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    Randy torfin, lcm presentation Randy torfin, lcm presentation Presentation Transcript

    • MSC Maintenance Management Systems and Life Cycle Management MSCHQ N711 & PM 1
    • Agenda
      • Maintenance Management Policy
      • Reliability Initiatives
      • Life Cycle Management Planning
      • N7 Maintenance Management Programs
      • USFFC Maintenance Initiatives
    • Policy: Framework ~ MSC Mission (Guiding Document)
    • Policy: MSC’s Maintenance Philosophy
      • The people:
        • Providing skilled, career, licensed marine shipboard engineers
        • Maintaining trained, motivated and forward thinking shoreside management
      • The tools:
        • Providing technology and tools to analyze existing conditions and enhance maintenance planning and execution
    • Policy: MSC Maintenance Policy Documents
    • Policy: MSC Maintenance Policy Documents
      • COMSC Instruction 47XX.X Ashore Maintenance Management Policy
        • Planned Maintenance Development Process
        • Maintenance Effectiveness Reviews
        • Maintenance Feedback Process
        • SAMM Audit
        • Post Availability Analysis
        • Work Item Library Management
        • Root Cause Analysis Implementation Process
      • COMSC Instruction 3540.6A Engineering Operations and Maintenance Manual (EOMM)
        • Preventive Maintenance
        • Corrective Maintenance
      • More simply put, the 3-Rs:
      • The R ight Maintenance
        • on the R ight Equipment,
        • at the R ight Time,
      • Employ an efficient and cost-effective maintenance approach that strives to ensure safety, meets regulatory requirements and supports reliability in support of MSC mission.
      • Maintenance: The set of actions taken to ensure that components, equipment and systems provide their intended functions when required.
      • Reliability: The ability of an item to perform a required function when needed.
      • Function: The intended action or operation which it is intended to perform.
      Policy: Maintenance Strategy
    • Design/ Build Storage Maintain Operate Install/ Startup Root Cause Analysis Defects Defects Defects Defects Defects Reliability: THE RELIABILITY PROCESS Source: Making Common Sense Common Practice 3 rd Edition By Ron Moore Reliability Centered Maintenance Uptime & Necessary Work Loss of Ship Availability and Equipment Downtime Unnecessary Maintenance and Repairs
    • Reliability: MSC Maintenance Technology Adoption Lifecycle
    • Reliability: Paradigm Shift “ Prove to me that failure won’t occur if you change this.” “ Prove to me that failure will occur if I change this.” Limits of Applicable and Effective Maintenance CM Cost PM Investment Total Maintenance Cost Cost $
      • DO WE HAVE THE RIGHT MAINTENANCE?
        • How does this equipment effect our Maintenance Cost?
          • Total Maintenance Cost
            • Annual Cost of Maintenance as a Percent of Asset Replacement Cost
            • PM cost vs. CM cost
        • Does this equipment perform when I need it?
          • Operational Availability
            • Mean Time Between Failure
            • Mean Time To Repair
        • What is the Reliability of the equipment at X hours of operation?
          • Reliability R(t)
            • Mean Time Between Failure
      Reliability: Measures
    • LCM: Background
      • Life Cycle Plans intended to assist with Life Cycle Management of all NFAF ships and to refine POM and budget development .
      • Development of Life Cycle Plans for all NFAF ships identified as a FY 10 Corporate Plan Initiative, removed mid-year to be picked up in FY 11-12.
      • Life Cycle Plan development will be coordinated with MSFSC and N7.
        • Plans will also include regulatory body life cycle requirements.
        • Will benchmark with US Navy and commercial industry practices where possible
        • Reviewing Integrated Class Maintenance Plans (ICMP), met with Maersk Lines Limited
    • LCM: Current Status
      • Way Ahead brief presented to COMSC
      • Multi-year effort with contractor support required.
