emjoct2005

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Reactive or ‘fire-fighting’ maintenance procedures are costly in terms of money and freight time as well as disruptive to a workforce’s morale. The Facility Maintenance Management System is a software application that brings together a high level of functional sophistication • Equipment Asset Register • Condition Assessment & Monitoring • Preventative Maintenance Libraries • Work Order (Planning & Control) • Performance & Maintenance History • Maintenance Planning & Scheduling • Resource Management (Materials, Resources, Facilities) • Essential Component Tracking • Maintenance Task Budgeting • Statistical Analysis Performance • Work flow Management Now, a simple-to-use software system to efficiently manage it is within your reach. Above: Railway maintenance team in action and screen dumps from KDR’s FMMS software FMMS is a powerful asset maintenance management tool that your personnel will want to use. FMMS is an application that brings together a high level of functional sophistication yet maintains a simplicity of operation that belies its far-reaching capabilities. To find out more about how FMMS can lift your company’s performance, on the production line and the bottom line, call, or visit our web site: KDR Creative Software Suite 15, 85 Turner Street Port Melbourne Victoria 3207 Australia [email protected] www.kdr.com.au Telephone: +61 3 9646 1788 Fax: +61 3 9646 9680 Winner of Excellence in Rail Export 2004 • Purchasing & Inventory management • Contracts Management • KPIs • On-Line Reporting • Multi-Lingual And More… GBDFMMS 2, 2005 buildings and facilities. photocopying. See his article in this issue titled Maintenance in Iraq Regular Features 70 Maintenance News Current Maintenance and Product News 75 Subscription Subscribe To Either The Print Or eMJ Versions of The Maintenance Journal .com Web Site: www. monitoring. For all Enquiries Contact: Engineering Information Transfer Pty Ltd PO Box 703. advertising inserts and any other editorial contributions. Fax: (03) 5975 5735. McFarland 28 Scheduling More Profit Reliability Solutions.maintenancejournal. including electronic. equipment. stored in a retrieval system or transmitted in any form by any means.Contents A journal for all those interested in the maintenance. servicing and management of plant. Copyright: This publication is copyright. Inc..com 10 Asset Management John Wilson 12 Maintenance Of PLC’s Don Fitchett 16 Metrics For Managing Maintenance Raymond P. May. October 2005 Published by: Engineering Information Transfer Pty Ltd Publisher and Managing Editor: Len Bradshaw Publishing Dates: Published in February. August and October. 32 Survey 2005 Special Maintenance Applications Software Survey 48 Generating Failure Codes Bill Keeter 54 Business End Of Maintenance Deryk Anderson 60 Moving From Reactive To Proactive Rod O’Conner Cover Shot: Helicopter Engine Replacement In Iraq This month’ s cover shot has been supplied by Ricky Smith who until recently was a company commander supporting maintenance operations in Iraq. mechanical. without the prior written permission of the publisher. Material Submitted: Engineering Information Transfer Pty Ltd accept no responsibility for statements made or opinions expressed in articles. E-mail: mail@maintenancejournal. submitted advertising. Victoria 3931. No part of it may be reproduced. Mornington. Australia Phone: (03) 5975 0083. recording or otherwise. No 4. features. October 2005 8 Maintenance In Iraq Ricky Smith Volume 18. . Asset Management. and other applications. Reliability and Availability Analysis. Ricky Smith’s article “Maintenance In Iraq” has perhap the unexpected viewpoint that maintenance in a war zone has much in common with maintenance of an industrial plant. Wanted.000 words. The first article in this issue takes us to Iraq. at [email protected] Editorial Welcome to the October 2005 issue of the Maintenance Journal.com Maintenance Web Links In the February 2006 issue of the Maintenance Journal will be published a listing of Web Links to important Web Sites around the world that provide information or services on Maintenance.of over 10. Condition Monitoring. The survey report . “Metrics For Maintenance Management” and “The Business End Of Maintenance”. . Also in this issue there are a number of articles orientated to the Business issues in Maintenance and these include articles on “Asset Management”. has listed dozens of special maintenance software for such applications as Reliability Centred Maintenance. We again have a wide variety of articles from around the World.com Entries for the new Web Links listing close on 14 November 2005. We are also clearing out all current links at our web site www. Without appropriate and timely maintenance those untimely breakdowns of a vehicle or helicopter in a war zone could have dire consequences.com Should your organisation wish to have your web site listed in the Feb 06 issue of the Maintenance Journal and added to our web site links please contact Len Bradshaw at: mail@maintenancejournal. Failure Analysis. your articles / case studies: The Maintenance Journal welcomes the submission of your maintenance related articles. editor. Reliability. The October 05 issue includes the annual survey of “Special Maintenance Applications Software”. Maintenance Frequency Optimisation.. The basic rules still apply . Contact Len Bradshaw.“Military units that perform maintenance properly and on schedule didn’t have untimely breakdowns”. papers and case studies. Parts Optimisation. Maintenance Modelling and Simulation. Life Cycle Analysis and Costing. Essential reading for all involved in maintenance. who was complaining about not having armor on military vehicles. The soldier. brake systems and the like during the mission.000 kW). when all supply convoys in Iraq were being destroyed.’ That means we were ready to fight at all times. transmissions. During this time. we were ordered to repair more than 135 broken Military Police Humvees and to armor them for convoy security. Navy and Air Force) stationed in Kuwait. vehicle repair. A/C repair (on vehicles and facilities). convoys could begin to roll again. Czech. The problem is that the world doesn’t have enough armor plate to provide every unit with all the armor they feel is needed. Most insurgents are looking for easy prey. among others). We are one of two units involved with adding armor to vehicles going to Iraq. generator repair (to 1. including engines. My unit hit the ground running.000 labor-hours to accomplish this task in less than three weeks. We provide support in Iraq to coalition forces (Polish. the convoy in front of ours was attacked and the convoy behind was attacked.S. I was a company commander of a maintenance company stationed in Kuwait in support of Operation Iraqi Freedom. What angered his unit was that they wanted more armor than what was being given to them. Mongolian and Bulgarian. my soldiers responded in one way or another to everything you saw on the news. U Apache Helicopter Maintenance In Iraq Major Smith with Musket! . a war zone and an industrial plant have much in common Ricky Smith (USA) This article first appeared in Plant Services Magazine www. In fact. My specialty in civilian life is industrial and facility maintenance. My unit operated under what we call ‘guns up. My unit supports all U. didn’t tell the whole story.S. including vehicle recovery. In April 2005. a soldier asked Secretary of Defense Rumsfeld about the vehicle armoring program in Iraq. and returning home.com ntil recently. my soldiers worked more than 35. not risky targets that may get them killed. Once these vehicles were sent back north. We changed more than 3.000 parts. During the year.8 Maintenance In Iraq When it comes to asset care. A few months ago. passing through to Iraq. Army vehicles. and fabrication and installation of armor plates on all types of U. Marine. weapons repair.plantservices. We supplied them with all types of maintenance. Ours wasn’t hit. Of course. flying our Jolly Roger flag didn’t hurt our image. My soldiers entered Najaf by convoy when the big fight was going on there. military units (Army. ’ If you hear those statements.S. Completing Engine Changeout HMMWV I know all of you have heard things like ‘We don’t have time to do all of this maintenance’ or ‘We’ll get to maintenance after we complete all of the problems we have. I know. but believe me maintenance is maintenance.’ no matter what maintenance field you’re in.9 The quantity of armor and where it goes has been based on reports from drivers whose vehicles were hit with small arms fire. other units might not get any armor at all. My U. Yes. such as during an ambush or firefight. yes. CMRP. More than 90% of the equipment we repaired had unnecessary failures that probably wouldn’t have occurred if proper operation and maintenance procedures were followed (even in a war zone). don’t believe everything you hear. equipment isn’t maintained very well in the absence of a strong management commitment to maintenance. Also. I only had 40% of my mechanics available to work on equipment. Typically. I know your situation is different.” Escort Security in Iraq 9 .C. and I’m looking forward to getting back to the technical training company I own. If we overload a vehicle with too much armor plating. “Military units that performed maintenance properly and on schedule didn’t have untimely breakdowns. The rest of them were on force protection or other additional duties. If you learn one thing today. I met many of my maintenance buddies in Iraq and Kuwait and. I understand the problem. Ricky Smith. S. If we gave this soldier’s unit all the armor it wanted.smith@success-in-training. I hope it’s that in maintenance you aren’t alone. On my best day. With a background in maintenance management. it will suffer premature failure. is president of Maxzor in Charleston. Military units that performed maintenance properly and on schedule didn’t have untimely breakdowns. RPGs and IEDs. Army Reserve unit returned home recently.com. My unit appreciated support from all over the world during the past year’s deployment. the vehicles we armor have a maximum load limit. You can contact him at ricky. So. Something I have found to be true about working in a war zone with a focus mainly on vehicle maintenance is that ‘maintenance is maintenance. maintenance is a small world. because we see it all the time. but maybe you need to reexamine your maintenance process. and many of us face the same issues you face on a daily basis. you’re not alone. had the system been maintained effectively. This information leads to the analyses of the vocational training requirements that are needed in future.10 Asset Management John Wilson (Malaysia) Vice President.what level of service is required? A . In some cases it can take 7-10 years before the impact is realised and by then the management can attribute the breakdowns and failures. These are not new problems. Many Governments. The service delivery criteria then becomes a function of the status or condition of the assets. They have been accumulating all over the world in almost every government and private sector for decades. Much of the situation stems from under-funding routine refurbishment.a saving of $600m. The holistic approach involved in the Asset Management model for service provision. In general. It’s a truism that maintenance can be deferred for many years. www. Under Asset Management ‘rules’ any deferral of maintenance must have documented engineering and economic justifications that are transparent to all. This situation is made worse by the current business practices of evaluating results on a quarterly basis. Recent scorecards by the Institution of Engineers. cuts to the maintenance budget have little or no obvious immediate effect. Australia showed that major infrastructure such as roads. The submissions must include a listing of the physical assets needed to deliver those services. When mishap or disaster strikes.5 billion to repair the buildings. is not just bad luck. If the assets are neglected then the level of service will decline. vehicles.000 buildings and structures with a replacement value of $650 billion. which could have been used for other public projects. to make the most of their service delivery potential and manage the related risks.com. and in some cases disasters. Under these scenarios there is a dawning of a new business awareness called Asset Management or Sustainment Modeling. The submission noted that the management had neglected and under-spent on repairs and maintenance for decades. managers want to maximise profits and report positive quarterly results. refuse dumps. Again. Each year the condition of the assets is inspected and appropriate replacement. this massive injection of capital would have been much reduced. People don’t like paying for poor service and tend to get annoyed and complain right up to the ballot box. office systems. The loss or waste of such a large sum. water systems. However. maintenance and repairs. In 2001 the management of the world famous Smithsonian Museums asked the US Congress for a staggering $1.bintai.and the US Congress made that known and publicly admonished the Smithsonian Administration for its poor maintenance management. Bhd. The assets may be buildings. The Government is hoping that privatisation may help solve the problems but it rarely does. much of which is nearing the end of its economic life. The Asset Management models have broader implications as they must also consider the skills available to properly care for the assets. Asset Management is the philosophy that guides facilities management and maintenance management because it addresses the front end of the issue that concerns everybody . Asset Management policies force the agencies to detail and prioritise the services they are responsible for (usually the public expectations are considered in the process). Similarly. use and disposal of assets. Of course. The US Government has adopted Asset Management or Sustainment Modeling out of need . repairs and maintenance strategies are implemented using the quality of service delivery as the benchmark. Asset Management offers a systematic approach to realising the extent of the problem and providing a mechanism for improvement. it’s bad management . acknowledging that any change to the quality of service delivery has social and political ramifications. now insist that before agencies are funded they must submit yearly Asset Management Plans. parks and gardens. In my own estimation I figured that had the properties been routinely maintained then the cost may have been $900m . stakeholders expectations and support services is far more rigid and more logical than arbitrary cuts to the maintenance budget. asset care. The managers of infrastructure have made the most of the ‘savings’ resulting from deferring maintenance. The Department of Defense alone has 517. gas and ports are falling below acceptable stakeholders standards and the Government is facing huge expenditures for repairs and replacements in coming years. this mismanagement of asset maintenance is insidious and eventually affects the products and services delivery. and costs over the full life of the asset. Kejuruteraan Bintai Kindenko Sdn. Attempting to show growth each quarter leads to short-term management actions. the UK rail system is undergoing £30 billion repairs and modernisation. etc.it can no longer fund replacement of infrastructure on the scales that were looming plus maintain let alone improve service delivery. particularly after privatisation. The maintenance budget is an easy target and is one of the first attacked in any cost-cutting/profitmaximisation initiative.my sset Management is a process of guiding the acquisition. to simply bad luck. rail. effective and efficient. plus bodies such as the UN. The assets have deteriorated to such an extent that major accidents and near misses are regular occurrences and the risks are increasing. not long-term strategies. The common factor is maintenance. A high level of service requires assets that are reliable. the CEO or CFO announces that some bad luck struck and effected profits. . part availability. The PLC is used to control AND to troubleshoot the machine. the maintenance technician will be using the PLC as a troubleshooting tool to reduce downtime. Outputs from the PLC can be motors. The maintenance technicians we train. are the brain surgeons. program copies. Thousands to millions could be lost by one little PLC in an electrical panel that you never even knew existed. In a reliable maintenance management environment. the machine is dead. damage to machine and personnel could result from improper maintenance management of your company’s PLCs. The PLC replaces thousands of relays that were in older electrical panels. USA bin95@bin95. indicator lights. (His mouth drops open.12 Maintenance Management Of Your Company’s PLC (Programmable Logic Controller). air solenoids. As this article is not just for the maintenance technician. and details for your company? Do you have at least one trained person per shift. When the PLC is not functioning properly. A little more detailed definition of a PLC: A programmable controller is a small industrial strength computer used to control real world actions.. ‘. you train brain surgeons?’) Important Note: Just as a doctor asks the patient questions to figure out what is wrong. Why? Because the PLCs (Programmable Logic Controllers) are the brains of your operation. and allows the maintenance technician to change the way a machine works without having to do any wiring. a maintenance technician asks the PLC questions to troubleshoot the machine. Don Fitchett Business Industrial Network. machine operator data. A PLC (Programmable Logic Controller) is the type of computer that controls most machines today. The program is typically in ladder logic. what a PLC is. based on its program and real world sensors. That is how I explain it to my doctor any way. which is similar to the wiring schematics maintenance electricians are already accustomed to working with. sensors. plant managers and corporate managers. The maintenance technician uses a laptop computer to see what conditions have to be met in order for the PLC to cause an action to occur (like turn a motor on). and procedures? If you could not answer with confidence or you answered “No” to any of the above questions. lines shut down. Inputs to a PLC can be switches..com Topics Covered In This Article: • • • • • What is a PLC? How many PLCs is your bottom line depending on? Do you have an up to date list of all PLC model types. plants shutdown. The PLC is the brain of the machine. even city bridges and water stations could cease to operate. you need to read this article on maintenance management of PLCs. etc. but for maintenance managers. Without it. What is a PLC? First I’d like to explain in the most† non-technical terms possible. . bar codes. to maintain and troubleshoot your plant PLCs? Does your maintenance personnel work with PLCs following written company or corporate policy. etc. But most importantly. 