SKF Asset Management Services


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SKF Asset Management Services

  1. 1. SKF Asset Management Services Your trusted resource for life cycle support and sustainability of physical assets
  2. 2. SKF Asset Management Services People, processes and technology to optimize asset efficiency and effectiveness In virtually every industry, in every part of the world, industrial facilities are turning to outside experts to help them optimize their processes and plant assets to remain competitive in a global economy. SKF Asset Management Services brings a unique combination of expertise, services and tools to benefit your organization. With 100 years of manufacturing experi- Our industry experts have multiple ways ence and knowledge of rotating machine of looking at every machine, system and reliability; decades of consultancy exper- process – all to optimize asset efficiency tise in process industries; and leadership in your unique organization. in condition monitoring, SKF provides a complete array of strategic and tactical SKF Asset Management Services offers: asset management services worldwide. • Experience and expertise • Proven methods We begin with a proven process to identify plant improvement opportunities • Technology enablers and help develop solutions. Our consul- • Measurement systems tants work to understand your business • Ongoing support goals, application challenges and plant culture to create a road map for You believe that an effective asset improving reliability. Together with you, management strategy can benefit your we develop strategies and programmes organization, but where do you begin? to achieve bottom-line results. The answer is wherever you are.
  3. 3. SKF Asset Management Services has the people, processes and technology to assist with: Strategic planning Work logistics Assessments and benchmarking Application engineering Achieving business goals Maintenance engineering Risk analysis Reliability engineering Maintenance strategy review Maintenance management systems Spares and inventory management Life cycle costing Asset performance SKF Asset Management Services focuses on Strategy, Identification, Control, Execution, and Optimization. Improvement can begin anywhere along the continuum and proceed indefinitely – a living process for asset optimization.
  4. 4. Defining and measuring success Strategize Assessments and benchmarking Maintenance strategy development and review By obtaining a comprehensive Choosing the right technologies and processes to maximize asset efficiency understanding of your plant’s unique requires knowledge and experience to identify and pursue the highest value requirements, our consultants can strategies for your unique situation. SKF has the people, processes and identify improvements that help you technologies to help you choose the most appropriate path. achieve optimum results. Our assessment tools provide a snapshot of current maintenance efficiency. Criticality analysis SKF SRCM process We help you not only measure Our unique Point-Based Criticality (PBC) SKF SRCM is an RCM process that uses performance against benchmarks and is a qualitative method to establish and substantially less time and resources, best practices within your company rank equipment criticality at system and yet achieves results by focusing on the or industry – we develop continuous tag level without considering individual dominant failure modes of equipment improvement options. machine failures. The points-based and the significant effects of those system uses severity and frequency failures. Critical areas include plant safety, Key Performance Indicators of failures in safety, environment and environmental and regulatory violations, and Balanced Scorecard production, and delivers a relative reduced production or shutdowns. RCM Because success depends not just criticality ranking. and SRCM change the maintenance on one department or function, it’s culture by helping plant personnel important to link major operational Reliability-Centered Maintenance (RCM) develop an appreciation for a reliability- perspectives with your business A core tool in the development of a based maintenance strategy. objectives. One way to accomplish maintenance strategy, RCM is often this is with the establishment and recommended for detecting and prevent- Risk-Based Maintenance (RBM) measurement of Key Performance ing failures where criticality is high and A quantitative, financially-based analysis Indicators. SKF can help to assess confidence in existing maintenance is low. technique, RBM establishes the relative performance based on business The process determines what is required worth of various maintenance tasks and objectives, define critical indicators for an asset to keep fulfilling its intended serves as a continuous improvement tool. and recommend actions to reach a function in its present operating context. RBM defines opportunities for incremental targeted goal. Using the Balanced RCM is effective in delivering a roadmap improvement by eliminating low-value Scorecard approach, our experts help of appropriate tasks, frequencies, tasks and introducing tasks that address to establish individual and group goals, man-hours and skills mix. high commercial risk areas. Risk-based and map and measure results desired. maintenance evaluates the current Failure Modes and Effects commercial risk and analyzes the costs Analysis (FMEA) and benefits of steps to mitigate failures. FMEA, an integral part of the reliability- centered maintenance process, identifies equipment failures and consequences by examining ways a component or machine can fail; causes for each failure mode; and effects of each failure. Especially useful during the design or operational phases, results are used as input to design trade- offs, safety engineering, maintenance engineering, maintainability, logistics service support analysis, test equipment design and planning, and more.
