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Equipment Criticality


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Criticality is a tool that allows the objective evaluation of the potential consequences of equipment breakdown on a plant as a result of functional failures. It helps determine the characteristics that make one piece of equipment more critical to overall plant performance than another.

Published in: Business, Technology
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Equipment Criticality

  1. 1. Deploying Criticality Analysis in Multi-Plant Reliability Improvement Programs Michel Cote & Serge Mathieu Prosygma Reliability and Maintenance Professional Services 1
  2. 2. What is Criticality ? A tool used to evaluate how equipment failures impact organizational performance in order to systematically rank plant assets for the purpose of : PM /PdM Development To prioritize activities dedicated to PM / PdM development or optimization Material Classification To better prioritize work out of the maintenance backlog 2 Reliability Improvement Initiatives To support MRO initiatives to identify critical spares Work Prioritization To ensure that reliability improvements are made based on risk rather than perception
  3. 3. The Process Cross-functional analysis and input from Operations and Maintenance, and as required, input from Engineering, Material Management, Environment and Health and Safety representatives Weigh the impact of a failure on each asset across all 4 criteria Impact on safety (0 to 4) x Impact on environment (0 to 4) x Impact on quality (0 to 4) 3 x Impact on cost or production (0 to 4) = 0 to 256
  4. 4. Impact on Safety 0 Potential to cause death or permanent injuries 1 Potential to cause non-permanent bodily injuries 2 Potential to cause significant inconvenience to personnel 3 Potential to cause minor inconvenience to personnel 4 Will have no significant impact on personnel 4
  5. 5. Deploying Criticality Analysis in a Multi-Plant Reliability Program 5
  6. 6. One of the Major Tissue Producers in North America • Quebec (4) • Ontario (2) • Wisconsin (1) • Pennsylvania (2) • North Carolina (1) • New York (2) • Oregon (1) • Arizona (1) • Tennessee (1) Mills located in the United States Mills located in Canada 6
  7. 7. The Objective • For all of the 15 mills, associate a criticality ranking to each asset in the CMMS. The Challenge • Have the criticality ranking done for all of the 15 mills within a schedule of 8 to 12 weeks. • A total of 45,000 assets, ranging from 600 to 16,000 per mill. 7
  8. 8. Criticality Ranking The criticality ranking is calculated by multiplying each of the scores (from 0 to 4) obtained for each of the 4 criteria. The total is then converted into one of the following 4 criticality rankings, namely A,B,C or D. Equipment Number PE-002 PE-005 VE-100 AG-201 CL-403 Description Pump xyz Pump ABC Blower YYZ Agitator DBC Air Conditionning Criticality Evaluation Environment Quality Economical 4 4 1 4 4 2 4 4 3 1 4 4 4 4 4 Safety 4 4 4 0 4 Evaluation Score Criticality Ranking 0 ≤ Criticality ≤ 96 Extreme 97 ≤ Criticality ≤ 145 High 146 ≤ Criticality ≤ 193 Moderate 194 ≤ Criticality ≤ 256 Low =A =B =C =D 8 Total = 64 128 192 0 256 Criticality Ranking A B C A D
  9. 9. Lessons Learned • Prevent mill personnel from taking shortcuts –this is an objective and quantitative process • Avoid entering rankings one by one - work with IT to import the criticality rankings in the CMMS • Take the time to explain the advantages of a criticality ranking system • Make sure equipment hierarchy is adequate before you start 9
  10. 10. Keys to Success • There is a wide variety of criticality tools and methods out there, Keep it simple! • Make sure to adapt the matrix with the operational context of each facility • It is OK to use the copy/paste method for identical or very similar equipment in a facility • Make sure you arrive prepared and organized 10
  11. 11. Questions ? Michel Cote: Serge Mathieu: WWW.PROSYGMA.CA 11