Implementation Guide

Process Name:

Purpose of the Process:

Revision:

Sub-Process
1. Understand Plant
Requirements
2. Perform Reliability
Studies
3. Implement Condition-
Based Maintenance (CBM)

4. Develop and Optimize

Maintenance Plans
Maintenance Plans

5. Manage Life-Cycle
Analysis
5. Manage Life-Cycle
Analysis
Reliability Maintenance
Maximize lifetime of the equipment and minimize consequences of the failures. Define a set o
processes and tools for maintenance activities across the site, focusing on preventive & predi
organization with the maintenance plan reviews and asser life cycle management.
2.01

Actions
Purpose of sub-process:

Understand MMMP (Maintenance Management

Master Plan)

Map Process and review current situation

Establish or Review the Plant Equipment Hierarchy

and update in CMMS
Install Fault Codes

Load Maintenance Type

Establish Work-order priorities

Define critical points of the production process

Perform criticality / classification analysis

Purpose of sub-process:

Phase 1: Assure that Maintenance Basics are in

place

Phase 2: Perform RCM / FMEA (first for class A)

Understand functional requirements, operational
context, and failure behavior

Define maintenance strategy

Review spare parts (inventory levels, CMMS links)

Purpose of sub-process:
According to RCM / FMEA analysis, apply CBM
whenever is possible

Purpose of sub-process:

Phase 1: Develop job plans including duration,

resource groups and disciplines

Create job plan routes

Upload/update improved job plans into CMMS

Perform required training on maintenance tasks

Phase 2: Develop audit process to verify suitability

and quality of the maintenance tasks

Forecast the time to fail for individual component.

Perform Life Data Analysis and define the

reliability behavior for the population

Purpose of sub-process:

Establish life cycle plan for selected equipment

Simulate the operation of the system and obtain

an array of system maintainability and availability
results

Validate the maintenance plan policy for the whole

plant
Optimize maintenance plans, according to the
reliability modeling

Create major repair/investment plan

Review and repeat for next set of equipment

Reliability Maintenance
nimize consequences of the failures. Define a set of consistent standard
ties across the site, focusing on preventive & predictive maintenance, assist the
views and asser life cycle management.
2.01

Explanation
Establish the basis for Reliability Maintenance, including equipment hierarchy & criticality classificatio

The MMMP must recognize the Reliability focus that is required on site, or there will be
difficulty in implementing Reliability Maintenance (RM) process. Before any RM tasks
are initiated, they need to be assessed against all the other tasks required, and the
timing and resources identified. Information regarding the development of the MMMP
is found under Partnership Fulfillment process.

The production process should be mapped if not currently done. Process flows and
major data like volumes, pressures, temperatures and stockpiles should be detailed to
give current and new employees a high level understanding of the process. Any
constraints that the maintenance department needs to work under need to be
identified. The maintenance constraints template is just a record of issues that may
limit the progression of the MMMP. Constraints may include issues such as plant
shutdown frequency or duration (limited access getting to some of the machines),
cost, labor etc. These need to be identified so a strategy can be developed around
them.

A proper plant equipment hierarchy, and update it in CMMS, is essential for:

- determining equipment criticality and the risk associated with their failure
- optimizing preventive/predictive maintenance programs
- facilitating technical reviews (HAZOP, FMEA, RCM)
- capturing reliability and cost data

The plant equipment should reflect both the structural and process flow
characteristics of the plant.
As inspections and failures occur, valuable information is gathered regarding
equipment problems. It is important to capture this information in the CMMS for future
analysis.

This information is used in two ways:

1) Proactive - when maintenance plans are reviewed, history is always looked at. If it
can be seen on a site that bearings, for example, are a common failure component,
the maintenance plans can be focused on these.
2) Reactive - the process Plant Performance Improvement focusses on the
identification of issues on the site so they can be prioritized and focused on.

Part of the data gathering would be to identify equipment failures, so information can
be analyzed to see what types of equipment are causing the greatest OEE and Cost
losses across site, and what components are the largest OEE and Cost loss
contributors. By seeing component information, the site will understand that some
component types are causing problems for several equipment. This type of analysis
will show whether a specific machine should be focused on, a type of equipment
which is causing loss in multiple departments, or a type of component which is
causing loss on multiple equipment / departments.

Initial information required is a code for 'equipment' type and 'component' that failed.
A code for 'reason' is desirable, but understands that unless a Root Cause Analysis has
been performed, this will be guesswork for the person entering the reason code.
It should be a requirement that all work orders should have a fault code before being
completed.