  5. 5. Risk Based Inspection (RBI) Fleet Maintenance SKF expertise extends to defining Recommendation Analysis inspection levels based on Risk Based (FMRA) Inspection analysis. To provide a high In an FMRA, SKF and client experts quality outcome, the analysis examines work together to organize common assets risks of regulatory categories; failure across the fleet by reviewing existing consequences; remaining life prediction strategies and maintenance tasks for and equipment deployment. The analysis common assets, and developing a includes corrosion management and fleet-wide plan to improve equipment inspection intervals optimization to reliability. conform to industry specifications and legislation. Spares and inventory management Regulatory Integrity Level Managing inventories means balancing Analysis – Safety, Environment, supply and demand to achieve minimum and Commercial (SIL, EIL, CIL) asset ownership with minimum risk to SKF performs regulatory inspections reduce the total cost of inventory. SKF for SIL, EIL, and CIL to determine risk in has a Spare Parts Alignment, Rational- equipment designed to protect people ization and Optimization programme to and assets, and recommends appropriate identify and address problems or audit risk reduction measures. This approach an existing programme. The process considers the consequence of failure, takes into consideration downtime exposure probability, possibility of avoid- costs; delivery lead-times; safety and ing the hazard and demand rate. Based environmental consequences; capital on the level of risk and acceptability, cost; warehouse charges and write-off Ident function test frequency can be calculated costs. Analysis is applied to critical, slow ify based on the probability of failures and taking credit for levels of redundancy in safety systems to ensure maximum moving, expensive spare parts with an actionable report showing recommenda- tions for spare parts purchase based on availability of protective equipment. cost versus risk. SKF experts are trained in meeting OSHA, EPA and individual regulatory agency requirements to gain or remain in compliance.
  6. 6. Identifying asset performance Identify SKF asset performance services use proven processes and enabling technologies to determine the condition of equipment and predict when maintenance will be required. The process begins by collecting condition monitoring data from process instrumentation installed on the machine for continuous monitoring or portable diagnostic equipment used for periodic inspections. Recorded data such as machine vibration, thermography, lubricant condition, motor current analysis, process parameters and more can be stored, analyzed and trended using SKF asset performance management software. Our experience with prognostics and decision support systems facilitates knowledge retention, increased confidence and consistent analysis and action. Predictive Maintenance (PdM) Proactive Reliability Operator Driven Reliability (ODR) Predictive Maintenance is a process Maintenance (PRM) SKF was a pioneer in the Operator aimed at detecting a machine condition Through a defined process including Driven Reliability process empowering that will eventually lead to failure and best practice predictive maintenance operators to be a proactive resource then estimating the amount of time activities, the root causes of failures are to contribute to a company-wide before failure occurs. While most PdM systematically diagnosed and proactive maintenance strategy. Enabled by programmes stop at detecting a problem steps are taken to help eliminate their automated technologies, operators and making a residual life prediction, recurrence. This process incorporates perform tasks that include process SKF uses this information as the basis setting and using performance indicators parameter inspections, minor adjustments, to diagnose the problem with the and regular operational reviews to and general observations of machine objective to determine which proactive monitor improvements toward performance. An SKF ODR programme tasks are necessary to achieve an benchmarks for your industry. enables operators to accurately and extension of machine life. consistently record, trend, store, communicate and act upon process and inspection data to generate improvements in process availability.
