Show Me the Value! - a CBM Strategy Development Story
This document discusses condition-based maintenance (CBM) and how implementing a proactive workflow model focused on CBM can help organizations achieve objectives like increasing equipment availability and reducing maintenance costs. It presents dramatizations of meetings from 1990 and 2015 where organizations discuss how to address these objectives with less failures and resources. The proactive workflow model incorporates things like failure mode analysis, preventative maintenance inspections, and root cause analysis to perform mostly predictive and preventative work. Real-world results from utilities and packaging lines show significant reductions in scheduled downtime hours and maintenance costs when implementing this CBM-focused approach.
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Show Me the Value! - a CBM Strategy Development Story
- 1. Organized by: Show me the Value! Felix M Laboy, CMRP, CRL Jesus M Laboy, MBA, CMRP
- 2. What is Condition Based Maintenance? • Condition Based Maintenance (CBM) is a maintenance strategy that uses the actual condition of the asset to indicate what maintenance needs to be done. • CBM dictates that maintenance should only be performed when certain indicators show signs of decreasing performance or upcoming failure.
- 5. Dramatization: 1990 Situation: Meeting Room • We need less failures • What can we do?
- 8. Dramatization: 2015 Situation: Meeting Room • We need to increase availability and decrease our maintenance costs! • We need to do MORE with LESS. • What can we do?
- 10. Objectives
- 11. Strategy
- 13. Value • Asset Management Policy • EHS Policy • Quality Policy • Mission / Vision Objective • High Quality Products • Low Production / Maintenance Cost • On Time Delivery • Zero Loss Time Strategy • Reliability Centered Maintenance • Total Productive Maintenance (TPM) • Lean Manufacturing • Risk Management
- 14. Objectives “Got it: • Objective 1: increase equipment availability • Solution: Buy more systems. A redundant system, is a reliable system! • Objective 2: reduce maintenance cost • Solution: Predictive Maintenance!”
- 17. Pray to the Reliability Gods
- 18. W. Edwards Deming To Achieve Success Focus on Improving the System Not On Individual Performance
- 20. Felix Laboy іMi Santo, No Seas Abusador!
- 21. Proactive Workflow Model Asset Catalog Criticality Analysis Failure Modes Analysis Equipment Maintenance Plans (EMP) PM/PdM Inspections Results of PdM Preventive & Predictive Work 80% of Total Work MOC Procedures Planning MOC Procedures Scheduling Daily Coordination Work Performed Requested Work 20% of Total Work Job Plan Improvement Equipment Reliability Improvements MOC Procedures Failures Breakdowns AssetHealthAssurance Failure Modes Analysis Failure Codes Creation Work Order History Analyis Root Cause Analysis Strategy Adjustment F.R.A.C.A.S Kaizen Loop ProactiveWorkflowModel Source: Allied Reliability Group
- 22. Method / Process • Proactive Workflow Model – Focused on failure elimination – Reduces maintenance costs and increases availability – Implementing CBM is a tool necessary to realize the company's value objectives – No need to justify CBM technologies if the right process is used!
- 25. Real World Results: Packaging Line 0 50 100 150 200 250 300 350 400 450 Actual New 70% Reduction in Scheduled Maintenance Downtime Hours Eliminate: No added value 10% Reassign to operators 26% Replace with PdM 11% Redesign 22% No change 31%