      • Activation/Deactivation schedules identified for all classes
      • Critical equipment/systems (as found in SMS and SAMM records) have been identified for all ship classes
      • T-AOs identified as first class for Plan development
        • Contain most mature data, largest ship class and at midpoint of life cycle
        • As reported in POM 12 class beginning to experience life cycle issues
      * T –AOE Class commissioned 1994, MSC Operation 2001 ** T-ARS Class commissioned 1986, MSC Operation 2006 *** T-AH Class commissioned 1976, MSC Conversion 1986 SHIP CLASS EXPECTED SERVICE LIFE T-AKE 40 YEARS T-AOE 40 YEARS* T-AO 35 YEARS T-ATF 40 YEARS T-ARS 20 YEARS** T-AH 30 YEARS***
    • LCM: Current Status (continued)
      • Benchmarking with Commercial Industry and NAVSEA Surface Ship Life Cycle Management (SSLCM) Activity continues
        • Mtg held end of Aug with Surface Maintenance Engineering Planning Program (SURFMEPP) formerly SSLCM to share information and ideas
        • Reviewing Technical Foundation Papers and Ship Sheets for methodology and processes
      • T-AKE Equipment Life Cycle Matrix being mapped to T-AO configuration
    • LCM: Way-Ahead
      • Conduct market research to identify COTS software and contractor support for Life Cycle Management planning
        • Shipping and Stationary Plant Industries
      • Conduct solicitation for software and contractor support if identified from market research
      • Using SAMM, PENG, and CMLS data for T-AO MPDE determine Total Maintenance Cost and Mean Time Between Repair (MTBR)
        • To include data external to systems such as service order data, tech reports, etc. for period prior to implementation of CMLS
      • Apply MTBR methodology to rest of critical equipment
    • LCM: Way Ahead (Continued)
      • Identify all Operational, Intermediate and Depot Level Maintenance for T-AO Class from SAMM/PENG/Service Orders and Port Engineers to Establish Baseline LCM Plan
      • Integrate T-AO OERA results, MSFSC 5-YR M&R data, and planned TRANSALTs into Life Cycle Plan
      • Present Life Cycle Plan for T-AO Class to All Stakeholders
      • Continue development for next ship class: T-AKE
    • Integrate, Execute, Document and Feedback (MSFSC/PM1) Technical Requirements Execute Plan Long Range Requirements into Availabilities (PM1/N7/MSFSC) Document & Feedback Class LCM Requirements Ship LCM Baseline Schedule & POM Integrate Package Plan Availability Balancing Technical, Operational, and Financial Risk to increase Ao and decrease $$ LCM: Life Cycle Management Plan
      • SAMM 5.07 Service Pack 3 Development
        • Internet Browser Interface
        • Dashboard
        • Machinery History and Condition Monitoring Module Integration
        • Workbook, Maintenance, and Repair Module Integrated
        • Depot Level PM visible in Maintenance Module
        • Virtual Tech Library Integration
      • PENG Web Development
      • MSC IS Portal Development
        • Corrective Maintenance (Ashore PM Tool, TRANSALT Manager)
        • Condition Based Monitoring Analysis
        • Data Maintenance Manager
        • PENGWeb Integration in Corrective Maintenance
        • Virtual Tech Library Integration
      • SnapShot Development to combine SMART and OCI Inspection
    • N7 Maintenance Management Programs: MSC IS Portal
      • Life Cycle Management
      • Voyage Repair Request
      • Life Cycle Management
      • Voyage Repair Request
      • Industrial Maintenance (Depot & Intermediate)
      N7 Maintenance Management Programs: MSC IS Portal
      • Life Cycle Management
      • Voyage Repair Request
      • Industrial Maintenance (Depot & Intermediate)
      • Service Orders
      N7 Maintenance Management Programs: MSC IS Portal
      • February 2011:
      • TRANSALTs
      • PENGWeb
      N7 Maintenance Management Programs: MSC IS Portal
    • USFFC: Maintenance & Supply Working Group IT EXCOMM
      • The MSWG vision is to develop an integrated naval maintenance and supply IT solution set that aligns capability development to mission needs and delivers affordable enhancements through standardization of processes and tools, and cost efficiencies through IT automation.
      • Enterprise Options
        • A: All SAP
        • B: Some Maintenance in SAP / Some Bolt-Ons (w/Navy ERP Supply and Financials)
        • C: Existing IT Consolidation Plan (w/Navy ERP Supply and Financials)
        • D: Single GOTS Maintenance Solution (w/Navy ERP Supply and Financials)
      • Due to time constraints in support of POM 12 decision, options B and C will be the primary focus of the MSWG strategy
    • USFFC: Maintenance & Supply Working Group IT Applications
    • USFFC: MSWG Maintenance Strategy
      • Common Technical Requirements
      • Drives to Single Processes
      • Reduces “Stovepipes”
      • Increases Functionality
      • Classified/Unclassified
      • Shore and Deployable
      Enterprise Solution (ERP + bolt-ons) Number of Apps 400 300 200 100 0 2009 2016 MFOM SMLIS NALCOMIS NDMS 2012 2014 Transition to ERP Group Apps into “ Family of Systems” Reduce # Apps to Support Transition to Enterprise Solution Identify ERP Early Adopters Requirements ERP early adopters MSC IT Align with ERP Reduce Apps Group
    • USFFC: MSWG Maintenance Strategy
        • Purpose : “ …to provide guidance on the most cost effective standardize maintenance requirements and assessment procedures across Carrier, Submarine and Surface Ship Enterprises….
        • Activities
          • Identify Maintenance Requirements for Review
          • Conduct Maintenance Reviews using principles of RCM
          • Identify best practices for cross-enterprise implementation
          • Develop policies and other documentation to institutionalize the strategies and practices
      USFFC: Common Maintenance Planning Working Group
      • Common Areas of Interest with MSC
        • Upcoming NAVSEA Maintenance Effectiveness Reviews
          • Cargo/Weapon Elevators – Dec 6 – 10, 2010
          • Reverse Osmosis – Aug 8 – 12, 2011
          • Start Air Compressors – Sept 12 – 16, 2011
        • Upcoming Best Practices Sessions
          • Piping Nov 8 thru 11
        • Upcoming CMPWG briefing
          • CFFC – March 2011
      USFFC: CMPWG Events