Maintenance Types are required to aid in the analysis of what is happening on site.
Detailed information is available through the Maintenance Operations process, but the
maintenance types important to the reliability analysis of the plant includes:
- PM - Preventive Maintenance, which involves only those tasks which are maximizing
the life of the equipment e.g. cleaning, lubrication, alignment, balancing etc.
- PdM - Predictive Maintenance. It is still important to understand the condition of the
plant, so condition monitoring tasks are very important. By knowing the issues, they
can be addressed in a planned and efficient manner. If the proportion of PdM tasks
trends downward, it can be predicted that more breakdowns will occur.
- CM - Corrective Maintenance. If issues are identified through PdM, they can be
corrected in a planned manner. CM should be planned 'shut' work to bring the
equipment back up to an acceptable condition. Trend down in the CM proportion of
work may either be good news that the equipment is lasting longer, or bad news that
the identified tasks through PdM are not being executed, and increased downtime is
likely.
FTR - Fixed Time Repair / Refurbishment. Repair or replacement at a fixed interval
regardless of the condition at the time. This is a form of corrective Maintenance; the
difference being CM results from PdM, whereas FTR does not. CM will reduce as the
equipment lasts longer; FTR will stay the same unless the frequency is manually
changed. FTR should only be a small portion of the maintenance activity (<5%)
- BD - Breakdown. It is important to know how many issues stop the plant, but further
analysis is required to understand the data. Part of this figure will be issues that could
have been prevented, whereas the other component will be from the strategy of
Operate To Failure, where BD is the most cost effective option. OTF is usually the
smaller proportion, so a trend downward in BD is targeted.
When more than one task is required to be performed and there are limited resources,
there needs to be a method to choose which is most important. The MO process gives
the detailed prompts, but guidance should be gained from the Classification process.
Equipment that will give the largest production, environment and safety impact
should be addressed first. Classification values should not be used: Class C equipment
may have a severe production impact but was lowered in priority due to infrequent
failure.

WO priority is all about impact at time of failure.

It is important to identify critical points and start next phase from those points to
ensure we will get fast results. This can separate site priorities from maintenance dept
priorities.

With the amount of equipment on the plant and the workload involved, it is important
to know where to focus the maintenance effort. A clear understanding of the Plant is
required to ensure the equipment with the largest potential return is addressed first.

Equipment is classified in three classes (A, B and C) according to its criticality in this
specific production process. This criticality is determined according to following
factors:
- Safety - Risk to people and environment
- Quality - Effect of failure on product quality
- Working Shift - Utilization rate of the equipment
- Production- Failure effects on the production process;
- Frequency - Quantity of failures in a determined period
- Cost - Time and expense to repair the failures.

The output from this review highlights which equipment needs to be addressed first.

Perform reliability studies and establish maintenance strategies, starting with the basics (quick wins -
analyses of the most critical equipment (phase 2).

Maintenance basics can be understood as the activities that provide a base level of
reliability such as:
(a) Basic Inspections
(b) Basic lubrication
(c) Basic precision maintenance and cleanliness
(d) Basic operator inspections

Ideally, this should be completed during the mobilization stage (prior to start of FS
execution), but is also done during the initial startup phase.

As soon as possible, following the Mobilization phase, Class A equipment should be

subjected to a RCM / FMEA analysis. People experienced in the operation,
maintenance and history of the specific equipment must be included on the analysis
team. The RCM / FMEA analysis should consider the customer's current maintenance
plan and failure history. From this process the RCM / FMEA team will determine the
optimum maintenance plan necessary to meet availability and reliability expectations,
according to the following steps below described. Use ReliaSoft RCM++ or Quant
FMECA tool for the process.
Functional requirements: it is important to understand our primary aim is not to
prevent equipment from failing - it is to maintain function.Identify & understand the
required function - not the design function.
Where possible identify upper and lower limits. Also include secondary and tertiary
functions.
Operational context: it is the physical environment in which the equipment operates,
demands made on it and the details of how it is used.
The operating context is one of the most significant contributors to performance, and
is the main reason why maintenance strategies cannot be copy/pasted across
equipment on your site.
Failure behavior: before a strategy can be chosen for an important
failure mode, information has to be gathered about when and how it may fail.
Probability curves are assigned to understand if the equipment may fail early, whether
the failures are random, increase with age or have a reasonably regular life. These are
not just accepted - there are prompts available to help assist in the reduction of early
failures. Analysis of this information will help guide or discount strategies. P-F
intervals, or warning time, is also required to understand better the strategy and
frequency.

