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Improved Reliability through PM Optimisation

This project aims to improve reliability by optimizing preventive maintenance schedules and increasing the quality of maintenance. The objectives include better managing Cell C operation and maintenance, understanding equipment failure history, improving detection and rectification of failures, and communicating findings.

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Improved Reliability through PM Optimisation

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  1. Improved Reliability through PM Optimisation Project Team: Electrician Planner Mechanic Operator Reliability Engineer Facilitator: Steve Turner

  2. Why investigate the Residue Cell C’s • PM Optimisation will fall in line with the business plan for the Site. • The only cost centre in the plant consistently over budget. • Opportunity to improve reliability as Cell C’s have highest failure rate in the area. • Opportunity for more consistent performance to meet plant expansion plans. • The experience is that there is more work in the area than there are people assigned.

  3. Objectives • Better focus of PM schedules. • Increase the quality of maintenance. • Understand the rationale behind each PM task. • To better manage the Cell C operation and maintenance. • Exchange information and increase understanding of each role ie mech ,elect, process. • Understand equipment failure history. • Improve detection and rectification of failures. • Communicate findings.

  4. Objectives…cont • All of the previous will result in greater abilityfor us to meet the business plan.

  5. How we went about it • Started with the existing PM lists • Applied the process to the all schedules including: • SAP schedules • Maintenance and Process task lists • Check sheets • Created a new daily schedule for both operator and maintenance technicians. • Review failure modes and the PM’s which addressed these.

  6. How we went about it….con’t • Review operating logsheets • Determined the most appropriate maintenance strategy. • What task (preventive, predictive or corrective) • Who does it • How often. • Develop implementation list/plan for approval.

  7. Opportunities identified • Numerous new PM tasks that should be done. • Task frequency could be more effective particularly in the mechanical area. • Some job descriptions were not specific or reflective of actual work. • Identified a opportunities for reliability engineering.

  8. Opportunities Identified…cont • Better utilisation of maintenance and operations resources by eliminating task duplication. • The maintenance strategy needs to be better documented so that it can more easily be reviewed and communicated. • There is an opportunity to transfer some of the knowledge to other processes and sites.

  9. Outcome PM Optimisation Analysis

  10. Outcome PM Optimisation Analysis

  11. Downtime Analysis-Mechanical

  12. Downtime Schedule

  13. Some interesting issues • Some valve failures could possibly be managed by condition monitoring rather than in breakdown. • Breakdown history was recorded incorrectly. This precludes any efficient analysis. • Some task were carried out too often…others not often enough. • The existing mechanical PM were difficult to complete but now broken into three PM’s. • Not all process tech inspections are recorded.

  14. Some interesting issues….cont • Greater involvement of process tech’s in fault finding is possible for maintenance and operations problems. • The justification for each maintenance task is now documented. • The existing PMs are not all being completed. • Pizza Hut do not deliver on public holidays.

  15. Other benefits... • More knowledgeable and empathetic workforce. • More descriptive tasks with acceptable limits. • Improved team work. • Greater sense of ownership in the maintenance and equipment performance. • Better understanding of failure modes and objective of tasks • Planned downtime reduced (1hr per fortnight per unit). • Unplanned downtime will add to this.

  16. Benefits..con’t • Move to a less reactive environment by adopting more frequent inspections where warranted. • The PM program can now be achieved.

  17. What needs to happen now • Input changes to SAP (already started). • Implement the Process Tech check procedure. • Modify Elect Maintenance Tech check sheets. • Develop Mech Maintenance Tech check sheet. • Improve failure reporting in SAP. • Carry out some minor plant modifications. • Implement new tasks ie NDT and Structural inspections .

  18. Improved Reliability through PM Optimisation • Project Team: • Electrician • Planner • Mechanic • Operator • Reliability Engineer Facilitator: Steve Turner

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