13 How many PLCs is your bottom line depending on? My company has had an ongoing PLC related global maintenance survey ( www. It is common to only learn about a PLC once the machine is down and the clock is ticking at a thousand dollars an hour. bottlenecks and other factors will help you assess priorities. that they know of. No two addresses will be the same. but many of the participants are from fortune 500 companies having hundreds of employees. Ex: Allen Bradley. and write down the PLC brand. The odds are most of them have 12-30 PLCs in their facilities. I want to share with you our company PLC audit form:(Ex = Example) Collected Information Machine or Area Name PLC Program Name Network Node Address Network Name PLC Brand PLC Model Number Is Spare Available Date Program Last Backed Up Discriptored Copy of program avail. Schneider. or even the entire plant? Do you have an up to date list of all PLC model types. or more. Open every electrical panel. Or other method of storing backup program in a chip on PLC Remember to log when outside consultants or OEM make program changes too. DL 405 Yes on shelf. or only in less critical machines or no Make program backups part of your semiannual PM program Without discriptored copy of program. Unfortunately. Most plant air compressors have a PLC. and in other similar machines in a company or corporation. P3. Strap2. program copies and details for your company? The first step to take is to perform a PLC audit.bin95. How much would it cost if the bottleneck or plant air shut down a line. Starting with the highest priority PLC. Line 7. Once you have collected the basic information in your Plant wide and/or corporate audit. but most machines are controlled by a PLC. you will need to ask more important questions. . 5872443. Some older electrical panels may only have relays in them. Ex: 1789GAA1. In the risk analysis. pump station 3. 3. Currently the average is 6-9 reported. it is also common that after the fire is out. Strapper 2. Traffic signal west main. to avoid unnecessary risk and to insure reliability. without fully learning what can be done to avoid these costly downtimes in the future. but not mandatory. so the good news is that industry as a whole is becoming more PLC aware. WestMainTL. See manufacturer’s data for recommended change frequency. it's on to the next fire. then act on that analysis. • Do we have the most common spares for the PLC? • Is the OEM (Original Equipment Manufacturer) available 24/7? Or even in business any more? • Do we have a back up copy of the PLC program? • Does our program copy have descriptions so we can work with it reliably and efficiently? • Do we have the software needed to view the PLC program? Are our maintenance personnel trained on that PLC brand? These are some of the questions our managers must ask. Should be saved to EEPROM (Burned) after every successful program change. Might be facility location when corporate HQ is using this form. reported 3-6 PLCs in their facility. A bottleneck machine in your facility may have a PLC. SIMATIC S5. 17. Siemens. a section of your facility. SLC-504. The majority of the participants back in 2001. model. Does PLC have EEPROM Last date Program Changed Last date EEPROM Burned Date battery last changed Other information you may need Recommended Action Ex: warehouse conveyor.com/survey/survey ) since the year 2000. Omron Ex: PLC-5/25. etc. troubleshooting and downtime are greatly increased. and other pertinent information. Granted most participants are managers and don't open electrical panels much. Mitsubishi. part availability. To help you out. DirectSoft. Then go the next two steps. MELSEC FX1N. you need to analyze the information to develop an action plan based on risk analysis. 21 Common to be same as Program name. etc. Ex: 2. Analyze the audit information and risk. Some other good ideas to get more out of your PLC training investment would be to get hands on training using the actual PLC programs and software the maintenance technician will be working with in the facility. • All PLC 110v control voltage will have a line filter on it. It amazes me how an organization can write guidelines for what they believe is the health of the entire organization’s body. 3. Online programming is somewhat of a safety risk. The training you decide on. • If available. All personnel working with PLCs will be trained on that PLC equipment. (SOP) 2. I can tell you here. it is not smart management to place all your eggs in one basket. I have reviewed many policy and procedures as well as books on the topic matter and hardly ever see maintenance management of the PLCs included. USB. I can give you a couple of good reasons why you should have at least one trained person per shift.. I will donate a few random items below to get you started:1. they shall be removed within 24 hours and a more permanent solution found. should stress working with PLCs in a Safe and Reliable way.idcon. Backup copies of the PLC programs will be made every 6 months regardless of change status. 4. • All forces should be documented in software and a written log before being enabled.com . and leave out the brain (the PLC ).If outside vendor changes. . (See safety SOP) 7.. etc. You do not want to see greater downtime on off shifts because the knowledge base is on day shift only. • It will be documented in the software copy. Forcing inputs and outputs on or off shall be treated as a Safety issue.14 Do you have at least one trained person per shift to maintain & troubleshoot your plant PLCs? Is your maintenance staff trained on the PLC? Silly to squander over a couple of thousand in maintenance training when the lack of PLC knowledge could cost you 10 thousand an hour. to work reliably with PLCs. Future equipment purchases . if policy and procedures are not written and enforced. I feel the two criteria above are the most important. a-d will be performed by maintenance personnel 5. • Multiple copies will be stored on laptop. what should we look for in training? Well I have been training individuals for over a decade and could easily write another article on just PLC training alone.com/toastforum6503/toast/toast. • A common PLC brand in all equipment will be sought out (Standardization of PLC types) • OEM will be required to provide a descriptor copy of PLC programs in the customer’s native language. in the printed copy and in the CMMS program. • Copies of the PLC program will be stored on a media more reliable than floppy disk (CD. we eventually stray back to the old unreliable ways. Secondly. 6. Write PLC policies and procedures into your existing maintenance policy and procedures. the training should be actually centered around the PLC products you are using or plan to use in your facility.. Also with all the baby boomers (our core knowledge base in the industry) about to retire.). a complete PLC policy and procedure manual is out of the scope of this article. • All PLCs will have the backup EEPROM option for zero downtime in some failure modes. PLC Training CBT (Computer Based Training) CDs are a great way for employees to follow up 6 months after the initial training. Once again. normal procedure is to change offline and download to the PLC. 8. If a PLC program has been changed .. (not just textbook knowledge or self learned knowledge) 2. Hope this helps. Inputs and outputs shall not be forced on or off with out a clear understanding of complete effect on PLC program and a second opinion. However. EEPROM will be updated with new changed program. equipment and encouragement to continue with self education. maintenance manager’s office and off site (corporate). Then the question should be asked. • If forces are installed. that you should seek training with two primary objectives:1.bin95.asp?sub=show&action=topics&fid=10 Business Industrial Network www. Do your maintenance personnel work with PLCs following written company or corporate policy and procedures? It seems that in our industrial culture. Some other ideas you could do is to provide them with simulation software and/or a spare PLC off the shelf to practice with. Ensure your personnel have the software. if you have a specific question you can find me in our PLC discussion area at the www. THE LATEST INFRARED CM/PM PACKAGE FROM NEC • FULL 320 X 240 UNCOOLED FPA DETECTOR • IN-BUILT VISIBLE CAMERA & LASER POINTER • STORES OVER 1000 IMAGES INTERNALLY • LIGHT-WEIGHT AND SMALL PACKAGE • STRONG & ROBUST TO IP54 • “FLIP-UP” 3.com.000” Infratherm Pty.au . NORTH [email protected]. Limited Infratherm Pty Ltd PO Box 117.au web: www.5 INCH LCD SCREEN • NEC QUALITY AND RELIABILITY “ALL FOR UNDER AU$ 25. NSW 2756 AUSTRALIA Tel:+ 61 2 4579 7334 or +61 2 4322 2100 Fax: +61 2 4579 6333 or +61 2 4323 7439 E-mail: [email protected] . One metric by itself is not enough. A wide variance between paid hours and reported hours on the daily work schedule will discount the reliability of all other reports. performance to budget. They are goals that can be achieved with very good performance. T Planning & Scheduling Metrics Unreported Man-hours The Maintenance Supervisor records on the daily work schedule the actual hours expended by the maintenance crew each day. The paragraphs describe the periodic charts and metrics prepared for the Maintenance Manager to allow a quick overview of the health of the Maintenance organization. but must be combined together to measure the total effectiveness of the maintenance operation. But if the emphasis is placed on the lead metrics the lag metric will generally turn out as desired. The Maintenance Supervisor must account for every hour worked by the crew. but they also serve as the measure of achievement towards goals. lead metrics and lag metrics. The first metric is therefore. including all overtime. and this paper provides some criteria that can be used to measure value received in maintenance activities. The maintenance metrics not only serve as the basis for evaluating benefits received. McFarland (USA) Recently published in the Reliability Magazine. and the target figure is zero percent (See Figure 1). This paper was originally presented at the 2003 SMRP conference. Unreported man-hours represent the difference between hours reported on the daily work schedule and the man-hours-paid. the relationship between the actual hours reported by the Maintenance Supervisor and the direct worked hours paid to the craftspeople. they must be brought together to give the complete picture of the maintenance operation.16 Metrics For Managing Maintenance Raymond P. At the end of this paper is a table of representative values for each of the 30 metrics presented. This is critical information because all other reports and metrics are based on the hours and information reported by the Maintenance Supervisor. he Maintenance Manager is faced with the challenge of offsetting or moderating increased cost through better use of cost control techniques. Vol 10 Issue 3. and it is important for all maintenance work to flow through the work order system. The control metric is unreported hours as a percent of total hours paid. The emphasis should be to improve the Maintenance Manager’s ability to measure value received. The principal shortcoming in cost control methodologies is the absence of measurements that relate value received to maintenance dollars spent. The lag metric the Maintenance Manager is most familiar with. The following paragraphs provide the metrics that allow the Maintenance Manger to assess the effectiveness of the maintenance operation. The goals acts like the par rating for each hole on the golf course. Figure 1 . There are two primary metric types. Each metric should have a target goal the Maintenance Manager is striving to achieve. The metrics that follow in this paper depend upon the values derived from the work order system data. The benefits of the planning and scheduling program can only be realized when each maintenance craftsperson is scheduled for a full day of planned work every workday. The target is 90% or better for world-class maintenance organizations. Figure 3 . The chart shows the percent of man-hours worked as scheduled and the percentage or jobs completed as scheduled. such as vacations. The maintenance workforce is normally available to work for a known number of hours per week. because the difference between available man-hours and scheduled manhours is affected by unexpected absences or workers returning from absences. Schedule Compliance In addition to scheduling a full day for each maintenance craftsperson. the second most important metric is the percentage of available man-hours scheduled each week. This must be fully planned work to be effective. and schedules them on the day they are expected to return to work. The difference between regular hours available and man-hours scheduled is reported as a percent of regular hours available (See Figure 2). The target is zero plus or minus 5 percent.Total Hours Scheduled ----------------------------------------------------------------.X 100% Total Craft Hours Paid 17 Unreported Time % = Unscheduled Man-hours In the Planning and Scheduling arena. Any reading that exceeds the control limits of ±3% must be investigated by the Maintenance Manger.X 100% Total Hours Available Unscheduled Man-hours% = A zero percentage cannot be consistently achieved. Figure 2 The metric is calculated as follows: Total Hours Available . This metric tries to determine if this goal is being meet within reasonable limits. The Planner/Scheduler anticipates the return of workers from planned absences.The metric is calculated as follows: Total Craft Hours Posted to Work Orders -----------------------------------------------------. the Maintenance Manager must make sure that jobs are being worked and completed as they have been planned and scheduled. This is illustrated in the chart shown in Figure 3. There should be a full day of planned work that is scheduled for every maintenance person expected to be at work each workday. The Maintenance Manager has delegated the responsibility for weekly work scheduling to the Maintenance Planner/Scheduler.18 The metric is calculated as follows: Total Hours Worked as Scheduled ---------------------------------------------. but the recent use of Predictive Maintenance techniques helps control this problem. estimates are used to measure performance. because small time differences make large percentage changes on the performance chart. The trend pattern of the indicators is what the Maintenance Manager monitors on all metric charts. Finally. and once the Operations and Maintenance Managers approve the schedule it becomes the plan of action for the following workweek. This last part can be like a two edged sword that cuts both ways. Failure to meet estimates by the maintenance workforce is just an indication that further analysis is required to uncover the cause of the problem.X 100% Total Hours Scheduled Man-hours Schedule Compliance % = Jobs Schedule Compliance % = Total Jobs Worked as Scheduled ---------------------------------------------. The Maintenance Manager monitors the compliance to the weekly schedule by reviewing the percentage of manhours and jobs completed within the target range. Extenuating circumstances can greatly affect maintenance jobs because the extent of repairs cannot be determined until the workforce is well into the job. Figure 4 The metric is calculated as follows: Total Hours charged to Completed Jobs ----------------------------------------------------------. Initially the Maintenance Manager should seek a percentage level where all jobs are completed at 100% plus or minus 20 percent. they help the Planner/Scheduler in scheduling jobs to properly align jobs with available manpower. Other reasons for not meeting estimates include the inability of the Planner/Scheduler to anticipate the job requirements.X 100% Total Jobs Scheduled When jobs are not worked or completed as scheduled. This is particularly true if the predominance of work falls in the small-job category. Estimates serve three prime functions.X 100% Total Hours Estimated for Completed Jobs Estimate Performance % = . the Maintenance Manager is expecting the work execution