Select maintenance type / frequency (DO, PM, CBM, FTR, OTF): For each equipment,
five strategies are available and should be reviewed in this order:
1. Design-Out (DO) - what can be done to extend the life, make inspections
easier or make repair / replacement easier?
2. Preventive (maximize life) (PM) - what can be done to ensure
maximum life, e.g. lubrication, cleaning, alignment, balancing, operations, etc.
3. Condition Based Maintenance (CBM) - what inspections can
be done to predict if the equipment is deteriorating?
4. Fixed Term Replacement / Refurbishment (FTR) - if it
cannot be cost effectively conditioned monitored, can replacement at fixed time
period be suitable? 5. Operate to Failure (OTF) - some things either cannot be
predicted prior to failure, or not cost effectively predicted. In a number of cases, the
most cost effective solution is to repair at time of failure. These should be highlighted
and a contingent action plan put in place. Frequency of PM, CBM and FTR needs to
then be determined to ensure tasks are not done too frequently (additional cost) or
infrequently (less effective)

Review spare part situation at plant and its link in CMMS: Bill of Materials (BOMs)
refers to an itemized list of components that are required to make up each piece of
equipment. This is required for two reasons: 1. at time of repair, the repairer needs to
efficiently obtain the parts required. The more time this person needs to identify and
source parts, the longer the repair will take. If this is at the time of a breakdown or a
planned shut, availability of the plant will suffer. If this is at the time of a normal
refurbishment of equipment, the task will take longer; hence the tradesperson will not
be able to complete as much work. 2. Stores need to know what and how many of
each component are required on site so they can develop max/min stores levels. If
they have too many, stores cost is excessive, too few and there will be stock-outs and
repairs will be delayed.
The purpose of this sub-process is to highlight typical applications for some of the more common pred
consider before choosing method include: accuracy of inspection method, speed, warning time requir
available to perform
According to RCM / FMEA analysis, apply CBM whenever is possible:
Vibration Analysis: is used to check Rotating Equipment condition.
Infra Red Thermography: is used to check: electrical connections, thermal insulation
conditions, leaks in heat exchangers and valves, and mechanical equipment issues
such as wear, friction and slack .
Oil Analysis: is used to define three basic machine conditions related to the machine’s
lubrication or lubrication system: condition of the oil, lubrication system condition and
the equipment condition itself;
Insulating Oil Analysis: from transformers, oil-filled circuit breakers and other
equipment is used to detect signs of abnormal equipment condition and prevent
catastrophic failures.

Investigate other predictive maintenance techniques that may apply to your plant
equipment such as:
Ultrasonic Analysis
Motor Analysis
X-Ray
etc.
Include estimations for implementation cost and schedule,
including implementation resources, regulatory requirements, the type and version of
applications and systems, proprietary data sources, and types of processes that will
be impacted.

Implement quantPredict
Translate the maintenance strategies based on reliability studies into site & organization specific job p
Operations)

The Reliability Studies will identify the tasks that need to be executed.
Part of the Planning function is to detail how that task will be done. Detail is required
to be added so the person performing the task knows the steps and hence the extent
of the job.The site also need to assign the persons who will perform each task - who
has the skills and is the most suitable to do each task.
Information for this section would come under Maintenance Operations - as it is part
of the planning function.

Once the tasks have been allocated to the discipline best suited to execute them, the
order of execution, or 'Route' that they perform the tasks can be developed.
This is a planning - or efficiency - function, so is not an output of the reliability study.
Information on generating a route, or the format the site prefers for their PM of PdM
tasks can be found either in the Maintenance Operations process, or at the site level.
There is no global standard format for tasks as different sites have different
preferences.
Performing Reliability Studies determines what tasks are required for each piece of
equipment. Unless this is uploaded/updated in the CMMS it will add no value.
Current maintenance tasks ('PMs') will have been used in the study, but now the
routines need to be updated.
The output of the reliability study will specify current unnecessary tasks that need to
be deleted, current tasks that need more detail added or new tasks that need to be
created.
This step relates to ensuring the tasks in the CMMS are as is recommended from the
reliability studies.
Train the trades on the maintenance tasks.

Assess the process to verify opportunities of improvement. Also the time and cost
required for every work order should be reported and analyzed to provide guidance
for more accurate planning in the future. It is important to determine what causes the
task and times to change. Comparisons should certainly be made between different
individuals doing the same tasks in order to evaluate results in the amount of time
required, what was accomplished during that time, quality of workmanship, and
equipment performance as a result of their efforts.

Using Degradation Analysis, forecast the time to fail for individual component.

