Presented by Alain Pellegrino

1. CH2S
CH2
SPARTAKUS™
THE LINK BETWEEN STRATEGIC OBJECTIVES AND RELIABILITY INITIATIVES
OVERVIEW

2. RELIABILITY
ASSESSMENT

3. STRATEGY
DESIGN A DETAILLED ACTION PLAN FOR YOUR MAINTENANCE
AND RELIABILITY PROGRAM

4. RELIABILITY
PROGRAM
Vision and master plan

5. PROBLEMATIC
“THE MAP IS NOT THE TERRITORY”
Alfred Korzybski
PERFORM A MAINTENANCE AND RELIABILITY ASSESSMENT
SO THAT YOUR RELIABILITY INITIATIVES AND STRATEGIC
OBJECTIVES ARE FINALLY LINKED TOGETHER

6. RELIABILITY ASSESSMENT
RELIABILITY
SPECIALIST
2 DAYS
PLANTINTERVIEWS WITH STAFF

7. ASSESSMENT
250 QUESTIONS
Question 1: ………….
Question 2: ……
Question 3: ………………………..
Question 4: ………….
Question 5: …………….
Question 6: ………….
Question 7: …………………………
Question 8: ………….
Question 9: ………….
Question 10: …………………
Question 11: ……….
Question 12: …….
Question 13: ………….
Question 14: …….
RELIABILITY ASSESSMENT

8. ASSESSMENT
250 QUESTIONS
Question 1: ………….
Question 2: ……
Question 3: ………………………..
Question 4: ………….
Question 5: …………….
Question 6: ………….
Question 7: …………………………
Question 8: ………….
Question 9: ………….
Question 10: …………………
Question 11: ……….
Question 12: …….
Question 13: ………….
Question 14: …….
DELIVERABLE
OBSERVATIONS
RECOMMANDATIONS
FIGURES
3 YEARS ACTION PLAN
DYNAMIC AND EVOLUTIVE

9. ASSESSMENT
250 QUESTIONS
Question 1: ………….
Question 2: ……
Question 3: ………………………..
Question 4: ………….
Question 5: …………….
Question 6: ………….
Question 7: …………………………
Question 8: ………….
Question 9: ………….
Question 10: …………………
Question 11: ……….
Question 12: …….
Question 13: ………….
Question 14: …….
DELIVERABLE
SPARTAKUS

10. DELIVERABLE
EVOLUTION
Monitor the
improvement of your
plant's maturity while
you are completing
reliability projects.
KPI
Update and display
your OEE or overall
plant uptime on a
dynamic dashboard.

11. DELIVERABLE
DASHBOARDS
AND KPI
Each pillar has its
own dashboard and
its own KPI that can
be updated and
monitored.
ASSET MASTER
DATA
WORK
MANAGEMENT
ASSET HEALTH
MANAGEMENT
LEADERSHIP FOR
RELIABILITY
INVENTORY
MANAGEMENT
DEFECT
ELIMINATION
CRAFT
SKILLS
Data collected
(as a % of all assets)
80%
(Goal: 100%)
Up 20%

12. DELIVERABLE
DASHBOARDS
AND KPI
Each pillar has its
own dashboard and
its own KPI that can
be updated and
monitored.
ASSET MASTER
DATA
WORK
MANAGEMENT
ASSET HEALTH
MANAGEMENT
LEADERSHIP FOR
RELIABILITY
INVENTORY
MANAGEMENT
DEFECT
ELIMINATION
CRAFT
SKILLS
Data collected
(as a % of all assets)
80%
(Goal: 100%)
Up 20%

13. COMPARE YOURSELVES TO THE BEST
Take advantage of 9 years of analysis of published &
private survey data from sources such as SMRP, CMA,
Townsend, Solomon, AISE, SAE, PIMA, TAPPI, EPRI and
AT Kearny. Benchmarks are set for 11 different types
of industries.
1st quartile 2nd quartile 3rd quartile 4th quartile

14. OUR OBSERVATIONS VS. TODAY’S BEST PRACTICES
Observations Best practices
Work Identification Here’s what we found out during our visit…Here’s
what we found out during our visit…Here’s what we
found out during our visit…
Any maintenance employee can create a work order as long as
detailed information is provided. Operators bring feedback to
maintenance personnel and corrective ….
Work Prioritization Here’s what we found out during our visit…Here’s
what we found out during our visit…Here’s what we
found out during our visit…
Work Orders are prioritized thanks to asset criticality ranking,
time to failure and work types. Daily meetings between
maintenance a…..
Planning Here’s what we found out during our visit…Here’s
what we found out during our visit…Here’s what we
found out during our visit…
Planners received a specific training. They exclusively manage
future work and do not get involved into reactive work. Jobs
are planned 2 to 3 weeks in advance. A Job Plan database is
available and includes …………..
Scheduling Here’s what we found out during our visit…Here’s
what we found out during our visit…Here’s what we
found out during our visit…
Schedulers are informed of the available maintenance
workforce, by skillset, for the upcoming weeks. They
coordinate with Operations during a weekly meeting to
schedule planned work, provide spec………
Follow-up and
Analysis
Here’s what we found out during our visit…Here’s
what we found out during our visit…Here’s what we
found out during our visit…
Failure coding is widely used when closing Work Orders to fuel
the failure elimination work process. Feedback from the teams
is recorded on the Work Orders(schedule conflict, parts
missing), planners…..
Details

15. ACTION PLAN
Your dashboard was created
2016-01-05
Reliability analytics definition
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Completed on
2016-03-15
Completed
Asset master data workshop
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Completed on
2016-04-19
Completed

16. Criticality analysis
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End on
2016-09-01
In progress
Data collection
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End on
2016-08-19
Late
PMO - FMEA – RCM
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Start on
2016-09-15
Not started
!