forces to complete the weekly work schedule as it was approved except for true emergency interruptions. First. and more importantly. Figure 4 illustrates the type of chart useful for reporting performance on completed jobs. the maintenance work force is not being utilized to its most effective level. The range should be reduced to 15% and then 10% as the Maintenance organization and planning/scheduling operations mature. they help the equipment owner decide if the job is worth the cost of doing it. and this is particularly true for performance against estimate. Second. Performance on Completed Jobs The next important planning and scheduling metric is the performance of the maintenance workforce against the job estimates on jobs that were completed during the week. The weekly work schedule is reviewed and modified if necessary. because there are many variables that adversely affect the ultimate outcome of the job. The scope of the job can change as the job progresses. Therefore. The Planner/Scheduler prepares a recommended plan of action for the following week in the form of a weekly work schedule for each Maintenance Supervisor. Performance is judged on a total jobs basis and not on just one or two keys jobs that have management attention. Small jobs of 4 man-hours or less can play havoc with performance against estimates. The workforce may not work effectively. Internal wear and damage is a prime example of this particular case. and the job takes longer to complete than originally estimated. . are not done. A second helpful backlog figure is the total crew weeks of work waiting to be executed. Figure 6 20 . the benefits of the planning and scheduling process cannot be achieved. such as preventive maintenance. jobs classified as emergencies should be kept to less than 10% of all work executed by the maintenance organization. The chart shown in Figure 6 shows these metrics. and a chart such as shown in Figure 5 will help the Maintenance Manager make personnel adjustments as necessary. The backlog trend is the key factor. a backlog that is too low means that the workforce cannot be effectively utilized and the probability of excessive manpower is fairly high. Emergencies represent an interruption to the weekly work schedule and work efficiency is decreased. conversely. outside contracting is the best way to stabilize the backlog trend. the Maintenance Manager would find it advantageous to show backlog by individual crafts or areas of the plant. Otherwise. a long-term drop in the backlog indicates the possible need to reduce staff. The backlog trend also indicates where to schedule preventive maintenance jobs to best take advantage of dips in the workload level. This backlog should average between 5 to 6 crew weeks of work. Emergencies and Overtime The percent of emergencies and the percent of overtime are key factors in judging the performance of the maintenance organization. including those jobs for which all the resources are not yet available. On the other hand. Decisions of this magnitude must take into consideration future expansion or alterations plans of the facility or production operations. Figure 5 The metric is calculated as follows: Total Estimated Hours Ready to Work -----------------------------------------------------Total Hours Available for Week Backlog in Crew Weeks = A long-term rise in the backlog indicates the need for additional craftspeople. otherwise there are reliability issues that need to be addressed). A backlog that is too high means that the workforce cannot do the work within a reasonable period and that some important jobs. Overtime should be kept within 5% of all regular hours worked. A backlog of demand driven jobs gives the Planner/Scheduler the opportunity to properly balance and distribute the workforce to meet all operational requirements.Backlog Backlog is one of the key metrics that indicates how well the maintenance organization stays on top of its workload level. A backlog of 2 to 4 week of ready to work jobs is a reasonable level to keep the workforce occupied and still meet the equipment demands. Therefore. While Figure 5 only shows total backlog. (It is decidedly unlikely that true emergencies will routinely amount to more than 10% of all work. Backlog is derived by dividing the total estimated man-hours on all ready to work jobs by the available man-hours for the week. If the backlog has a tendency to peak during short intervals. it is important that the use of blanket orders be limited initially and reduced to a minimum over time. the work orders need to be planned in a timely manner. the number of PdM generated work orders completed per week. reduce the administrative labor required to assign and account for maintenance labor. A key indicator in this regard is the turnover rate of work orders generated as the result of predictive maintenance finds. and everybody reaps the benefits. The number of PdM work orders open should trend down or be steady at a fairly low level. However. This metrics gauges how well the Planner/Scheduler is staying on top of the planning workload.X 100% Total Hours Worked for the Week Every effort possible is required by each company employee to anticipate maintenance work requirements as far in advance as possible if the Maintenance Department is to be efficient and effective.X 100% Total Craft Hours Posed to W/O System Blanket W/O % = PdM Work Order Execution The greatest benefit of the various predictive maintenance programs is their ability to indicate impending failures far enough in advance that the work can be properly planned and scheduled. to create administrative devices to absorb craft time. Fewer emergencies means the Maintenance Department can do more jobs with the same workforce. Because Metric Calculations. the number of PdM generated work orders per week. collectively referred to here as blanket orders. Figure 7 . they also proportionally reduce the resolution and thereby the value of the equipment history data collected by the work order system. The metric is calculated as follows: Total Craft Hours Posted to Blanket Orders ----------------------------------------------------------. particularly in the early stages of the work order system implementation. One way to measure this is to determine how many unplanned work orders are greater than one week old. The metric is calculated as follows: Unplanned Work Orders = Number of Unplanned Work Orders Greater than Seven Days Old Craft Time Posted to Blanket Work Orders Many organizations find it convenient.21 The metric is calculated as follows: Total Overtime Hours for Week ----------------------------------------------------. and Engineered Maintenance activities all depend on the equipment history stored in the work order system.X 100% Total Regular Hours Worked for Week Overtime % = Emergency % = Total Hours Worked on Emergencies ----------------------------------------------------. and the total number of PdM work orders still open for the week. Failure Analysis. This metric looks at several things. These devises. Unplanned Work Orders For the maintenance organization to be effective in the planning and scheduling of work. The metric is calculated as follows for the given period: # of Failure Analyses Performed -------------------------------------------------------------------------------------. and Other Unplanned Work Proactive to Reactive Ratio = Overall Vibration Level A key indicator of the health of rotating equipment is the overall vibration level of the equipment in the vibration analysis program. First determine the number of PM and PdM work orders that were completed by the due date. This metric denotes the portion of the total maintenance related man-hours that are recorded by operators in the performance of maintenance related tasks within a given period.X 100% Total number of PdM’s due during the period Proactive to Reactive Ratio This metric denotes the portion of maintenance work dedicated to preventing or mitigating equipment failures as opposed to work dedicated to restoring failed equipment to operation.X 100% # of Equipment Related Process Inter ruptions that exceeded the threshold Failure Analysis % = . Reduce the number of PM’s completed on time by the number completed on time without labor charges. The PM Compliance percentage should be 95% or more. emergencies. Also a reasonable amount of labor has to be charged to the completed PM and PdM work order. Call-ins.09 inch per second in velocity. The numerator is the sum of the craft hours consumed by PM and PdM work plus the craft hours consumed for planned corrective work that originates as a direct result of the PM and PdM activities. Emergencies. The world-class maintenance organizations have a ratio of 7:1. The vibration analysis software should allow this metric to be easily generated. The metric is calculated as follows: Operator Maintenance Hours -------------------------------------------------------------------. and call-ins for maintenance). breakdowns.e. The denominator is craft hours consumed by all other unplanned maintenance work (i.X 100% Total number of PM’s due during the period PdM Schedule Compliance = # of PdM’s completed on time -------------------------------------------------------. It should be reported for all the equipment in the vibration analysis program plant wide. This metric needs to be reported on a monthly basis by the Vibration Analyst in chart form.X 100% Maintenance Craft Hours + Operator Maintenance Hours % Operators Maintenance Work = Failure Analysis Percentage This metric assumes that failures which stop or slow down the production process to some predetermined threshold receive some type of formal failure analysis. Select an appropriate time period and compare the number of failure analyses performed during the period with the number of equipment related process interruptions that exceeded the established threshold during the period. Percent of Maintenance Performed by Operators In the world of Total Productive Maintenance (TPM) the concept is to have operators perform minor adjustments and maintenance activities. and the PdM Compliance percentage should be 100%. For world-class organizations the overall vibration level across the plant is less than 0. and by individual production units if the plant is broken up into such units. An example of an established threshold would be a policy that calls for failure analysis to be performed whenever there is an equipment issue that stops production for over 30 minutes.22 Proactive Maintenance Metrics PM and PdM Schedule Compliance The goal is to determine the portion of PM and PdM work orders that were completed on or before the due date and had labor charges posted to them. The metric is calculated as follows: PM & PdM Craft Hours + Planned Corrective Work Hours -------------------------------------------------------------------------------------------Craft Hours spent on Breakdown. The metric are calculated as follows: # of PM’s completed on time with a reasonable amount of time charged PM Schedule Compliance = --------------------------------------------------------------------------------------. For this reason care must be exercised in determining the equipment count for both the numerator and the denominator.X 100 Total Equipment Count* *Note: It is likely that not every entry in the master equipment list should count as a piece of equipment. which tailor the level of service to the demand exerted from the equipment. and consumables are replaced in inventory within the span of a year. Engineered Maintenance Percentage The Engineered Maintenance percentage denotes that portion of the equipment for which the PM program has under gone some type of formal analysis such as Reliability Centered Maintenance (RCM). the Asset Replacement Value (ARV) will likely have to be estimated. plants with a reactive culture typically have PM’s that originated as a reaction to a failure event and were instituted without the benefit of an overall maintenance strategy. The result is a PM program that risks over-maintenance and may not be as effective in preventing or mitigating failure as generally believed. lean organizations tend to have Engineered PM and PdM programs. The insurance carrier may have already estimated the replacement value of the assets as part of providing insurance coverage.X 100% Sum of Maintenance Hours Paid Rework % = Note that the denominator requires hours paid. Conversely. or Failure Cause Analysis (FCA). For example. pump proper.e. however. For the purpose of this calculation. The metric is calculated as follows: Total Inventory Issues (in dollars) During the Year ------------------------------------------------------------------Total Inventory Value (in dollars) at End of Year Inventory Turns = For world-class maintenance organizations the inventory turn over rate is three times per year or more. Algebraically these relationships simplify to the equation shown below. If the work order system captures near 100% of the time paid then time posted in the work order system may be used instead of time paid. There are two methods for estimating the ARV. i. Most work order systems have some method of flagging work orders as rework. While most plants have some form of a PM program. a pump includes the motor. etc. gearbox.23 Maintenance Rework Percentage The Maintenance Rework percentage is an indicator of the quality of the maintenance work performed It calculates the percentage of hours spent on jobs that were not performed right the first time. Financial Metrics Ratio of Total Maintenance Budget to Asset Replacement Value (MB/ARV) Typically the maintenance budget is readily available. If this is the case then the insured value of the facility may suffice as the ARV. Annual Maintenance Budget --------------------------------------Insured Replacement Value MB:ARV = 2. which is typically around 15%. The Maintenance Rework percentage is calculate as follows: Sum of the Maintenance Hours Spent in Rework -----------------------------------------------------------------. this is to exclude errors stemming from incomplete time posting to the work order system. 1. and possibly a gearbox. The Engineered Maintenance percentage is calculated as follows: Count of Equipment* for Which Engineered PM & Engineered Maintenance % = PdM Programs Have Been Developed -----------------------------------------------------------. Failure Modes and Effects Analysis (FMEA). spares. then the ARV may be approximated by taking the annual total sales of the facility and dividing by the firm’s stated Return on Assets (ROA). . If an insurance value is not available or found not to be relevant. and motor starter. Annual Maintenance Budget --------------------------------------Annual Sales ÷ Stated ROA MB:ARV = Maintenance Stock Inventory Turns This is the average number of times that maintenance parts. a piece of equipment is defined as an equipment group that performs a specific function in the production process. a pump assembly may be listed as not only the pump assembly but may also have a listing for the motor. Like the metric above. Second. Under no circumstance should the Store Department unilaterally eliminate a non-active stock item. and indicates the maintenance cost per unit of product produced during the year. First and foremost. the reliability of the production equipment is improved to allow greater production.24 Vendor Stocked Maintenance Inventory Percentage This metric denotes the portion of the total maintenance inventory (i. This list must be reviewed by the Maintenance Department to determine if the non-movement items can be eliminated from stock. Many times there are highly critical stock items that don’t move annually. providing that they are not held in the vendor’s inventory specifically to address a potential demand by the company. These are generally small parts that are stocked on site by the vendor. parts. The metric is calculated as follows: Number of line items for which material was not in stock --------------------------------------------------------------------Total line items requisitioned for the period Out-of Stock % = X 100% Percent of Maintenance Inventory Showing No Movement in 12 Months Once a year the Stores Department should published a list of all maintenance stock items that showed no movements for the last 12 months. The metric is calculated as follows: Number of Maintenance Items Stocked and Managed by Vendors ---------------------------------------------------------------------------. It can be positively influenced by Maintenance in two ways. the cost of maintenance services can be reduced to lower the cost of maintenance per unit produced. Second. These items must be keep in stock to support the on going operations of the plant. such as critical spares. but consideration might be made to having these items vendor stocked at the vendors warehouse. it can be positively influenced by Maintenance in two ways. the cost of maintenance services can be reduced to lower the percentage the Maintenance Department contributes to cost of production. Items that are not kept on site may be counted in the numerator. It is similar to the Maintenance Costs as a Percent of Production. consumables) that are stocked and managed by vendors such that it does not become part of the company’s inventory system. The metric is calculated as follows: Number of maintenance line items showing no movement in 12 months ------------------------------------------------------------------------------------Total Maintenance line items Non-Active Stock % = X 100% Maintenance Costs as Percent of Production This metric should be reviewed on an annual basis with a