Using Degradation Analysis with Life Data Analysis, define the reliability behavior for
the population in order optimize component replacements at fixed intervals and
optimize spare parts inventory levels

Assist the customer in optimizing lifecycle cost of major equipment, using reliability and maintenance
Lifecycle Management is the big picture of what is required for the equipment. It does
not only include what is required to be done now for the equipment, but includes all
actions over the entire life of the equipment - and these actions may change as the
equipment gets older.
Some of the considerations include:
- Design, Functionality and Operability: Functionality, Maintainability (inspections and
interventions), Standardization and Parts availability, Safety and Environment,
Lifecycle Costing (life cycle economic evaluation), Infant Mortality considerations and
Monitoring
- Installation: Installation, commissioning procedure and quality control, Training,
Documentation, BOMs, and Equipment register update, etc
- Aged Equipment Management: Obsolescence, succession or investment plan,
decommissioning

Using Reliability Block Diagram software tool simulate the operation of the system
and obtain an array of system maintainability and availability results (reliability
modeling) to improve the system.

Use Reliability – Availability – Maintainability (RAM) analysis to validate the

maintenance plan policy for the whole plant. The asset performance analysis is
commonly denoted RAM analysis, referring to the three essential elements: Reliability,
Availability and Maintainability - RAM. In a RAM analysis, simulations are used to
calculate availability figures for a technical system, taking both equipment reliability
and maintainability into account.
Reliability modeling and prediction is a methodology for estimating an item's ability to
meet specified reliability requirements.
Basic Reliability prediction estimates the demand for maintenance and logistic
support caused by an item's unreliability.
When used in combination, the two predictions provide a basis for identifying areas
wherein special emphasis or attention is needed, and for comparing the ownership
cost effectiveness of various design configurations.
The two predictions may also be used as a basis for the apportionment (allocation) of
ownership cost and operational effectiveness requirements to various subdivisions.

This step refers to the need for maintenance to be more involved with the customer
investment plan which includes planned upgrades or expansions.
Maintenance input at the design stage will help ensure that the equipment purchased
is the most appropriate, most cost effective and the easiest to maintain.
The life cycle cost (LCC) of any piece of equipment is the total “lifetime” cost to
purchase, install, operate, maintain, and dispose of that equipment.
Determining LCC involves following a methodology to identify and quantify all of the
components of the LCC equation.
When used as a comparison tool between possible design or overhaul alternatives,the
LCC process will show the most cost-effective solution within the limits of the
available data.

When the whole sub-process is completed for the slected critical equipment, then the
same process activities should be applied to the next select critical equipment and so
on.
Tools, documents, Templates
ierarchy & criticality classification, and CMMS codes & priorities.

MMMP for the site (see also PFF and Mobilization processes)

Process flow_example.pptx

Asset_Hierarchy.ppt
Failure_Codes_by_Class.xls

CMMS Work Type and Priority.ppt

CMMS Work Type and Priority.ppt

Process flow_example.pptx

ABC Classification spreadsheet.xls

ABC Classification procedure.doc

ing with the basics (quick wins - phase 1), then continuing with systematic

Basic_Inspections_Implementation_Guide.doc
Lubrication_Implementation_Guide.doc
Lubrication Presentation V1.ppt
Precision Maintenance Brochure V1.doc
Precision Maintenance_v1.pptx
Operator Inspection_Implementation_Guide.doc
Operator Inspections.ppt

Software tool: ReliaSoft RCM++

Quant tool: Quant FMECA v1.0.xls
Establish Maintenanceplans_Implementation_Guide.doc
Establish
maintenance plans.ppt

Software tool: ReliaSoft RCM++

Materials_Management.ppt

some of the more common predictive maintenance technologies. Issues to

hod, speed, warning time required, running or stopped inspection and skill
CBM Overview.pptx

CBM Overview.pptx

quantPredict
site & organization specific job plans (done in conjunction with Maintenance

Establish Maintenanceplans_Implementation_Guide.doc
Establish
maintenance plans.ppt
One Point Lesson.pptx

Software tool for Life Data Analysis: ReliaSoft's Weibull++

Software tool for Life Data Analysis: ReliaSoft's Weibull++

sing reliability and maintenance methodologies and data.

Lifecycle Management.ppt
Reliability Block Diagram software tool: Reliasoft BlockSim

Reliability Block Diagram software tool: Reliasoft BlockSim

Reliability Block Diagram software tool: Reliasoft BlockSim

Reliability Block Diagram software tool: Reliasoft BlockSim

LCC_model.xls
Reliability Block Diagram software tool: Reliasoft BlockSim