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FORUM: Design for Maintainability CII Construction Project Improvement Conference September 11-13, 2005 Austin, Texas. George Conner Richard Danks Robert Post. Presentation Agenda. Making the Case & Concept Overview NASA Implementation D for M Implementation Model

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FORUM:Design for MaintainabilityCII Construction Project Improvement ConferenceSeptember 11-13, 2005Austin, Texas

George Conner

Richard Danks

Robert Post

presentation agenda
Presentation Agenda
  • Making the Case & Concept Overview
    • NASA Implementation
  • D for M Implementation Model
    • Chevron Texaco Implementation
  • Benefits of D for M
    • Rohm & Haas Implementation
design for maintainability making the case concept overview

Design for Maintainability:Making the Case& Concept Overview

Richard A. Danks

Deputy Chief, Facilities Division

NASA Glenn Research Center

Cleveland, OH

life cycle cost 30 year period

The Case for Design for Maintainability

Life Cycle Cost — 30 Year Period

Operation & Maintenance

60% - 85%

Land Acquisition,

Planning, Renewal,

Revitalization, & Disposal

5%-35%

Design & Construction

5%-10%

Source: Stewardship of Federal Facilities, 1998

landscape of interrelationships

Reliability

Sys Configuration Equip Performance

Availability

Uptime

Prod Eff / Utilization

Production Losses

Equipment Criticality

Productivity

Maintainability

Factors affecting ability to perform Maintenance

Total MTTR

$$$$

Operability

Asset Economics

(Differential NPV)

Operational Flexibility

Degraded Performance

Improvements

OPEX & CAPEX

Landscape of Interrelationships

Chevron Pre-Operations Impact to Asset Performance

cii research project
CII Research Project
  • D for M research project 1997 - 1999
  • CII Guidebook - 1999
  • CII Education module - 2002
research results
Research Results
  • Defined “levels” of implementation
  • Common approaches to implementation
  • Common attributes of success
  • Model implementation process
maintainability principles
Maintainability Principles
  • Reduce or eliminate wrench time
  • Optimize Safety, Accessibility, & Ergonomics
  • Reduce Complexity or Task Difficulty
  • Optimize Standardization, Interchangeability, and Modularization
process characteristics
Process Characteristics
  • Integrates downstream knowledge early in
  • design process
  • Model process provides implementation
  • structure
  • Long-term perspective –
    • Reduces life cycle costs
  • Short term perspective –
    • Integration into existing processes
    • Alignment
    • Start up
slide11

D for M Process Highlights

  • Early implementation =Greatest impact
  • Suite of tools to expedite implementation
  • Continuous improvement carries
  • over to future projects
nasa implementation
NASA Implementation
  • Engineering & Construction Innovation Committee
    • D for M selected as best practice for implementation
  • Development of week-long course
    • Presented at Field Centers
    • D for M material presented in Sustainability course
  • Centers implementing sustainable projects
nasa implementation1
NASA Implementation
  • Interdependent concepts
  • D for M integrated with
    • Sustainable (Green) design
    • Commissioning
    • Safety & security
  • Supports other NASA programs
    • Reliability-centered Maintenance
    • Reliability based equipment acceptance
implementing design for maintainability

ImplementingDesign for Maintainability

George Conner

Staff Reliability Engineer

Chevron Corporation

Houston, Texas

approaches to implementation
Approaches to Implementation
  • Standard design practice
  • Contract specification
  • Cross functional participation
  • Pilot program
  • Integration into existing programs
  • Formal maintainability program
  • Comprehensive tracking
model process
Model Process

Source: CII Implementation Resource 142-2

Page 16

model process elements
Model Process Elements
  • Milestones
    • Milestones are achieved through
    • maintainability practices
  • Practices
    • Maintainability practices are
    • implemented using tools
  • Tools
    • Tools basically document process
    • steps in a checklist format
implementing d for m
Implementing D for M
  • Assemble cross-functional proj team
  • Formal maintainability reviews
  • Design to project maint. strategy
  • Consider maintenance staff skills and
  • training requirements
implementation resources
Implementation guidebook

22 Maintainability Practices

16 Implementation tools

Implementation suggestions

Establish a champion

Pilot program – if a new start

Implementation Resources
chevron s application
Chevron’s Application
  • Post Startup Performance unacceptable
  • Developed Operations Assurance Process

Team approach to selecting, developing, assessing and executing specific pre-operations activities, throughout the course of a project, that impact asset performance.

  • Project development and execution is based on a structured phase gate approach:

Identify, Select, Develop, Execute, Operate

  • Maintainability is part of the Operations Assurance (OA) process.
chevron s application oa foundational philosophies

Reliability

Maintainability

OA

Operability

Chevron’s ApplicationOA Foundational Philosophies

Human Factors Assmt

Maintenance Strategy

Mobilization Delays

Resources & Competency

Shift/Spares Constraints

Mechanical Handling Plan

BID Specifications

Qualified Vendors

Standardization

Reliability Modeling

RCM

Performance Indicators

Production / Utilization

Operations Strategy

Resources & Competency

Operational Flexibility

Work Environment

implementation summary
Implementation Summary
  • CII has developed a robust D for M process.

Milestones Practices Tools

  • Early commitment / implementation is critical
  • The implementation can be customized based on current state and ultimate goals.
  • For Chevron, D for M is not a standalone effort
  • Specific D for M applications adapted for the OA process generally reference:

Milestone 4: Plan Maintainability Implementation

Milestone 5: Implement Maintainability Process

design for maintainability benefits

Design for MaintainabilityBenefits

Robert Post

Technical Fellow Project Engineer

Rohm and Haas Company

Bristol, PA

slide24

Project Benefits

  • Smoother project startup
  • Less project rework
  • Less costly maintenance
  • Lower life cycle costs
  • Metrics & Continuous Improvement
  • Supports CII Best Practices
long term benefits
Long Term Benefits
  • Eliminate the need for maintenance
  • Increased task efficiency
  • Reduced accidents
  • Decreased downtime
  • Access & ergonomics
  • Standardization/modularization
  • Task simplification
experience at rohm haas
Experience at Rohm & Haas
  • Domestic US Projects:
    • “Reliability Design”
      • Functional focus
      • Looks at reliability issues first
      • Minimize failures and maintenance
      • Identify/Resolve maintainability issues
      • Mostly done prior to execution
experience at rohm haas1
Experience at Rohm & Haas
  • Domestic US Projects: but….
    • Superior FEL definition yields faster/cheaper
    • execution
      • Everyone knows this, but……
    • Getting Front End schedule time & resources
    • Actual results vary
    • US work is limited these days anyway…
experience at rohm haas2
Experience at Rohm & Haas
  • Overseas Projects: difficulties
    • Engineering Processes Vary
      • Owner processes
      • Contractor processes
      • O&M processes
    • Cultural Viewpoint / Values differences
      • Language
      • Safety
      • Quality
      • What does “Yes” REALLY mean?
benefits summary
Benefits Summary
  • The know-how exists!
    • Domestic: Must get commitment of
      • management and engineers
    • Overseas: Much steeper learning curve
slide30

Want to Know More?

  • CII Publication
    • Design for Maintainability:
    • Improving Project
    • Return on Investment
  • CII Research Reports
    • A Model Process
    • for Maintainability Implementation
    • State-of-Practice in
    • Maintainability: Seven Case Studies
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