downward trend as the desired direction of the indicator. The metric is calculated as follows: Maintenance Costs as % of Production Costs = Total Cost of the Maintenance Department for the Year ---------------------------------------------------------------Total Cost of Production including Maintenance X 100% Maintenance Cost per Unit Produced This metric should be reviewed on an annual basis with a downward trend as the desired direction of the indicator.e. The metric is calculated as follows: Maintenance Cost per Unit Produced = Total Cost of the Maintenance Department for the Year -----------------------------------------------------------------Total Units of Production Produced . First and foremost. It indicates what percent of the production cost is contributable by the Maintenance Department. spares. the reliability of the production equipment is improved to allow greater production. This metrics highlights the percent of time material is out-of-stock when it is requested by the Maintenance Planner/Scheduler or Maintenance Craftspeople during emergency jobs.X 100% Total Number of Maintenance Items Inventoried Vendor Stock % = Out of Stock Percentage One thing that slows down the maintenance scheduling process is stock outages when the job needs to be scheduled. GST For a FREE evaluation copy of MainPlan please contact Dbase Developments on 0500 59 59 55. To calculate availability.com or visit us at www. The metric is calculated as follows: Calendar Time for the Period Planned and Unplanned Shutdown Time for the Period -----------------------------------------------------------------. Then.25 Production Process Metrics Availability Percentage The equipment availability metric is expressed as percent of the total calendar time the equipment is available for production operations.100 inc. Utilization Percentage The equipment utilization metric is expressed as percent of the total available time the equipment is utilized for production operations. subtract from the calendar time the time lost during planned shutdown (for planned maintenance and production adjustments) and the time lost in unplanned stoppages (equipment and process failures). then availabilities from each of the process areas may be averaged together to obtain an overall value.X 100% Calendar Time for the Period Availability % = Availability should be calculated at the individual process level.X 100% Available Time for the Period Utilization % = MainPlan Features include: • • • • • • Maintenance Management System Windows 98/NT/2000/XP Compliant Easy to install and use Powerful graphical report writer LAN and WAN compatible Citrix Metaframe certified Training and Support throughout Australia by Dbase Developments From only $1. divide the result by the calendar time as shown in the formula below. To calculate utilization. send an email to sales@mainplan. Availability as it is represented here does not account for variances in the operating speed of the production process.Non-utilized Time for the Period ----------------------------------------------------------. Then. fax this coupon to 03 9502 0250.mainplan.com Name: ____________________________________ Company:____________________________ Address: ________________________________________________________________________ Phone: _________________ Fax:__________________ Email:__________________________ 25 . If an overall availability is needed. divide the result by the available time as shown in the formula below. subtract from available time the time the equipment is not being utilized to produce product. which is discussed below. The metric is calculated as follows: Available Time . Adjustments for processing speeds that are below the design speed are accounted for in the Performance Rate Metric. These are just a few of the yardsticks Day & Zimmermann has found useful in appraising the maintenance operation. OEE measures the effectiveness with which the plant is being used to add value to the company. November 1970.26 Performance Rate Percentage Performance Rate is an expression of the actual production rate as a percentage of the plant’s design capacity (speed). If Maintenance is to be a dynamic force in the plant organization it must be able to show improvement. Raymond P. Editor. IL. operating speed. Both design capacity and actual production rate are expressed in units produced (U) per unit time (t). Cleveland. Cost reporting through the use of a well functioning computerized maintenance management system supplies the information that is required to make these comparisons. The most important requirement is that the basic information is accurate and reliable. Some industries refer to this at the "first pass yield" or "first right intent". Utilization percentage. Circle the answers that best match the company’s status on the metric listed. Management Handbook for Plant Engineers.(Units Downgraded + Units Scraped + Units Reprocessed) -----------------------------------------------------------------------------------------------. Improvement is accomplished through control and control is exercised as the result of measurement. Each Maintenance Manger could come up with many more metrics that are appropriate to the local situation. The Author: Ray Mcfarland is a Principal Adviser with the global mining giant Rio Tinto. Maintenance must make every effort to charge costs as accurately and finitely as possible. McFarland. Performance Rate percentage. National Plant Engineering and Maintenance Conference. It is a comprehensive indicator of the plant’s condition that takes into account operating time. and product quality. National Plant Engineering and Maintenance Conference. The actual production rate is expressed as an average and is calculated by dividing the actual production by the operating time. AIPE Plant Engineering and Western Maintenance Conference. The metric is calculated as follows: Total Units Produced . “Managing Maintenance With Planning and Scheduling”. “Maintenance Cost Analysis for Cost Reduction”. The stage of the maintenance organization is determined by were it ranks in the maintenance metrics as summarized in Table 1. Bernard T. The metric is calculated as follows: Average Actual Production Rate (U/t) ---------------------------------------------. . McFarland. April 1970. and it refers to the amount of product that can be shipped without further processing.X 100% Total Production Units Quality Rate % = Overall Equipment Effectiveness The Overall Equipment Effectiveness (OEE) is the product of Availability percentage. If you can measure maintenance you can improve maintenance. Inc. September 2002. San Francisco. Lewis. The concepts presented in this paper were developed while working for Day and Zimmermann International. Raymond P. “Cost Accounting and Budgeting for Maintenance”. McGraw-Hill Book Company 1977. McFarland. In effect. The metric is calculated as follows: OEE = Availability % X Utilization % X Performance Rate % X Quality Rate % Metrics Score Card Every maintenance organization is in one of four stages of development (see Table 1). March 1971.X 100% Design Capacity (U/t) Actual Production (U) ---------------------------Operating Time (t ) Performance Rate % = Where: Average Actual Production Rate = Quality Rate Percentage The Quality Rate percentage expresses the amount of acceptable product as a percentage of total products produced. McFarland. OH. and the Quality Rate percentage. Strive to improve maintenance using the managerial technique of performance metrics. References: Peter C Chalich. “Stage Metric Data Gathering Guidelines”. “Maintenance Cost Analysis for Performance Improvement”.. Chicago. Day & Zimmermann International Inc. Raymond P. operating utilization. Raymond P. The resulting value is the percentage rate at which the plant’s potential is being utilized. 8 Crew Weeks 1% .12 in/sec 4:1 .84% 85% .0.5% .89% 3% .5 .84% 80% .17 in/sec 0.25% 16% .59% 85% .09 .15% 4 .5% 80% .3.79% 2% .32% 30% .5% 1% .95% 95% .0 .2.10% Large Up Trend Large Up Trend 3.16 .5% ≥ 3.10 Crew Weeks 6% .94% 60% .6 Crew Weeks <1% <1% ≥ 90% Estimate ± 10% 2 .10 5% .20% 70% .9% Small Up Trend Small Up Trend 2.30% 2% .20% 6% .94 % 0.0 ≥ 80% < 2% < 1% Trend Down Trend Down 50% .25% 8 .9 20% . .79% 0.89% 85% .09 in/sec ≥ 7:1 ≥ 33% ≥ 90% < 2% ≥ 90% 21% .3 > 7 days old 10 .69% Estimate ± 21% .13 .9% 10% .0.9% ≥ 89% 3.25% 8 .1. There are many other metrics that can be used to measure the effectiveness of the maintenance organization.2% 2% .1:3 3% .94% 93% .59% 70% .19% 6% .0 .0.0% .5% 1.89% ≥ 95% 100% < 0.10% 40% .7 > 7 days old 16 .20% 11% .10% 1 .79% Estimate ± 16 .6% 4% .4 Crew Weeks 20% .0.13 11% .27 Table 1 Metrics Score Card Stage 1 Reactive Stage 2 Transitional Stage 3 Proactive Stage 4 Lean Planning & Scheduling Metrics Unreported Man-hours Unscheduled Man-hours Schedule Compliance Performance on Completed Jobs Backlog Emergencies Overtime Number of Unplanned Work Orders Over 7 Days Old Craft Time Posted To Blanket Work Orders Open PdM Work Orders Proactive Maintenance Metrics PM Schedule Compliance PdM Schedule Compliance Overall Vibration Level Proactive / Reactive Ratio % Maintenance Done by Operator Failure Analysis Percentage Maintenance Rework Percentage Engineered Maintenance Percentage Financial Measures Percent of Maintenance Budget to Asset Replacement Value Maintenance Stock Inventory Turns per Year Vendor Stocked Maintenance Inventory Out of Stock Percentage Percent of Inventory Showing no Movement in 12 Months Maintenance Costs as Percent of Production Costs Maintenance Cost per Unit of Production Production Process Metrics Equipment Availability Percentage Equipment Utilization Percentage Equipment Performance Rate Percentage Equipment Quality Rate Percentage Overall Equipment Effectiveness 80% .15% 5-7 ≤ 5% ≤ 5% 0 > 7 days old <10% <5 WARNING!! .20% 6 .4% 2% . Target figures change according to industrial circumstance and the Maintenance Manager should establish the target level that is applicable to their plant.9 50% .15 in/sec 1:1 .88% ≥ 95% ≥ 95% ≥ 99% ≥ 99.30% 11 .6:1 10% .99% 73% .39% 75 .0.98% 95% .30% 21% .0% 0.49% 5% .3.3% Level Trend Level Trend < 2.0% 2.99% 0.92% 50% .74 % 80 .7% 9% .19% 60% .89% 90% .89% 90% .5% .4.72% 90% .20% 20% .95% 90% .20% 8 -10 > 7 days old 26% .The metrics listed in Table 1 are offered for representative purposes and are not applicable in all industries.30% 50% .94% 95 .9% 21% .29% 11% .10% 5% .9:1 1% .2:1 .90% Estimate ± 10 -15% 4 .9 2% . But making exceptions to the scheduling discipline is a risky venture when you are trying to change a culture. Production. The goals should reflect understanding. These drivers must be clearly understood and communicated to the organization. Inc. but that in itself is not a money maker. the reason to schedule is to demonstrate “control” of the process of outage management. As stated above. and coordination is either luck. be effectively taught the tool. The cultural barrier is much the same as the hurdle to be overcome in developing effective and detailed planning packages. Flexibility is important given changing conditions. As with any education process. The scheduling tool is what will sell the value in the end. the people must have a leadership champion for support. an argument can be made that linking these jobs sequentially may not be a requirement.28 Scheduling More Profit Reliability Solutions. This is the skill that leadership must expect to compete in today’s manufacturing processes. and reducing idle labor costs. and results measured by leadership. Some times it is easy to hold on to old ways if they are allowed to co-exist. Storeroom. At the end of this paper. Just as craftsmen balked “Why would you need my skills if you have the steps detailed in print?” and forcing discipline in reliability methodology. while adaptive organizations can keep focus on the long term goal by phasing in the approach. must see the benefit in dollars through reduced effort to achieve better results. Doing it when you planned allows every supporting resource to align their time. but we must remember that flexibility cuts many ways given interdependencies. T The Systemic Challenge Making it Happen The challenge to make effective scheduling a norm in any organization is basically two fold. Purchasing. overcoming the cultural barriers and removing the technical barriers. Everyone in the organization. then improvement. then learnings. The money maker is very clearly the desire to do such a good job of scheduling that outage durations are reduced (provide more profit generating production time) and maximizing resource effectiveness by coordinating the myriad of resources in a way there is no standing around time. regardless of level. (USA) www. The ability to use a good scheduling tool provides two benefits. Flexibility is an important value to the maintenance mindset. It is nearly impossible to implement full success at one fell swoop. The higher achievement is to do it when (with a correct duration) it was planned. then application. there has to be a benefit to drive the change. and allows production planning to understand how much downtime is required. after a review of the tool. Meeting commitments is a requirement. Contractors. and Facility Craftsmen must be involved to make this work. If there are work orders that are not time sensitive. but still difficult. be expected to learn and utilize the tool. and laying out a detailed schedule is a definitive threat to that flexibility. Everyone. The classic barrier is “It will happen when it happens.reliabilitysolutionsinc.com he intent of this article is to demonstrate how a scheduling process can provide a way to facilitate discipline in a manufacturing environment and how it can be implemented. the same type questions will arise during scheduling implementation. The concerns are legitimate but there exist compelling reasons to do effective scheduling. Software vendors and educators understand the value of end user practicality over technical software wizardry. and the documentation of what the growth opportunities are over time. Making the software work at the base level is key. The organizations ability to change drives the change methodology. Goals As with any undertaking. or resource dependent externally (production or maintenance). a suggested implementation plan will be discussed. some organizations require an all or nothing approach to scheduling. Scheduling is the medium by which this challenge can be achieved. The expense of resources can only be minimized when coordination is achieved. the actual schedule. The barrier to overcome is effectively teaching the tool so that the difficulties of coordination and resourcing hundreds and even thousands of tasks needed to coordinate an outage can be accomplished. . no matter what the computer says”.. The technical challenge is somewhat more straightforward. The tools are becoming more user friendly with the evolution of the software. or the result of effective scheduling. and most importantly must be performance metrics that are widely communicated. PowerPoint. These are the skills that the modern manufacturing environment must demand of the people who work there. Having details on the operational activities will help to alleviate confusion between Operations and Maintenance during periods where overlapping work happens. the crane is a shared resource and determines the length of the outage. This way the outage becomes a team effort with interlinking tasks and dependencies. The mobile crane is identified as a resource. and schedules are of limited value without everyone’s participation. Access. The reporting and graphics are simple to invoke and descriptive in their information. Maintenance and operations can develop effective hand off points like lock out / tag out operational tasks being used for milestones to begin maintenance work. Providing a Methodology for dealing with Changes 3. There are many other scheduling tools available. “plan your work and work your plan. The best way to implement a complicated process is to use simple tools that are easy to learn and effective to communicate. This is where the MS Project tool can be used to document and perform “what if” analysis on different scenarios presented by the team members in putting together the project. One of the first things that happens is that the organization grasps onto the governing job. Effective communication when hundreds of concurrent tasks are occurring is a key to success. The commonality of some of the basic elements of MS Project with its companion Microsoft applications (Excel. To coin the intent in a simple phrase. Communicating Effectively to All Stakeholders Scheduling Tasks Scheduling effectiveness is critical when many people are involved. With this tool. The following schedule is an example of just such a scenario. and maintenance. Some of the resources that you use may be people and some may be equipment. The data transfer capability allows portability into other mediums very simply. The major tasks to be accomplished include: 1. The ability to communicate to the entire organization exactly when the crane will be used. contractors.29 The Tool Starting with the Correct Balance of Power and Ease of Use The power of the MS Project tool lies in the power of user friendliness. It is important that maintenance and operations work together to create a schedule that works. For instance. etc. The governing job typically is a capital . but this tool can easily achieve 80% of the value with 20% of other scheduling tool’s effort. We all want downtime to be minimized.) saves trying to learn some of the keystroke basics. the crane may become a resource in your schedule. You