Global Maintenance Management Maintenance Objectives • Maximize Production. • Minimize Energy Consumption. • Reduce Breakdowns. • Reduce Downtime. • Improve Equipment Efficiency & Life Time. • Control Annual Budget. • Optimize Resources Utilization. • Minimize Total Cost / Ton. • Increase Product Quality. • Improve Safety Level. CONTENTS: • Maintenance Strategy. • Maintenance Cost. • Reliability and Availability. • Key of Performance Indicators. Finally: Why should I have to know this level of managerial knowledge NOW ??? Maintenance Strategy Maintenance Policies Planned Stoppage Time Base Condition Base Unplanned Stoppage Risk Base Failure Base Unplanned Stoppage • Failure Base “Reactive Maintenance” Run To Failure Maintenance. Corrective Maintenance. Breakdown Maintenance. Advantage: fix-it when fail, to minimize PM maintenance costs for non-critical equipment (cheap). Dis-Advantage: 1. High spare stock level 2. Outage increased causes less productivity & increase TOTAL maintenance cost. Planned Stoppage 1/3 : Time Base “Preventive Maintenance” Based on Calendar (year, monthly, weekly, Daily … etc.). Based on Running hours. Based on Production Limit. ( after certain tonnage; end user should change or replace the spares) Advantage: 1. Give reliable production plan. 2. Increase equipment reliability and plant availability which lead to increase productivity. Dis-Advantage: Costly if implemented incorrectly Planned Stoppage 2/3 : Condition Base "Predictive Maintenance” This actions can be done ON-LINE ONLY Oil Analysis Vibration Analysis Temperature Analysis Pressure Analysis Sound Analysis Advantage: Spot a potential failure. Dis-Advantage: Costly. Planned Stoppage 3/3 : Risk Base “Proactive Maintenance” To implement successful re-design; first; you have to detect the source of failure. Proactive Maintenance Approach Policy RCFA: root cause failure analysis. FMEA: failure mode effective analysis. HAZOP: hazard operation study. RCM: reliability center maintenance. RBI: risk base inspection. Approach Identify the root cause of failure. Identify the criticality of failure. Goals Failure elimination by explore the weak point. Improving the equipment availability. Identification of hazard and problems related to operation. Improve HSE effect. Determination of best maintenance requirements for critical equipment. Keep system function and improve reliability. Determination of an optimum inspection plan for critical equipment. Improve system of HSE and plant availability. Advantage: 1. Redesign to eliminate the root cause of failures causes minimize the risk of failures for critical systems. 2. Less maintenance required Dis-Advantage: Sometime Costly (Bulk Cost / Semi-project). Maintenance Cost Optimum Maintenance Cost PM cost Total Maintenance Cost Optimum Maintenance Cost Cost Failure break down cost Optimum PM activities PM activity DIRECT COST “visible”: This is variable cost vary direct to the volume of production 1. 2. 3. 4. 5. 6. Spare parts (CAPEX, OPEX, tools & Consumables) + supply cost. Contracts and out sources. Spare repair. Down time (planned & unplanned). Maintenance Manpower. Risk Management. IN-DIRECT COST “hidden”: This is not related to the volume of production 1. Technical overhead cost: Sum of labor, training, technical engineering services (revamping or new project), planning, utilities & stores. 2. Managerial overhead cost: Sum of administration, IT, salaries, facilities, transportation & port. Reliability and Availability Calculation & Definition Total time (Calendar = 365 day) Planned Shutdown Planned (target) time Unplanned (delay) time Available time Available Time Availability = Total Time – (Planned Shutdown + Unplanned Shutdown) = Total Time Total Time Available Time Reliability = Total Time – (Planned Shutdown + Unplanned Shutdown) = Planned (target) Time Total Time – Planned Shutdown Reliability:- The probability that machines will produce the required product without interruption (unplanned) through planned running time within low cost per ton and accepted product quality specifications. Availability:- Indicate the plant availability to produce the required product at target rate with less total stoppage (planned & unplanned). Key of Performance Indicators Maintenance KPI’s Target: is to improve personnel’s awareness of maintenance performance KPI’s is direct related to AQS overall goals; which is determine the critical activities that must be done well for a particular operation to succeed. Maintenance Department Key of Performance Indicators (KPI’s) Maintenance KPI’s classify into: 1. Maintenance Performance Evaluation KPI’s 2. Maintenance Cost KPI’s 3. Maintenance Safety KPI 1. Maintenance