17. VIZUALISE YOUR IMPROVEMENT
ASSESSMENT
250 QUESTIONS
Question 1: ………….
Question 2: ……
Question 3: ………………………..
Question 4: ………….
Question 5: …………….
Question 6: ………….
Question 7: …………………………
Question 8: ………….
Question 9: ………….
Question 10: …………………
Question 11: ……….
Question 12: …….
Question 13: ………….
Question 14: …….
RECOMMENDATION #1
A PREVENTIVE MAINTENANCE OPTIMIZATION PROCESS SHOULD BE PUT IN PLACE FOLLOWING THE
CRITICALITY ANALYSIS OF THE EQUIPMENT. THE OPTIMIZATION PROCESS SHOULD BE BASED ON THE
ANALYSIS OF THE FAILURE MODES AND THEIR EFFECTS FOR EACH EQUIPMENT CLASS (EG, AC MOTOR,
CENTRIFUGAL PUMP, RECIPROCATING COMPRESSOR). A CUSTOMIZED MAINTENANCE STRATEGY SHOULD BE
BUILT TAKING INTO ACCOUNT OF EACH FAILURE MODE AND THE CRITICALITY OF EACH ASSET. PREVENTIVE
MAINTENANCE FREQUENCIES SHOULD BE OPTIMIZED AND RELATED TASKS SHOULD BE FORMULATED
OBJECTIVELY. THE USE OF PREDICTIVE TECHNOLOGIES MUST BE MAXIMIZED AND ALL NON-VALUE ADDED
TASKS SHOULD BE ELIMINATED.
START DATE: JAN 1ST 2017
END DATE: MAR 31ST 2017
MIN COST: 25000$
MAX COST: 36000$
EDIT AND UPDATE STATUS, ENTER PROGRESSION,
COMMENTS, ETC.
COMPLETE

18. VIZUALISE YOUR IMPROVEMENT

19. ASSET HEALTH

20. MONITOR WHAT MATTERS
VIBRATION
OIL ANALYSIS
THERMOGRAPHY
ULTRASONICS
PRIORITIZE YOUR ACTIONS THANKS TO A
DYNAMIC DASHBOARD THAT INCLUDES
OPERATIONAL RISK AND GLOBAL PLANT HEALTH

21. PRIORITIZE YOUR ACTIONS
DASHBOARD PRIORITIZES
ACTIONS BY AREA AND/OR
ASSET

22. PRIORITIZE YOUR ACTIONS

23. VISUALIZE YOUR RESULTS IN 2 CLICKS
VISUALIZATION AND PDF
EXPORT

24. HEALTH DEFINED AT EACH LEVEL OF THE HIERARCHY
FOCUS ON WHAT MATTERS
FAILURE CODES, OBSERVATIONS,
RECOMMENDATIONS
!
EXPORT IN PDF AND ATTACH TO
YOUR WORK ORDERS
PDF

25. MANAGE CLIENTS/SITES/HIERARCHY
PLANT A
0100 – RECEIVING
0200 – REFINING
0300 – PAPER MACHINE
0200-AGI-001 AGITATOR 1
0200-PUL-030 PULPER 3
MOTOR AC
GEARBOX
ETC.
PLANT
AREA
AREA
AREA
EQUIPMENT
EQUIPMENT
COMPONENT
COMPONENT
COMPONENT
CLIENT CLIENT

26. OVERALL WORKFLOW
RESULT ENTERED IN
SPARTAKUS
NO FURTHER ACTION REQUIRED
YES
NO, RESULT IS NORMAL
FREQUENCY
BASED
REQUIRED
ACTION?
VIB. MEASUREMENT
TAKEN BY TECH
OPEN
ALERT
CORRECTIVE ACTION
PLANNED
IN PROGRESS
ACTION
CORRECTIVE ACTION
PERFORMED
COMPLETED
ACTION
VALIDATION
READING
REQUIRED
SUCCESS APPROVAL.
SAVINGS ARE
RECORDED
RESULT CONFIRMS
PREVIOUS PROBLEM HAS
BEEN FIXED
!

27. RESULTS AND ALERTS CLASSIFICATION
COLORS
Urgency Urgent Critical Attention Abnormal Normal
Action
Immediate action
required
Plan for next
shutdown
Follow
recommendation
Monitor closely -
Severity 25% 50% 75% 95% 100%
ALERTS/ACTIONS
!
OPEN IN PROGRESS COMPLETED APPROVED

28. CORPORATE GLOBAL VIEW

29. AVAILABLE
EVERYWHERE
ON ALL PLATFORMS

30. THANK YOU