can link jobs together and effectively utilize the crane to be able to get the most work done possible in the outage window. and as the outage critical path (shown as red tasks) demonstrates. For good scheduling to be effective. Another key manufacturing metric is asset downtime. It has been said that 90% of the benefit of developing a schedule actually lies in the planning process. Word. Shutdown and start-up activities are key to implementing a schedule. Changes to the plan have to be seamlessly added in a way that is evident and not destructive to clear understanding. Scheduling Tasks in a Effective Sequence given limited resources 2. if you are working in an area that uses a mobile crane for many of the jobs. especially when there are resources that are shared amongst operations. and for how long will alleviate any unnecessary confusion and therefore facilitate the teamwork needed for effective task execution.” It is a valuable exercise to think about which job has to be completed before another one is started and to do that with hundreds of tasks all running concurrently with many teams executing these tasks is an exercise in discipline and execution. Proactively determining the necessary length of an outage in plenty of time to finalize a scheduling backbone is important to the success of any scheduling process. obviously a good deal of thought and effort has to go into the sequencing and coordinating of these tasks. for the tool must be understandable to everyone. one way to shorten the outage and increase production time is to add another crane resource. by whom. The schedules may be complicated. Many organizations still leave the scheduling process to only the maintenance function. but making the use of the tool complicated doubles the difficulty. obviously a tradeoff in cost versus downtime. MS Project will show you a Gantt Chart view of what your baseline was vs.As a rule with so much going on. This effort brings two benefits. will reap benefits in the ability to make good business decisions based on changing conditions. Once the outage is over and all the planned vs. even though difficult. There are a myriad of reports that are easily available to the scheduler to provide specific details around resources.MS Project can set up daily schedules by any grouping and typically two day look-aheads are included in this work list. and each step being detailed allows for scrutiny and improvement opportunities that can reduce the time needed to perform the outage. as the tasks are statused. Communication The third and in some ways the most profitable is the ability to communicate statusing and opportunity in a way that the organization can respond quickly to any changes that may arise. and ends up in the hands of the Production team. A baseline is basically a snapshot of your schedule that you take prior to the start of the outage or execution of the schedule that you put together. The Daily Schedules .The Overview will provide outage performance statistics such as productivity and projected finish times for the outage. Given the statusing above. The schedule above shows that the critical path (or true length of the outage) is passed off from Production. it is prudent to just display tasks that are later than planned and in danger of effecting the outage duration. The reports that give the best advantage are: 1. but it is important to not overwhelm the organization. or outage critical path can not be determined. As the picture above demonstrates. to the Mill Maintenance Crew. The Daily Overview . Once a baseline is set. the projected startup can be moved up by 7 hours because Task 4 was done 4 hours early and Task 8 was done one hour early and Task 13 was 2 hours early. Once the work has been scheduled with linked tasks. statusing can begin on the progress of the work that was planned. The truth is until going through the process of linking all of the tasks (production and maintenance) the length of the outage. etc. Statusing jobs by percentage can lead to false results as to exactly where you are in your project. 2. a clearer picture is emerging as to what the opportunity to shorten the outage may be. Example is that you could have a job of changing out 1. Statusing an outage can be a very valuable tool to help the organization understand progress and opportunity but many organizations decide not to dedicate the effort to accurately status work progress given all the activity that is going on. Tracking and Communicating Progress The obvious first step to improvement is to set a baseline of performance. Once you have set the baseline.30 project or some major maintenance undertaking that most people associate with outage length. to the Contractor. and what-if scenarios. Sequencing the work and minimizing the overall duration of all of these linked tasks in the planning process is where there is money to be made. but typically impossible to communicate effectively. These daily schedules are also used to do statusing to document daily progress against the plan. 80% of the duration is not necessarily complete if the easy ones are done first. what the actuals are according to what has been statused. The Slipping Tasks Report . For this reason developing a reliable method of effectively statusing. It is possible to keep this calculation in your head. a critical path identified. it provides how tasks are faring against the original plan (measuring productivity or planning effectiveness) and secondly will allow rescheduling to comprehensively reschedule all tasks that are affected with schedule changes with one keystroke. accurate duration hours and any hours remaining to complete the work. This baseline serves as both a visualization of success. . it also serves as the foundation of being able to deal with changes in the process.000 tubes in a section of a boiler. This tool will allow everyone to understand how it happened and how they need to adjust to take advantage of the opportunity. It is time to set a baseline. Probably the best representation of the scheduling process is the actual statused Gantt Chart posted on the conference room wall. When statusing jobs you want to status the “duration” not necessarily the work or effort. critical path analysis. actuals are recorded the process of continuous improvement has begun by looking at opportunities to shrink those variances in the next planning cycle. The reporting function should be clean and concise. Confusion seems to lie in whether to status jobs by percentages or durations. If 80% of the tubes are installed. 3. It is necessary to give start dates and times. Every hour each team has the ball is an hour away from profit making. back to the Contractor. and look for areas where you can decrease either the time or resources who will do the work. you can use the tool to plan for a weekly schedule. until you are comfortable with how the software works. the easiest way to get your arms wrapped around the program is to practice what you learn on a small scale. For people in the organization to have the ability to use MS Project will benefit greatly because the organization will be able to use it for a long and short outages and even for weekly forecasting of maintenance work. It is best to master the planning process before implementing the scorecard. increasing the amount of tasks that you schedule does not matter. Reduced downtime and reduced resource cost all add profit to the bottom line. and schedule work for one day. The concept of scheduling is so intricate with the many processes that must be coordinated that introducing a complicated software tool only compounds the problem.31 Bridging the Gap between CMMS and MS Project Most organizations already are facing the challenges of implementing and using a computer maintenance management system (CMMS). Better yet. Schedule the work on the day that you want and leave the resources off the tasks. add resources. Once you have invested in a two day education session that provides exposure and a guidebook to all of the MS Project tools. Because MS Project has so much capability. It is important to teach the organization how to use the MS Project tool to not only save costs that occur when hiring an outside resource but also to educate people as to what it takes to put together an effective schedule. CMMS’s are typically tailored toward cost management and procurement. You will have the ability to keep the downtime to a minimum because you will be able to lay out the work.reliabilitysolutions. Another strategy that you can attempt for practice is to start by inputting the tasks and just use MS Project for a task list. putting constraints on tasks. Implementing MS Project The best way to use any new tool is to start in small chunks and work up to larger projects. resources. Using a tool like MS Project provides the user friendliness that allows the software to not get in the way of the scheduling. Don’t link jobs together. The good news is there are vendors that have accomplished seamless ways of transferring the data both from the CMMS to MS Project in a way that both systems have the information they need to provide value to the user without doubling up on the work. add things onto the process like start job links. a great way would be to start with a one day project. Tracking and incomplete or poorly planned schedule may have little value in the learning process. with the tool in place and properly scheduled the documentation in place will effectively communicate the plan to everyone in the organization so they can all participate in the execution of the plan. Both are important to managing the business. so adding another piece of software to do scheduling seems to be redundant. The same is true with MS Project.com 31 .www. The one thing to keep in mind when working on schedules is that once you master the process of how the software works. MS Project excels in scheduling. Contact: John Hoke or Lorri Craig . etc. Link jobs. To give people the tools to better schedule the work that they planned will help in educating or teaching people the discipline it takes to put a good plan together. evaluate the necessity of the scope of work. Once the confidence level in the quality and completeness of the schedule is in place the final step in learning the scheduling tool is to implement the tracking process. Then when you have practiced. Once you get the hang of how to plan and schedule for one day. and quantify economics of inspection methods.com. Manage Projects & Proposals. Using Aptools to assist this process will enable engineers to determine Total Business Impact based upon fact Determine Life Cycle costing. ALMS access is licensed or plans can be produced using your expert knowledge.au Web: www.aptgroup.reliability. and spares placement. (Does not require any additional hardware or software to operate the system. It consists of: ALMS Desktop (DTM) supporting condition assessment and data collection. Company Information: Name: Address: Contact Phone: Email: Web: Asset Future PO Box 1516 Toombul. Surry Hills NSW 2010 Contact: Geoff Soper or Ian Jones Phone: 02 93180656 Fax: 02 93180776 Email: info@aptgroup. data capture and analysis to enable strategic/best practice Asset Management decisions. from the respondents. CMMS work programs and ‘what if scenarios’. • Calculate the business impact of Not replacing at the optimal time.) ALMS Information Explorer for analysis and reporting using a powerful ‘drilldown’capability and report wizards. asset risk & condition analysis. determine the worst & best case. Optimise Shuts & Inspection Schedules. calculate the best inspection monitoring intervals. & risk exposure. • Investigate alternative work schedules.com. working practices. • Which monitoring method is most cost effective. ARMS Reliability Engineers Company Information: Name: Address: Contact: Phone: Fax: Email: Web: ARMS Reliability Engineers Melbourne / Brisbane / Perth / Florida / Vancouver Darren Gloster +61 3 5255 5357 +61 3 5255 5778 arms@reliability. escalation stages. 25 year plans (< 50 items) start at $250. determine correct levels. costs.com. Software Details .au www. calculate true optimum equipment life based on total business impact expenditures. QLD. correct work scope for inspection & maintenance tasks. • Evaluate the correct time to replace or upgrade an ageing asset. Risk Based Inspection. evaluate the worth of projects against resources & constraints.au ARMS AvSim+ AvSim+ is a powerful availability and capacity modeling software that lets you make better decisions about plant design.Functionality: AvSim+ is a powerful availability and capacity modeling software that lets you make better decisions about plant design. • Discover what data is worth collecting & for what reason. maintenance strategies. & risk exposure. ALMS Enterprise an Oracle web based planning system applying Oracle EBusiness technologies. central versus distributed options. and spares placement. • Determine optimal intervals. Maintenance Journal. Optimise Spares & Stock. Asset Life Management System (ALMS) ALMS is a strategic asset planning system that models equipment life to produce future maintenance budgets and work programs. • Determine the best frequency for testing standards based equipment or systems. EIT does not therefore accept any liability for actions taken as a result of information given in this Survey. as received. • Unavailability consequences. Asset Performance Tools (Aptools) Determine an assets whole of life criteria combined with its optimal operational reliability risk. Editor. Software Details . combine tasks & staffing.com Software Details: The ALMS is a set of planning tools producing long term budgets. performance & risk exposure. risk of alternative maintenance strategies. • Ensure OH&S compliance.com www. • Reliability modeling determines failure modes & risk pattern consequences. customer impression & other intangibles. Maintain Optimal Maintenance levels.au Company Information: Name: Apt Group Address: Suite 22.com.assetfuture. • Evaluate & demonstrate project viability. maintenance strategies. 4011 Name: Larry Woodland (07) 3268 3336 larryw@assetfuture. determine best preventive intervals or replacement benefits. cost & replacement value. • Reveal impact of over or understocking. select the right equipment.Functionality: Psychical Asset Management requires a process of workflow. 450 Elizabeth Street. criticality coding. With AvSim+ you can build Reliability Block Diagrams and populate them 32 . The data given in this DATE DATE Survey is extracted.Survey 2005 Special Maintenance Applications Software Special Maintenance Applications Software Survey 2005 This survey was conducted by Len Bradshaw. At each block the engineer can enter the capacity and the parameters representing the reliability. and flexible FaultTree application available on the market. unavailability levels. allowing the engineer to make comparisons between overall plant capacity. • Helping drive the maintenance budgeting process for New and Existing facilities.000 gates and 20.Functionality: 33 . To learn more about how FaultTree+ can help your business visit www. using world class analytical methods. FaultTree+ also allows the user to construct Markov models for use as the source of basic event data. The Markov models may also be analysed independently of the fault tree analysis. record and analyze system failures across multiple sites. • Projecting manning requirements into the future. On completion of the model the system analysis is performed. using The Failure Reporting Analysis and Corrective Action System (FRACAS). automotive. event tree analysis and markov analysis. maintenance costs. rail. FaultTree+ includes an event tree analysis option. operational losses. The fault tree method involves the creation of a fault tree diagram composed of gates and basic events that represents the logical description of a system failure. and operational risk. the plant can be simulated over a specified lifetime. these are known as the minimal cut sets.au Full working demonstration versions and online demonstrations can be arranged through our website.com.Survey 2005 Special Maintenance Applications Software with information about failure mechanisms. • Optimizing spare parts holdings to minimize investment in spares while maximizing facility performance. It is the most advanced. To learn more about how AvSim+ can help your business visit www. reliability. AvSim+ provides significant business benefit by: • Projecting the business impact of design decisions far into the future. Software Details .com.reliability. resource usage. Finally FaultTree+ calculates the quantitative parameters such as system unavailability and failure frequency. Avsim + is an availability. there are thousands of FaultTree+ installations world-wide that are currently being used on major projects in industries as varied as aerospace. and operational impact. FaultTree+ can efficiently solve fault trees of the order of 20. This is why Software Details . The powerful Monte Carlo simulation package then lets you make forward looking projections about plant capacity. oil & gas and medical amongst many others. and the associated costs. spares usage. ARMS FRACAS Collect. stability and ruggedness of its FaultTree+ product. environmental.000 basic events. Using a Monte Carlo simulation engine. in terms of the failure of the components that comprise the system. safety. defence. nuclear. After creating the diagram the user assigns failure characteristics of the system components. The event tree model may be created independently of the fault tree model or may use fault tree analysis gate results as the source of