull Services added
additionally
bull Elevators
bull Overhead Cranes
bull Compressed Air
bull Electrical Distribution
System Criticality
bull ForemenMaster
Artisans
bull Signed off - Section
Engineers
Asset Criticality
bull Sources to be
discussed
Search for Spares
bullCategories
bullEquipment
Criticality
bullSHE
bullMHSAMine
Regs
bull Absence of
Spare impact on
Asset
bullSupply Lead
time
bullSensitivity
bull gt 30 = C1
bull16-29 = C2
bull0 ndash 15 = C3
Material Criticality
bullPurchase History
bullNo of unitsasset
bullNo of units
across all Critical
Assets
ServiceLevels
Hyperlink to Sheet
6
Example of Tool used
7
Consequence amp Likelihood tables
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
4Value Proposition of Project
Value Proposition of Project
NB Only if spares are listed and kept on stock will project add value1 1 Mean Time To Repair
12 Production losses
13 Failure Avoidance ndash Components about to fail replaced timeously jobs scheduled
12 Anglo Americanrsquos vision for asset-care(P101 target) achieved ie liners
13 Possible reduction in squirrel stores ndash Trust in stores could be rebuilt
14 Reduced Safety risk ndash Preventing temptation to bridge out ie probes
15 Reduced Non-compliance risk ndash ie trip-wires
16 Artisan Overtime Costs
5Criticality Process
Anglo American Criticality Analysis Tool utilized ndash FMECA process rarr
bull Arranged SAP follow
Ore Flow
bull Performed with
MS+Production
bull Signed off - Section
Engineer
bull Risk Matrix
bull Services added
additionally
bull Elevators
bull Overhead Cranes
bull Compressed Air
bull Electrical Distribution
System Criticality
bull ForemenMaster
Artisans
bull Signed off - Section
Engineers
Asset Criticality
bull Sources to be
discussed
Search for Spares
bullCategories
bullEquipment
Criticality
bullSHE
bullMHSAMine
Regs
bull Absence of
Spare impact on
Asset
bullSupply Lead
time
bullSensitivity
bull gt 30 = C1
bull16-29 = C2
bull0 ndash 15 = C3
Material Criticality
bullPurchase History
bullNo of unitsasset
bullNo of units
across all Critical
Assets
ServiceLevels
Hyperlink to Sheet
6
Example of Tool used
7
Consequence amp Likelihood tables
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
5Criticality Process
Anglo American Criticality Analysis Tool utilized ndash FMECA process rarr
bull Arranged SAP follow
Ore Flow
bull Performed with
MS+Production
bull Signed off - Section
Engineer
bull Risk Matrix
bull Services added
additionally
bull Elevators
bull Overhead Cranes
bull Compressed Air
bull Electrical Distribution
System Criticality
bull ForemenMaster
Artisans
bull Signed off - Section
Engineers
Asset Criticality
bull Sources to be
discussed
Search for Spares
bullCategories
bullEquipment
Criticality
bullSHE
bullMHSAMine
Regs
bull Absence of
Spare impact on
Asset
bullSupply Lead
time
bullSensitivity
bull gt 30 = C1
bull16-29 = C2
bull0 ndash 15 = C3
Material Criticality
bullPurchase History
bullNo of unitsasset
bullNo of units
across all Critical
Assets
ServiceLevels
Hyperlink to Sheet
6
Example of Tool used
7
Consequence amp Likelihood tables
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
6
Example of Tool used
7
Consequence amp Likelihood tables
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
7
Consequence amp Likelihood tables
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
8
Consequence amp Likelihood tables
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
9
Rates worked at ndash how long will this take me
Planned Actual Reason
Identification of System level
+- 16minsystem line
15minline ndash JIG6minline ndash DMS
bull Initially failuresconsequences were discussions
bull Failure causes amp impact understood 2nd time round
Identification of Asset level
04minasset line 103minline bull More assets than estimated
Identifying Spares of Critical Assets
068minasset line 162minline bull Time taken to search for spares unknown
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
10
Final List Stats - JIG
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
11
Final List Stats - JIG
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
12
Final List Stats - DMS
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
13
Final List Stats - DMS
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
14
Assumptions amp Decisions 5 Assets Critical on Safety Low on Production not taken
forward
6 Smallest maintainable item ie Crusher up to O-ringsGearboxes up to Gearbox
7 Do you consider Fire Suppression parts Yes youshould In this case stock kept by Contractor
8 Equipment not considered critical Walkways LightsGuards Platforms Cable racks
9 JIG ndash Assume Link One Manuals are correct dataunless informed otherwise
10 DMS ndash Assume SAP orders are most recent and correct
11 P101 targets is it best practice to run the machinewithout that spare If the spare is not there impact onasset
12 Stock level recommendations consider
121 Same spare used on different places
122 Realistic number of spares replaced in one go
1 Failure scenarios -
bull Worst possible
bull Most likely
2 Systems = Dam walls bursting Conveyor structures burning down
3 Assets = Pump or Gearbox failures
4 Consequence and Likelihood if
bull No maintenance was performed
bull No spare kept on site
bull Installed redundancy considered
bull Hard Controls considered ie fire suppression temperature probes
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
15
Sources of Information
1 Equipment changed without updating Master Data at Drawing Office
2 Link One very useful tool when used correctly
3 Pulley Register Plumber-block amp adaptor sleeve registers ndash Drawing office amp reliability engineers
4 Service Equipment ie NB Overhead Cranes Electrical Distribution amp CampI obtained from Foremen Artisans
Contractors ndash Often overlooked
5 Links to existing SAP Functional Locations
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
16
Learnings amp Recommendations
1 NB NB - Update Link OneMaster Data for Sustainability ndash One source of information
2 Linking correct spares to Functional Locations on SAP
3 Specifically - Add Electrical Distribution amp Overhead Cranes Technical Information to SAP
and Link One
4 Pre-populating with possible failures amp consequences prior to confirming with client
worked better
5 Measure time worked - Actual times will assist greatly with future work
Support Equipment Critical Equipment
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
17
Special Thanks
Team members - Scheepers Schoeman amp Darius Booyens for putting in 15hr days
Gordian ndash Jelmen Grundel for Optimizing Stock levels
18
Any Questions
Thank you
18
Any Questions
Thank you