Performance Evaluation KPI’s: KPIs Description Calculation method Target Frequency KPI 1: Indicates the performance of utilizing the planned stoppages. KPI 1 Planned Stoppages Utilization Maintenance Target; utilizing monthly planned stoppages with achieving all preventive maintenance figures to ensure plant running smooth. Otherwise; decreasing planned shut down by increasing maintainability of equipment lead to increase this value. KPI 1 = 95% Monthly Calendar Hours – Scheduled Stoppages Hours Calendar Hours KPI 2: Indicates the performance of decreasing the unplanned stoppages. KPI 2 Unplanned Stoppages Utilization Maintenance Target; decrease monthly un-planned stoppages (monthly delays) to increase productivities. 90% Monthly Calendar Hours – Unscheduled Maintnance Stoppages Hours KPI 𝟐 = Calendar Hours KPI 3: (Reliability) indicates the reliability of equipment to produce the required product at target rate without interruption.. KPI 3 Reliability rate Maintenance Target; increasing the reliability by decreasing unplanned stoppage. KPI 𝟑 = 92% Monthly 87% Monthly Calendar Hours – Schedule Stoppage Hours − Maintenance Unscheduled Stoppages Hours Calendar Hours − Scheduled Stoppages Hours KPI 4: (Availability) Indicate the plant availability to produce the required product at target rate with less total stoppage (planned & unplanned). KPI 4 Availability rate Maintenance Target; increasing the availability by utilizing the planned shutdown which is leading to decreasing unplanned stoppage, while decreasing planned shut down by increasing maintainability will lead to decrease total plant stoppage. KPI 𝟒 = Calendar Hours – Schedule Stoppage Hours − Maintenance Related Unscheduled Stoppages Hours Calendar Hours KPI 5: (MTTR) Indicate the average maintenance time required to keep the equipment in operation mode (equipment wise not plant wise). KPI 5 Mean Time to Repair MTTR Maintenance Target; Reduce number of failures and reduce down time for equipment to increase productivity. KPI 5 = Total Maintenance Time (Maintenance Unscheduled Stoppages Hours) Total Number of Repair 30 min Monthly KPIs KPI 6 Description Mean Time Between Failure MTBF Calculation method KPI 6: (MTBF) Indicate the average amount of operating time between consecutive breakdowns for equipment (equipment wise not plant wise) which is also; reflect the repeated failure in each equipment and their reliability. KPI 7 6 hrs. Monthly 95% Monthly Maintenance Target; Reduce number of failures and reduce down time to increase plant productivity. KPI 6 = Planned Maintenance Execution Rate Target Frequency Calendar Hours – Scheduled Stoppages Hours Total Number of Repair (Planned Maintenance) Indicate the percentage of achieving the schedule/planned maintenance target (Preventive & Predictive Maintenance). KPI 𝟕 = Total Number of Performed PM Activities Total Number of Planned PM Activities 2. Maintenance Cost KPI’s: KPIs KPI 8 KPI 9 Description Maintenance cost Maintenance Budget Calculation method KPI 8: Maintenance cost (consumption budget): Indicate the maintenance cost per Ton of produced quantity. Maintenance Target; reducing maintenance cost to increase the benefits. RM=3 USD/Ton Total Maintenance Cost KPI 𝟖 = Total produced (Ton) SMP=6 USD/Ton KPI 9: Indicates the accuracy of the planned budget (yearly) compared with actual requirement. Maintenance Target; To reduce the difference between the actual and the planned budget by submitting yearly maintenance budget to be match with actual maintenance requirements. KPI 𝟗 = KPI 10 KPI 11 Warehouse Indicator Non Moving Items Target Frequency 80% Monthly Yearly Actual Requirment yearly maint. budget KPI 10: (Warehouse Indicator) WI Indicate the percentage of creating PR’s related to spare consumption. Maintenance Target; Number of PR’s created to be less than spare consumption to reduce non-moving items. Cost of Spares PR KPI 𝟏𝟎 = Cost 𝑜𝑓 𝑆𝑝𝑎𝑟𝑒 𝐶𝑜𝑛𝑠𝑢𝑚𝑒𝑑 90% Yearly 80% Yearly KPI 11: Indicate the percentage of consuming spares in Non-moving items in warehouse. Maintenance Target; reduce the non-moving items (spare parts & consumables) in warehouse. This KPI not including capital (insurance) spares. KPI 𝟏𝟏 = Cost of consume Spare Parts from Non−Moving spar Total Cost of Non−Moving spares 3. Maintenance Safety KPI Indicator KPI 12 Description Safety Performance Calculation method KPI 14: (HSE) Indicate the overhaul safety performance and record the frequency of injuries and incidents. Maintenance Target; reduce personnel injuries and number of incidents. In addition; ensure safety practices and equipment are working in safe mode. Total No. Of Accidents = zero Target Frequency Zero accidents Yearly quarter