event tree probabilities. To do this the FaultTree+ software first determines the minimum combinations of component failures that will cause a system failure. corrective maintenance actions. maintenance costs.reliability. ARMS FaultTree+ FaultTree+ is the world’s most popular fault tree software package incorporating fault tree analysis. sparing needs. maintainability simulator which allows the user to represent system failure logic using Reliability Block Diagrams to model complex systems.Functionality: Isograph RAMS software suite has built its reputation on the efficiency. chemical process plant. resource needs and any planned maintenance or inspection activities. known as the TOP event. accuracy.au Full working demonstration versions and online demonstrations can be arranged through our website. Survey 2005 Special Maintenance Applications Software A major problem facing organizations today is there ability to record. ARMS Network Availability Prediction The latest addition to the Isograph RAMS Suite. a ship. The libraries have been constructed by electronic and reliability engineers from manufacturers’ datasheets and other sources. Beneath this.com. IsoLib's ever-growing Electronic Parts Library currently contains many thousands of parts and can be imported directly into other Isograph analysis tools to produce system failure data quickly. Isograph have developed the FRACAS+ tool to compliment its current reliability. availability and maintainability analysis software suite. A limited number of requested parts are added per annum to the libraries at no extra charge.reliability. The analyzed FRACAS data may then be used to optimize planned maintenance schedules. The Failure Reporting Analysis and Corrective Action System (FRACAS) is the latest installment from English based software leader Isograph.Functionality: Hazop+ is an interface that allows the user to customize the HAZOP study. Hazop+ also offers a powerful report generator for the creation and printing of professional quality reports. Software Details . Users with a library maintenance contract may also request Isograph to add specific parts to the library if the part is not currently defined.com. When you have set up the Hazop study. analyze and control a variety of similar failures at various sites. Complex or simple networks may be modelled using NAP. or taken directly from existing public sources.reliability. a weapon system or a power station. Corrective Actions and Failure modes. without sacrificing handling speed.com. and hence determine the minimal cut sets that 34 .Functionality: The IsoLib Parts Libraries contain many thousands of modern electronic and non-electronic parts and provide a comprehensive source of failure data for users of Isograph’s reliability products. The NAP network availability model utilises an extended Reliability Block Diagram (RBD) methodology that addresses the specific characteristics of network elements and their connections.au ARMS IsoLib Project Management The IsoLib Project Management program is a powerful tool that can be used to manage all the project files associated with Isograph software. To find out more about the Isolib Parts Libraries contact ARMS Reliability Software Details . the hierarchical tree can be constructed to any level of complexity. modified and deleted a project can be determined. All the projects are compressed to minimise storage space. The SQL format allows access over a local area network as well as across an Internet connection. The easy to use input facilities will increase this members productivity and speed up the overall study. NAP will then automatically determine the allowable paths between a source and target. When using HAZOP+ all information is stored in an Access compatible database from where it can be filtered. In addition to predicting network availability. The libraries are regularly upgraded with new parts.Functionality: The IsoLib Project Management program is a powerful tool that can be used to manage all the project files associated with Isograph software. To learn more about how LccWare can help your business visit www. Engineers on +61 3 5255 5357 or visit www. the data can be swiftly imported into other Isograph tools. preventing multiple users from working on an individual project at the same time. engineers and anyone involved in the decision making of assessing equipment life or analyzing alternatives.Functionality: Life cycle costing is a methodology for calculating the whole cost of a system from inception to disposal. the Network Availability Program (NAP) enables users to predict the availability and reliability of communication networks. ARMS IsoLib Parts Libraries The IsoLib Parts Libraries contain many thousands of modern electronic and non-electronic parts and provide a comprehensive source of failure data for users of Isograph’s reliability products.au Full working demonstration versions and online demonstrations can be arranged through our website.reliability. These items could include research and development. Hazop+ provides a familiar visual environment in which to design and use the study and action forms that are the basis for entering Hazop information. construction. LccWare makes the calculations of these costs easy and comprehensive. will take charge of recording the Hazop information in the Hazop+ forms.au Full working demonstration versions and online demonstrations can be arranged through our website. The advantage of FRACAS over other systems is that as field failure and other maintenance data is entered in to the FRACAS system the data is automatically analyzed. Software Details .com. Usually one of the members of the study. reliability centered maintenance and Weibull software. using a checkin/checkout methodology. To learn more about how Hazop+ can help your business visit www. Whatever the system. ARMS LccWare LccWare gives you the power to create and develop a life cycle cost model in a user friendly visual environment and provides you with professional quality reports for analysis and budget predictions.Functionality: The Network Availability Program (NAP) enables users to predict the availability and reliability of communication networks. New library versions are made available to users with a library maintenance contract at regular intervals. inspections and design changes using Isograph’s powerful availability simulation. NAP provides many time-saving features to allow users to quickly construct the network diagram.reliability. along with personnel data details can then be assigned to each specific part of the failure report. The product maintains the project files from all Isograph products and stores them in a SQL Server database. Software Details .reliability. Hazop+ speeds up the process of recording and managing the potentially large amounts of information. To learn more about how FRACAS can help your business visit www. the major items of cost will be defined through its life.com. Failure and repair reports are assigned to a particular piece of equipment with its movements to other locations recorded. One of the important features of NAP is that it allows the modelling of data flow in different directions along the same network path. An audit log is maintained so that details of who created. Again. the life cycle costing technique will be the same. Users can then follow this audit trail for each project. The recording of equipment or system failure is broken down by site and functional location in a hierarchical structure that can be easily understood. you can use Hazop+ in the study itself.au ARMS Hazard and Operability Study (Hazop) One of the commonly used techniques in the preliminary phase of a safety study is a hazard and operability study. the true lifetime costs of each alternative are compared and the most cost-effective alternative can be chosen. a network element library facility that allows users to construct common network element diagrams and a fully interactive network diagram construction facility. This means that users need not be specific about the direction of data flow in selected parts of the network. and enter and store study information in a clean and conveinient way. sorted and displayed. The use of the SQL Server database format means that not only can the product easily sort and filter many project files. It provides full project control and historical tracking to those using the software in a corporate or enterprise situation. and is the perfect decision making tool for managers. By using the LCC method to compare product alternatives. NAP also provides criticality rankings that identify weak spots in the network. but all file handling is done very quickly.au Full working demonstration versions and online demonstrations can be arranged through our website Software Details . The system will vary from industry to industry and could for instance be a building. The IsoLib Project Management program controls access to these projects. IsoLib also contains two existing non-electronic libraries: the NPRD-95 library for mechanical component failure data and the IAEA-TECDOC-508 library for component reliability data. These include a parts library facility that allows users to import their parts data in convenient groupings. operation and maintenance and disposal. To find out more about the Isolib Project Management application contact ARMS Reliability Engineers on +61 3 5255 5357 or visit www. Survey 2005 Special Maintenance Applications Software determine the availability of the network. maintenance crew costs. many of the world’s leading companies are improving business profitability with: • • • • • Improved asset performance Reduced risk of catastrophic incidents Elimination of repetitive failures Lower maintenance costs Less plant downtime NEW RELIABILITY FORUM Visit www. MSG-3 and MIL-STD-2173(AS) by providing a structured method for entering FMECA data and simulating the effects of different maintenance strategies on cost. Become part of the Reliability Network For more information call: +61 3 5255 5357 Or via email: [email protected] to have your say on reliability issues affecting your organization.com. Reality Charting offers the perfect platform for collating and reporting an Apollo Root Cause Analysis investigation. spares costs and availability etc. ARMS Reliability Engineers RAMS Software Tools: Availability & Reliability Modelling ARMS Reliability Engineers provide business solutions that help profitability through improved asset performance and equipment reliability. Across the globe companies are turning to RCMCost to provide them with the full framework for building the RCM model to accurately represent data and analyse optimized maintenance alternatives.au 35 . The RCM decision making process is therefore substantially enhanced by the ability to quickly simulate the effects of preventive tasks.reliability.Functionality: Many of the worlds leading companies are using Reliability Centered Maintenance Strategies as a means to decrease maintenance costs. a program specifically designed to help conduct root cause analysis investigations using the Apollo Methodology. increase operational performance. a program specifically designed to help conduct root cause analysis investigations using the Apollo Methodology. RCMCost supports RCM standards such as† SAE JA1011. increase operational performance and meet risk.com.Functionality: Reality Charting.au For further details regarding the RAMS software suite visit www.reliability. Reality Charting is a tool that adds great value by expediting your analysis consistent with the rules of the Apollo method.reliability. individuals in separate locations can create Apollo Cause & Effect charts together. inspection tasks and condition monitoring taken into account ageing. ARMS Reality Charting Reality Charting. Reality Charting offers the perfect platform for collating and reporting an Apollo Root Cause Analysis investigation. RCMCost is empowering users with a decision making tool to understand the contribution of their assets to business performance. Software Details . RCMCost.com. safety and environmental goals using the powerful decision making tool. reporting and analytical facilities for developing and maintaining a Reliability-Centred Maintenance (RCM) programme. the environment and operational issues. Software Details . safety.au Full working demonstration versions and online demonstrations can be arranged through our website.com.reliability. To learn more about how NAP can help your business visit www. With simple methods. and help optimize their maintenance decisions to further enhance productivity through increased reliability. powerful software and a proven delivery approach. These facilities include : • Graphically constructed system hierarchy diagram To learn more about how RCMCost can help your business visit www.com. reduce risk and meet safety and environmental goals.au Full working demonstration versions and online demonstrations can be arranged through our website. In all. RCMCost provides the data management. Some more of the benefits of Reality Charting are listed below: • Cuts down on the time needed to prepare the RCA chart and report by 50% • Provides support to facilitators and participants: • Delivers thorough and accurate analyses in a polished and standardized format: • Using NetMeeting or WebEx. hidden failures. • • • • • • • • • • Failure Mode Effects and Criticality Analysis (FMECA) Identification of critical failure modes Advice for decision making based on performance simulation Redundancy modelling Weibull analysis of field data Optimisation plots for alternative maintenance strategies Group maintenance modelling Flexible reporting providing customised worksheets Copy and paste facilities for data transfer Import/Export to databases and spreadsheets ARMS RCMCost Reduce maintenance costs. & risk exposure. Software Details .reliability. working practices. the MIL-HDBK-217 standard for electronic equipment.au Full working demonstration versions and online demonstrations can be arranged through our website. analyse the system.interplansystems. criticality coding.Functionality: Fault and event tree analysis methods are widely applied to system availability and reliability problems in most engineering disciplines. correct work scope for inspection & maintenance tasks.com/ Software Details . Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Apt Group Suite 22. central versus distributed options. determine best preventive intervals or replacement benefits.Survey 2005 Special Maintenance Applications Software When investigators use the same format. helping to ensure that relevant information is captured in a consistent format. • Reliability modeling determines failure modes & risk pattern consequences. • Ensure OH&S compliance. Maximise your investment in Apollo Root Cause Analysis by utilizing a tool that helps to keep your reporting in a standardized professional reporting tool. Fault Tree Analysis.reliability. Failure Mode Effect and Criticality Analysis (FMECA). Using Aptools to assist this process will enable engineers to determine Total Business Impact based upon fact Determine Life Cycle costing. Maintainability Prediction. • Reveal impact of over or understocking.au Software Details .com. and report on the results. customer impression & other intangibles.O. RealityCharting™ guides the user through each step in the Apollo process. Optimise Shuts & Inspection Schedules. Whether you have a new project that is still being designed or an existing facility that you wish to improve. They may be used to predict the performance of a system at various stages of the design process and indicate reliability weak spots in the design. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: InterPlan Systems Inc. or taken directly from existing public sources.com. evaluate the worth of projects against resources & constraints. calculate the best inspection monitoring intervals. cost & replacement value.com. Maintain Optimal Maintenance levels. ATC Professional incorporates 36 . & risk exposure. ARMS RiskVu RiskVu can be used as a ‘Living PSA’ (PSA stands for Probabilistic Safety Assessment) tool or as a risk monitor. performance & risk exposure.aptgroup. Below is a list of the various modules and calculations that Reliability Workbench features: • Reliability Prediction • Maintainability Prediction • Failure Mode Effect and Criticality Analysis (FMECA) • Reliability Block Diagrams (RBD) • Fault Tree Analysis • Event Tree Analysis • Markov Analysis Failure rate predictions are calculated from the Bellcore standard for electronic parts.Functionality: ATC Professional is a proactive turnaround management system that is much more than just a Gantt chart program. It may also be used as a management tool to allow users to try out ‘what-if’ scenarios without knowing anything about the underlying fault and event tree models ATC Professional Shutdown Management System Project management system designed specifically for oil refinery and petrochemical plant shutdowns/turnarounds. determine the worst & best case. • Investigate alternative work schedules. 