  7. 7. Controlling work logistics with effective planning and scheduling Control Planned Maintenance Resource Leveling/ Routines (PMR) Work Packaging SKF can help to coordinate maintenance To simplify the scheduling process activities with production schedules without requiring an expensive and machine availability to improve planning software package, SKF production efficiency and promote developed Resource Leveling/Work cross-functional communication. By Packaging – a simplified, cost-effective aligning maintenance tasks to business approach of assigning Planned goals based on asset criticality, safety, Maintenance Routines to a long-term environmental and financial impact, schedule based on the average monthly measurable improvements can be made. man-hours for each PMR frequency. Some benefits include increased main- This approach can prove very effective tenance productivity, greater reliability of when maintenance regimes contain many existing capacity, improvement in uptime, relatively short-duration PMRs, and and enhanced personnel satisfaction by will produce a smooth manning profile meeting production targets and business throughout the scheduling period. goals. Effective planning and scheduling results in efficient Planned Maintenance Turnaround management Routines that can be incorporated While downtime that “just happens” into new or existing Computerized can be disastrous, a carefully planned Maintenance Management Systems shutdown can provide your maintenance (CMMS) or Enterprise Asset Management department with a rare opportunity to Ident Systems (EAM). identify and address issues in order to ify improve plant safety and efficiency. SKF can assist you in prioritizing needs and identifying what can be accomplished within time and budget restraints. Our project managers can prioritize and schedule the order of activities; plan for new or additional work during a shut- down; report and document preparation and execution, and identify future needs.
  8. 8. Expert execution – enabling asset improvements Execute Precision maintenance Applications engineering Based on 100 years of expertise in SKF offers a unique combination of bearings, SKF provides comprehensive competencies from different fields of service programmes for rotating engineering, including virtual testing machinery maintenance including using dynamic simulations of rotating precision alignment and balancing to machinery; lubrication and surface correct faults and optimize machine engineering, and material analysis and running time. We conduct bearing failure evaluation. SKF consultants can support analysis and root cause analysis to you from the first ideas to the realization determine why the failure occurred and of the products, and continue with you take corrective action to help eliminate on the aftermarket with evaluation of repetitive failures. field tests, lubrication management or finding the root cause to rotating Post-maintenance testing machinery problems. Our comprehensive approach can include bearing installation, technology advice, lubrication management, machine upgrades, rebuilding, redesign and refurbishment of bearings and assemblies. Our experts can conduct post-maintenance testing as a quality control to verify the effectiveness of equipment maintenance.
  9. 9. A living process for continuous improvement Optimize Reliability, Availability and The reliability engineering approach also Function Test Interval (RAFTI) provides a closed-loop framework for Calculator organizational learning – all of the This tool makes it easy and convenient information gathered and developed to automatically determine equipment during the model’s implementation is availability, reliability and function test fed back to the starting point to refine intervals to increase reliability of the the strategy. SKF consultants deploy overall system. The calculator allows the industry-standard statistical analysis user to evaluate the resulting Function techniques such as reliability growth, Test Interval (FTI) given a desired probability distribution and the cost of reliability and Mean Time Between Failure unreliability. Reliability, Availability and (MTBF) or calculate availability given a Maintainability (RAM) desired FTI and MTBF. Another comprehensive method is the Reliability, Availability and Maintainability Reliability engineering analysis, in other words, system Reliability engineering collects and modeling. SKF uses proven RAM analyzes data to either predict future methodology to provide an integrated reliability or to determine the causes of analysis of expected system performance past unreliability to help prevent their based on system design, operations and recurrence. SKF uses proven reliability maintenance. RAM models are used to engineering approaches to identify and evaluate reliability issues around specific coordinate critical elements to help equipment and/or systems focusing on improve key asset reliability. These include the cost implications through cost/benefit an effective maintenance and implemen- analysis of proposed changes. tation strategy; quality data capture and retention; the ability to determine key plant or equipment failures; a structured repeatable method of failure analysis and a method of capturing and implementing analysis recommendations.
