Presentation given at the MaRS Symposium in Galveston Texas

1. Developing a Reliability Based System from Scratch A Path to Success! Casey A. Connolly CMRP,PMP,SSBB, Lean Master Gulf Chemical & Metallurgical Corporation August 19-20 Moody Gardens Galveston, Texas

3. Preliminary Investigation MaRS 2010 From Innocence to Excellence Maintenance Grid Strategy Human Resource Management Planning and Scheduling Maintenance Tactics Performance Measures Information technology Employee Improvement Reliability Analysis Process Analysis Excellence (5) Set corporate maintenance strategy/asset strategy Multi-skilled independent trades Long term and major project planning and engineering All tactics employee based on analysis Equipment effectiveness, benchmarking, full cost database Fully integrated common database Autonomous work teams Full value risk program Regular reviews of process cost, time, quality Competence (4) Long term improvement plan Some multiskilling Good job planning, scheduling, engineering support Some CBM, some PM, few surprises MTBF/MTTR availability, separate maintenance costs Fully functional, linked to financials/materials Continuous improvement teams Some FMECA applied Some review of administration, engineering and trades procurement Understanding (3) Annual improvement plan Decentralized mixed trades groups Planning group established, ad hoc engineering Time and use based inspections, some NDT Downtime by cause, maintenance cost available Fully functional, no link to other system Formal workplace improvement committees Good failure database, well used Some review of trades processes, tactics Awareness (2) PM improvement plan Partly centralized for some trades Trouble shooting support, inspection scheduling Time based inspections Some downtime records, maintenance costs not segregated Basic maintenance scheduling, some parts records Some improvement, safety meetings Collect the data, little use A one time review of maintenance process Innocence (1) Mostly reactive to breakdowns Highly centralized No planning, little scheduling or engineering Annual shutdown inspections only No systematic approach, maintenance costs not available Manual or ad hoc specialty system Only mandated meetings No failure records Never reviewed

4. Needs Assessment

8. Design of Experiments MaRS 2010

11. Show Benefits of Reliability Program MaRS 2010 Multiples of 1X running speed indication of mechanical looseness and misalignment. Additional raised floor on low and mid frequencies indicative of possible bearing wear or mechanical looseness but shows more life can be obtained before a change is needed. High 1X running speed indication of mass unbalance issue. This has been verified by system shut down and visual inspection.

13. Measure Effectiveness MaRS 2010

14. Program Culturalization MaRS 2010 Develop approval checklist for new designs that incorporates all levels of the organization

15. Balance New Designs MaRS 2010