450 Elizabeth Street. • Which monitoring method is most cost effective. RiskVu also provides a more controlled framework to compare and record design options and the predicted performance parameters.au Full working demonstration versions and online demonstrations can be arranged through our website. calculate true optimum equipment life based on total business impact expenditures. This comprehensive tool is sold as separate modules or as a complete package to allow users the flexibility of purchasing the part of the application that is most applicable to their needs. data capture and analysis to enable strategic/best practice Asset Management decisions. Surry Hills NSW 2010 Geoff Soper or Ian Jones 02 93180656 02 93180776 info@aptgroup. A 30 day free trial can be downloaded by accessing our website at www. Risk Based Inspection. Reliability Workbench also features the Isolib Parts Libraries.Functionality: Reliability Workbench is the market leading reliability tool that accommodates all the reliability needs of a maintenance and reliability professional. RealityCharting™ uses drag and drop features that make creating and organizing the Apollo cause and effect chart extremely easy compared to other techniques. • Determine the best frequency for testing standards based equipment or systems.au www. combine tasks & staffing. the IEC TR 62380 standard for electronic equipment (as well as the RDF 2000 standard for electronic equipment) and the NSWC-98/LE1 Handbook for mechanical parts. The computer program FaultTree+ is used by thousands of engineers to hold the fault and event tree data. • Determine optimal intervals. and quantify economics of inspection methods. costs. • Discover what data is worth collecting & for what reason. • Unavailability consequences. select the right equipment. A detailed understanding of fault and event tree construction methods and the reliability logic for the systems being modelled is required to allow possible design changes to be reflected in the fault and event tree structures. Asset Performance Tools (Aptools) Determine an assets whole of life criteria combined with its optimal operational reliability risk. escalation stages. To learn more about how Reliability Workbench can help your business visit www. the integrated environment for performing Reliability Prediction. • Evaluate & demonstrate project viability. Optimise Spares & Stock. Event Tree Analysis and Markov Analysis.†our simple to use Reliability Workbench software provides solutions so your operation can realize outstanding results.com. Software Details . P. Other modules can be added at any time and there are cost benefits for purchasing multiple modules at the same time. risk of alternative maintenance strategies. It ensures that solutions are directly attached to causes and provides a final report that lists action items and due dates. Reliability Block Diagram (RBD) analysis. • Calculate the business impact of Not replacing at the optimal time.reliability.com http://www. Experienced reliability engineers may modify the structure of the fault and event trees in order to compare predicted system performance from different design options. To learn more about how RiskVu can help your business visit www. • Evaluate the correct time to replace or upgrade an ageing asset. The libraries have been constructed by electronic and reliability engineers from manufacturers’ datasheets and other sources. determine correct levels. The IsoLib Parts Libraries contain many thousands of modern electronic and nonelectronic parts and provide a comprehensive source of failure data for users of Isograph’s reliability products. it's easier to add information to an analysis as well as communicate the results across the organization.au The RiskVu computer program provides a high level interface to the FaultTree+ program allowing system designs to be compared by personnel with no experience in fault or event tree analysis methods.Functionality: Psychical Asset Management requires a process of workflow. Manage Projects & Proposals.com. Box 590131 Bernard Ertl 281-482-7126 281-648-1821 info@interplansystems. ARMS Reliability Workbench Reliability Workbench. CATLOC offers a unique flexible approach to LCC modelling. SWEDEN Oskar Tengo systecon@systecon. it allows the user to categorize. K.Functionality: CATLOC is a new whole life costing tool for calculations and comparative analyses of costs for development. > The facility of testing the effect.com/reliability-maintenance-optimization-software.m2k. Firstly. It encourages cooperation and allows all team members to contribute and succeed. > The opportunity to alter the weightings of each group of factors. of alternative design proposals and modifications. Lees +44 (0) 1382 803070 +44 (0) 1382 737736 [email protected] for further functional details and costs. Company Information: Name: Address: Maintenance 2000 Limited Broadhaugh Building. and objectivity and communication in the reporting cycle for successful project management towards your time and budget goals.se www. in the analysis. Scotland Mr. Camphill Road 37 . See http://www. COMPARE (Calculating Optimum Maintenance PARamEters) A Reliability Centered Maintenance package that enables optimum spares levels. slice and dice costs in almost any dimension including time. optimum proof test intervals and optimum replacement times to be obtained. > A positive calibration of the model using common mode/cause failure data. > The opportunity to add scoring criteria and re-calibrate against new common mode/cause failure data. CATLOC has intuitive input views as well as flexible graphical result views for accurate analysis and interpretation of results. Suite 110.Survey 2005 Special Maintenance Applications Software procedures that involve the entire turnaround management team to promote ownership and visibility of the plan.systecon. BETAPLUS A new generation Common Cause Failure (CCF) partial beta model that takes account of proof-test intervals and involves positive scoring of CCF related features rather than a subjective "range score".M2K.Functionality: BETAPLUS is a Common Cause Failure (partial Beta model) assessment technique that develops the partial Beta model beyond the currently available theories to include: > Recognising that proof test and auto-test intervals influence the value of Beta. on Beta.com www. Camphill Road Broughty Ferry. > Positive scoring of Beta related sub-factors rather than subjective assessment of a variable for each group of factors. CATLOC CATLOC is a sophisticated life cycle costing tool with a new unique flexible approach to LCC modeling. Suite 110. Secondly. Software Details . operation and maintenance of technical systems throughout their life cycle. Company Information: Name: Address: Contact: Email: Web: SYSTECON AB BOX 5205. It is ideal for identifying cost drivers.se Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Maintenance 2000 Limited Broadhaugh Building. production. it allows cost equations and cost break down structures to be fully defined by the user. SE10245 STOCKHOLM. Dundee DD5 2ND.com Software Details . . com/ Software Details . It helps users control and manage valuable EPA-regulated refrigerant inventory from purchase through final disposal. Microsoft Excel (for cost estimating) and more. study nodes.htm for further functional details and costs. corporate licenses available. FMEA. previous incidents. Using Markov analysis. failure rate. Up-to-the-minute reports monitor and verify the compliance status of each phase of an enterprise right from the desktop. version is $399. Columbus.Functionality: Compliance Suite™ Refrigerant Compliance Management Software helps users total compliance with EPA regulations by accurately tracking refrigerant usage. It also includes reliability theory and the application of these techniques. to reveal failed redundant units. the reasons why past decisions were made and the potential impact of new regulations on the cost of future operations Compliance Suite Compliance Suite™ Refrigerant Compliance Management Software helps users maintain total compliance with EPA regulations by accurately tracking refrigerant usage.com Software Details . OH 43212-1197 USA Robert W. Managers can identify ways to simplify procedures organization-wide. SILs. and prioritizing action items. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: ESS 1701 Research Boulevard. Features in the applications include custom 3-D reporting with Crystal Reports.interplansystems. No proprietary PHA program required. The application assures compliance. 40 . Graphical outputs for use in word processing packages. There will be an optimum replacement time for parts having a wearout characteristic. Lees +44 (0) 1382 803070 +44 (0) 1382 737736 kenny@M2K. Suite 210. Supported project management exports include ATC Professional. number of active items and the degree of redundancy for that item. Johnson (614) 486-2245 (614) 486-2141 [email protected] 2005 Special Maintenance Applications Softwar e Contact: Phone: Fax: Email: Web: Broughty Ferry. See http://www. COMPARE enables the optimum number of spares to be chosen for any combination of lead time.S. procedure HAZOP for each node. down time and failure rate. Single-process U. will lead to costly outage. P3e & P3e/c.ess-compliancesuite.com www. Choose between What-If. Scotland Mr. Suite 201.com/reliability-maintenance-optimization-software. Primavera P3. Having too many spares carries a cost penalty. The program. ePHA Excel®-based program for facilitating PSM/RMP process hazard analyses. The COMPARE user manual covers the basic theory behind these techniques.records all appliance information. responsive. resources and PDM schedule logic) for export to leading project management systems based upon quantities.com www. delegate and monitor compliance activities and prove compliance instantly. FARADIP (FAilure RAte Data In Perspective) provides a failure rate data benchmark which can be used to review the field data which users apply to COMPARE or as a source of data where generic figures are required. and the ability to prepare reports for appliances that exceed EPA leakage rates and identify potential problems for immediate preemptive action. and it has the added benefits associated with more agile.Functionality: Essential Compliance Manager™ is a breakthrough.by ESS . human factors. K. leaks and disposal.M2K. which is fully integrated with all of the other programs in Compliance Suite . risk matrix.com eTaskMaker Project Planning System Flexible tool for standardizing and improving best practices in estimating.m2k. process safety information.com Software Details . fabrication and installation). with five different methodologies and an order-of-magnitude risk based approach. browser-based software solution in the Essential Suite™ portfolio by ESS that helps users move beyond compliance by enabling them to use their environmental data to create drivers for sustainable growth. developing consistent compliance practices and reducing errors while learning today’s compliance status. Software Details . Rockville. PHA worksheets. durations. dimensions and answers to multiple choice questions. Microsoft Project. Suite 200. ePHA's order-of-magnitude approach is foundational to LOPA. Too few spares incurs expensive outage time. CO 80202 Julie Holmes 888-766-0220 303-297-1907 info@ess-compliancesuite. P. Coincident dormant failures. customized project schedules (including tasks. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: ESS 1201 18th Street. COMPARE enables the Weibull parameters of parts to be assessed from field or test data in order for the optimum time to be calculated. Dundee DD5 2ND. revalidations. eTaskMaker includes over 100 estimating modules related to plant maintenance (including piping demolition. HAZOP. Contact us for international pricing.Functionality: eTaskMaker generates detailed. including a complete history of service records. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: InterPlan Systems Inc.com www.Functionality: COMPARE (Calculating Optimum Maintenance PARamEters) is a Reliability Centred Maintenance software package that enables significant cost savings to be made in spares and maintenance resources. Box 590131 Bernard Ertl 281-482-7126 281-648-1821 [email protected] FARADIP (FAilure RAte Data In Perspective) FARADIP (FAilure RAte Data In Perspective) is one of the largest failure rate and failure mode data banks in the reliability profession.com http://www. MD 20850 Brian Mumpower 800-999-5009 Ext 1741 301-556-1701 info@ess-essentialsuite. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Unwin Company 1920 Northwest Blvd. COMPARE enables the optimum proof test interval to be calculated for a given outage cost. Too frequent proof testing. Software Details . The cost of an unplanned replacement may be much greater than the planned replacement of a part despite its not having failed.. Essential Compliance Manager™ Essential Compliance Manager™ helps organizations manage the most critical EH&S responsibilities more easily. action items. will incur a waste of maintenance resource. facility siting considerations. The eTaskMaker Module Editor allows you to edit/customize any module or easily build new ones. What-If/Checklist. bottomline-oriented organizations. proof test cost. site-wide. Make one-click moves between attendance. leaks and disposal. Include/exclude consequence categories for risk impact of environmental or business consequences along with safety impacts. Denver.Functionality: Excel®-based spreadsheets for leading/documenting process hazard analyses.unwin-co. hazards. planning and scheduling maintenance work. otherwise protected by redundant configurations. Save entire PHAs in one file ready for updates.ess-essentialsuitesuite. risk ranking.com www. refrigerant consumption and leakage rates. repair time.O. com/reliability-maintenance-optimization-software. > Connectors. mechanical.Functionality: FARADIP is one of the largest failure rate and failure mode data banks in the reliability profession.au 41 .assetivity. Equipment included: > Microelectronics (logic. fuses. Lees +44 (0) 1382 803070 +44 (0) 1382 737736 kenny@M2K. switches. SCADA. tubes.. DP and Comms. > Instruments and analysers. Camphill Road Broughty Ferry. DCS. N. offshore operations.M2K.com Software Details . K. procedures. business rules. > Full editing facilities for global files and component entries. instrumentation and protective devices.m2k. lamps.canweb.Survey 2005 Special Maintenance Applications Software > Pneumatic and hydraulic equipment. Assetivity Is The 37th Fastest Growing Company In Australia Call us. PCBs. logbooks. drawings.com. PO Box 1315. Scotland Mr.Functionality: • Enable tracking. Dundee DD5 2ND. > Mechanical items (incl. > Passive electrical components. N7T 7X1 Jackie Grant 519-332-6900 519-332-6464 sales@canweb. > Alarms. arrestors. • Brings non data like drawings. sorting and managing your assets • Enables faster fixes • Work from schematics. Software Details . equipment photos on or at work station monitor • Replaces binders at the work station with real time information in electronic format • Brings data from HMI.htm for further functional details and costs. > Power supplies. or visit our website. > Electromechanical and rotating machinery. PLC Data historians. linear & memory). telecommunications. maintenance records. > Ranges of failure rates spanned by the majority of published sources and an indication of the most common values. suppliers information to work station screen • Provides fix it information from root cause failure analysis and solutions • Electronic logbook data collection and organization of history • Compliance procedures where step by step maintenance sequences critical In BRW Magazine’s 2004 Fast 100 Survey. CanWeb Suite 204-265 Front St. electronic.com http://iware. Failure mode percentages are also provided. Suite 110. It provides failure rate data ranges for a nested hierarchy of items covering electrical. > Discrete semiconductors. Canada. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: iWare Division. and find out why Assetivity Pty Ltd. pneumatic. inspection reports. Operations and Maintenance Consultants. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Maintenance 2000 Limited Broadhaugh Building. based on over 40 published data sources together with M2K's own reliability data collection. FARADIP has been available for 10 years and is now widely used as a data reference. See http://www.com iWare iWare brings all maintenance information needed to the operator screen to empower the operation and maintenance expert. > Computers. sources and transformers.com www. > Nested menus of failure rates and failure modes from over 40 diverse data sources including military. Booragoon WA 6154 Ph 08 9474 4044 www. > FMEA's for two system failure modes together with parts count and MTBF calculations. process and aerospace industries. Sarnia. pumps and valves). cables. Ontario. fire protection. Alenia Marconi. Mount Waverley. SWEDEN Oskar Tengo systecon@systecon. cost elements and information categories. Provide a log of PM changes.au www. Mil-Std-1388 2B.systecon. life support costing and evaluation of maintenance and supply concepts. SE10245 STOCKHOLM. OmegaPS reduces the acquisition and life cycle costs of capital equipment through analysis and optimisation of the speed and frequency of maintenance related activities whilst reducing the total cost of ownership and increasing operational availability. Data is easily imported and exported from customer’s data sources. Eurocopter. Furthermore it includes the powerful LORA XT for system based. Often. We found the preparation and post analysis implementation of reviewed PM's consumed more elapsed time than the analysis. The software retains history of all PM's active. Software Details . 