  10. 10. A living process for continuous improvement, cont’d Optimize Root Cause Analysis (RCA) Root Cause Analysis seeks to identify the sequence of events leading to failures and creates a plan to help prevent future failures. The SKF service is based on the theory that every failure Building and implementing a stems from three causes: physical or Maintenance Management System technical causes; human causes such SKF Asset Management Services can as errors of omission or commission; help to build, implement and support latent or organizational causes that an Enterprise Asset Management stem from the organization’s systems, (EAM) system to integrate configuration operating procedures and decision- management, work execution, making processes. After investigating planning and scheduling, preventive each category, SKF delivers a set of maintenance, spare part management, causes and effects plus a comprehensive inventory and purchasing. Our plan of corrective actions to prevent experienced consultants create a recurrence. custom solution by thoroughly defining system requirements, selecting a Life Cycle Costing (LCC) system, developing interfaces, The Life Cycle Cost of any asset is the converting data, creating reports, cost of acquisition plus the total cost and managing data warehousing. of ownership, including operation and Continued support is available to maintenance costs. An SKF Life Cycle Cost optimize logistics, provide training analysis determines the future value of and perform application support maintenance engineering decisions on Computerized Maintenance made while developing a maintenance Management Systems (CMMS) management system. The LCC is and other plant-wide information associated with the total cost of management systems. ownership because by the time the maintenance system is under develop- ment, the design is complete and the asset is usually in the construction phase with 60-70 % of its maintenance costs already built in. However, significant cost savings can still be achieved by optimizing the maintenance required to meet the asset’s defined business goals, reliability targets, and production profile. An SKF LCC analysis compares a variety of scenarios for the asset to determine the best return for a given investment profile.
  11. 11. Real world success stories Oil refineries After three months, the maintenance Bulgaria’s LUKoil Neftochim refinery strategy was put into operation and at Bourgas is a subsidiary of LUKoil, the LUKoil was satisfied with the results and leading oil and gas company in Russia asked SKF to complete an additional and the biggest refinery in the Balkans. programme for three more units. When the refinery was transformed from The client expressed that in addition to a government-owned operation to a technical changes, there was the added privatized company, a goal was to raise benefit of creating positive cultural performance to world standards – or changes in medium-level engineers. better. The overall objectives were to most critical to continuing operation of increase the reliability of the refinery the plant received the highest level of while lowering maintenance and repair maintenance work. RBI evaluated the costs and reducing risks to safety, health risk element to make sure that inspec- and environment. tion and maintenance were prioritized for equipment where the probability of LUKoil chose SKF to perform an SKF failure was highest and consequences SCRM analysis to develop an optimized of failure most grave. reliability-based maintenance strategy, and a Risk-Based Inspection (RBI) study to focus on mechanical integrity. SKF SRCM concentrated on the reliability factor to make sure that the equipment SKF developed a Proactive Maintenance The customer reported: Programme applied to all key systems, encompassing 27 coal and gas-fired • 30 % reduction in equivalent forced operating units at 15 power plants. SKF outage rate (EFOR) studied the systems over a 30-month period. Implementation included: • 7 % increase in peak period reliability • Developed documentation for the • 30-40 % reduction in high priority maintenance programme corrective work • Focused planned maintenance on Power plants critical equipment and dominant After several years of cost-cutting measures, failure mechanisms a large utility was experiencing reliability • Emphasized condition-based tasks and performance problems. There was • Eliminated unnecessary routine and a clear need to improve performance outage tasks by decreasing equipment failure while ensuring properly focused maintenance • Reduced maintenance costs resources. • Improved availability and reliability
  12. 12. ® SKF and SRCM are registered trademarks of the SKF Group. © SKF Group 2006 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein. Publication 6406 EN Printed in Sweden on environmentally friendly paper.