5. SE10245 STOCKHOLM. Company Information: Name: Address: Contact: Email: Web: SYSTECON AB BOX 5205. OmegaPS World leading Logistics Support Analysis Software for the optimization of design and/or operational support of complex assets. for example. preventive/ corrective maintenance as well as repairables.Survey 2005 Special Maintenance Applications Software holdings/distribution. Northrop. BAE Systems.au www. Victoria 3149. discardables and partly repairables. OmegaPS Analyzer Life Cycle Costing. and incorporating the Australian Defence Force DEF-AUST(5692). It can model flexible/lateral re-supply/backorder priority.pennantaust.Functionality: The world's leading Logistics Support Analysis package conforming to local and international standards including: Def Stan 00-60.se www. 3. Sequential test plans can be applied to verify failure flows. MaDCAT analyses events as a function of time or any other time-based parameter. Altona Steve Turner +61 3 419 035 +61 3 9395 2512 steve@omcsinternational. Software Details . modified or deleted.se www.pennantaust. multi echelon model that accommodates any technology or support organisation. Swift upload of existing PM schedules.com. OPUS10 features a very flexible multi indenture.com. Provide a secure repository for PM schedules and Failure Management Strategy. GIAT.Functionality: MaDCAT (Maintenance Data Categorization and Analysis Tool) has special emphasis on analysing development of reliability.reliabilityassurance. are not conducive to good document control and are often lost as staff move on. Mount Waverley. For breakdown and accumulation of data (cost. very valuable corporate intellectual property. Analyzer applies analytical rigour to economically analyse or optimise equipment and organisational configurations to minimise cost and maximise availability. Jill Batkin 03 9886 7977 03 9886 7955 info@pennantaust. Dramatically reduce the time of implementation of new RCM / PMO analysis. Level of Repair Analysis.Functionality: Analyzer utilises practical real life inputs to support analysis of the Cost of Ownership for an equipment configuration utilised throughout an organisational structure (eg. Australian Defence Force. optimal allocation of repair resources. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Steve Turner 1 Slough Road. Analyzer is capable of extracting logistics support data from the OmegaPS product to aid in the rapid development of analysis models. The failure analysis techniques are versatile and any version of RCM logic can be applied. Each task is recorded with a justification.se OPUS10 OPUS10 is a comprehensive and flexible tool for spares optimisation and logistics support analysis. Canadian DND and Royal Netherlands Navy & Army. MaDCAT uses a unique flexible combination of user-defined hierarchical structures. Jill Batkin 03 9886 7977 03 9886 7955 info@pennantaust. This used to take us two weeks.com www. The software has an upload facility which enables upload of existing PM schedules from standard electronic formats.Functionality: PMO2000™ is a tool which stores the maintenance strategy / program for a company's assets and outputs these into user formatted Maintenance Schedules (normally MS Word) easily accessible to most CMMS. MaDCAT MaDCAT is a tool for categorization and analysis of experience data from the maintenance process. Provide a purpose designed tool to facilitate and make efficient the review and analysis of Preventive Maintenance (PM) schedules and plant failure modes not covered by PM.systecon. 4.se Software Details . How can the pmo2000™ software make your PMO / RCM Program 100% more Efficient? 1.com.Functionality: OPUS10 is the world-leading tool for cost effective spares optimisation. 2. SWEDEN Oskar Tengo systecon@systecon. we can now produce PM sheets for complete systems in the clients' own format. Boeing. inactive. The software is designed to be a secure repository for PM schedules and FMEA which are in essence.au Software Details . Implementation time has been reduced from two weeks to one day by using the software. cost and system performance over time. and Spares Optimization modelling incorporating proven military derived algorithms and modelling techniques. A justification for a task and or the modification of the task or the frequency of the task is recorded in the software with the task record. Old tasks are retained in the system as a historical record. Lockheed Martin. OmegaPS software is used by major manufacturers including: Australian Aerospace. number of events etc). economic repair locations or discard recommendations. manipulated by many. Multiple machines spread across multiple sites).au pmo2000™ PMO2000™ is a Maintenance and Failure Analysis Tool designed for defining the maintenance requirements and undertaking Reliability Growth Programs for industrial plant. By using dynamic filtering and merge functionality from the PMO2000™ database. Analysis of failure intensity is used to determine maintenance intervals.com. in one day. enabling maximum availability at minimum cost.com Software Details . Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Pennant Australasia Pty Ltd Suite 6/344 Highbury Road. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Pennant Australasia Pty Ltd Suite 6/344 Highbury Road. 6. Trend analysis is used to discover changes in event flows. Victoria 3149. Thales. Company Information: Name: Address: Contact: Email: Web: SYSTECON AB BOX 5205. The optimisation is made from a system perspective and will facilitate increased availability combined with savings of 20-40% compared with other methods. and provide an assessment of the whole of life ownership costs. clients retain this information in spreadsheets which are insecure. and government organizations including UK MoD. MS Excel. Individual or combined analysis runs can be performed to determine optimal spares 42 . effects and existing controls Selection and analysis of hazards requiring additional controls Relative risk calculations using the probability/consequence matrix Documentation of additional control. 2 Culdees Road. systematic.Functionality: qRA Toolkit is a unique software program to make possible the management of risk in a structured. by leading the risk analysis Facilitator through the risk identification and management process as defined by AS/NZS 4360.au Software Details . This software. Simple reports help track progress of actions against forecast dates to help 43 . The software has different levels of authority.com. The qRA Toolkit features a powerful report generator which provides the complete risk analysis report in the right order in addition to: • Documentation of the analysis systems and sub-systems Software Details . BURWOOD.rcart. consequence.Functionality: Effective defect elimination will provide an edge in today’s competitive markets. A PM schedule in the CMMS is hyperlinked to the PM document that is produced by the merge from the PMO2000™ software. Company Information: Name: Address: Contact: Email: Web: The Asset Partnership Pty Ltd Suite 1.com Company Information: Name: Address: Contact: Phone: Fax: Email: Web: RCA Rt Pty Ltd GPO Box 407 Melbourne 3001 Melissa Cameron +61 3 9919 1381 +61 3 9919 1388 Melissa@sirfrt. their cost/benefit and associated action plans Automated sorting in risk. It is essential that understanding is followed by action so the software includes a powerful action management system. • • • • • Documentation of hazards. defensible and informed manner.com www. A major challenge facing organizations is their ability to engage people at all levels in identifying.au www. The PMO2000™ software allows interface between modern CMMS systems that support hyper linking. offered in stand-alone and network versions. even when hard data is not available. is developed in Australia specifically for Australian and New Zealand Industry and is fully supported with comprehensive training. The embedded action management system converts “understanding” into “results”. NSW. Each task must be Authorised. The RCA Rt process and supporting software provides a framework that brings the shopfloor together with technical resources to eliminate defects. Each task must be reviewed and authorised by an 'Engineer' before it can be implemented. 3931 (IEC 60300-3-9) and MDG 1010. person responsible and required date • Common secure database for all risks • Built in audit and review capability qRA Toolkit qRA Toolkit is locally developed software for qualitative Risk Analysis in accordance with AS/NZS 4360.Survey 2005 Special Maintenance Applications Software 7. Provide a means to link the maintenance tasks with the CMMS.assetpartnership. The qualitative approach does not require group members to be skilled in mathematics but is designed to create a valid and defensible risk assessment. properly understanding and eliminating failures and defects.com. The RCA Rt incident management and root cause analysis software helps manage incidents. failure analysis and defect elimination across one site or multiple sites with ease. 3931 and MDG 1010 RCA Rt Incident Management & Root Cause Analysis A powerful process that identifies underlying problems and helps identify practical solutions. 2136 Shane Chiddy mail@assetpartnership. Available as standalone. NSW. Screens. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Strategic Corporate Assessment Systems Pty Ltd P. cost and performance. with a strong business-based approach. These include a criticality assessment. This software provides all the features expected of an SAE JA1011 compliant RCM analysis in addition to a wide range of reports including work packages sorted by task. with only one being open for input at any one time. 2136 Stephen Young mail@assetpartnership. 2 Culdees Road. RCM Professional 3. The RCM II process develops the most appropriate strategies to manage the consequences of equipment failure and this software quickly leads the RCM facilitator through the analysis to determine the most appropriate maintenance at the right balance of risk. then any preventative actions are explored.com Software Details .Functionality: This software supports an RCM II process that fully complies with SAE JA 1011 and is used by the world leaders in the application of RCM. Suite 110.com www. The full implication of doing no maintenance (or operate to failure) is then examined. lower cost. frequency and skill set. from a single function with an associated functional failure and failure mode. Its process incorporates the established principles of reliability centred maintenance. fields and reports may be easily altered to ensure that the existing successful methods already in place are supported and enhanced. A project may be of any size. It is a sound platform for the development of revised maintenance practice and evolution from reactive environments through to planned. A particular feature of this software is the way in which the most appropriate management policies are developed using the Failure Finding Interval (FFI) calculator.kelly@strategicorp. Final optimised schedules are generated by RCM Turbo after a process of automatic generation of user-defined workgroups along with a workflow smoothing facility which matches the newly optimised activities to available maintenance resources. There are many approaches to problem solving that are valuable and appropriate in different circumstances. fault finding guide (which allows for easy system fault diagnosis and hence a faster return to service). manipulate. network and internet versions. it is a platform underpinning the methodology. random or wearout failure pattern. RCM Turbo Leading expert decision support methodology for the implementation of the principles of reliability centred maintenance and development of new.au 44 . The software is user configurable. Australia Nick Hastings 03 9876 7188 03 9876 6138 Albany.Survey 2005 Special Maintenance Applications Software focus efforts on the essential tasks.com Software Details . analysis RelCode Weibull analysis of failure data to determine burn-in.strategicorp. Company Information: Name: Address: Contact: Email: Web: The Asset Partnership Pty Ltd Suite 1.interactive@bigpond. K. structured.htm for further functional details and costs. which prioritises equipment for assessment and strongly contributes to the 'thoughtware' component of a reliability analysis. RCM Turbo then provides a primary task optimisation module to support the decision on how often to perform these cost effective inspections.Functionality: RCM Turbo was developed by and for maintenance professionals. so that in every significant decision there is a clear comparison between any new. Victoria 3134. preventive replacement intervals and spares requirements. BURWOOD. Lees +44 (0) 1382 803070 +44 (0) 1382 737736 kenny@M2K. this proven and robust software makes your RCM analysis easy and fast. Camphill Road Broughty Ferry.0 RCM Pro 3.0 is an easy-to-use yet powerful reliability software program designed to hold. The thrust of an RCM Turbo assessment is to put before assessors all the best available information required to facilitate and justify decisions. and analyze Reliability-Centered Maintenance or FMEA data in an intuitive. Ringwood North. to (for example) the safety systems on an oil platform.com www.com/reliability-maintenance-optimization-software. If a predictive task cannot be found. with defined deliverables and expected outcomes. mean life.assetpartnership. RCM Toolkit Specifically designed to support SAE JA1011 compliant RCM. The successful usage of RCM Turbo is dependent on the level of assessor knowledge and understanding of reliability principles. The RCA Rt Software consists of three core elements.albanyint. The software is fully supported by a proven and world class training program and unlimited technical support. A number of expert components are combined to provide an information flow which leads directly to new. Appropriate end user training is always scheduled as part of the project. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Albany Interactive Pty Ltd 16 Wellesley Road. 3084 Chris Kelly 03 9455 2211 03 9455 2233 chris.com Software Details . The user can also easily merge maintenance tasks and create maintenance task packages for migration to your CMMS while maintaining the all important audit trail. • An Incident Management System complete with action management functionality. and • An Analysis tool to assist in identifying repeating faults and causes across the database of incidents.M2K.com. Box 427 Heidelberg. Thus an implementation of RCM Turbo is carefully planned in the format of a high profile project. The detailed failure modes and effects analysis component of an RCM Turbo assessment encourages assessors to explore alternative scenarios in order to gauge the resultant effects on both reliability and cost to the business. All the assessment is aimed at the minimisation of business consequence in the event of both operational and safety/environmental failure. • A Root Cause Analysis tool complete with user friendly cause tree development tool. http://www. Scotland Mr. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Maintenance 2000 Limited Broadhaugh Building.O. Dundee DD5 2ND. The software is highly user configurable and features: • Embedded Root Cause Analysis Process and training materials • Incident management and reporting facilities • Action reports to manage and track progress • Ability to link to the Computerised Maintenance Management Systems and other databases • Intuitive fault tree building process • Incident trending and tracking statistics plus many more. and flexible way. planned environment and a scenario of operating to failure. RCM Turbo seeks first to explore whether any predictive maintenance is technically (then on a cost basis) effective. optimised maintenance schedules ready for export and implementation in the existing computerised maintenance management system. FREE evaluation trial (full program plus sample analysis) available.com http://www.com www. The framework provided by the RCA Rt software is flexible so that these different approaches may be brought together to produce the desired outcome.Functionality: RCM Pro will hold any number of projects. RCM Turbo is not just a piece of software. optimised maintenance schedules.m2k. higher process reliability environments. Both RCM Turbo and SOS will deliver substantial and measurable business improvement. Calculates optimal preventive replacement intervals and corresponding spare parts requirements. the software facilitates the recording.com Software Details . data extraction and reporting.strategicorp. reports and projects will never be lost or forgotten. Rental prices start from just AUS $1700 p/a. RCM Turbo represents a powerful decision support platform while leaving a detailed audit trail of the basis for all assumptions. RIMSys RIMSys®.Survey 2005 Special Maintenance Applications Software RIMSys application to raise incidents into the RIMSys database using a basic Microsoft Word form to automatically submit data via your e-mail program. Now it is possible for staff without access to the SIMLOX SIMLOX is a powerful and versatile tool for event based simulation and TIME TO REVIEW MAINTENANCE STRATEGIES AND/OR OPTIMISE CURRENT PRACTICE ? The Australian owned and developed RCM Turbo methodology is the choice of organisations world wide for the development and review of optimised. management. resolution. This priority outcome is converted to a recommended max/min holding. For more information on how to get started contact Walter Grdovic at OMCS International. Tabular and graphic outputs to screen or printer. and which. and graphically indicates the failure pattern as burnin. and. giving a summary screen for a clear overview. action. Cost: Single user license $1750. Call Strategic for an on site presentation.com www. management. Altona Steve Turner +61 3 419 397 035 +61 3 9395 2512 rob@omcsinternational. or from parameter estimates. therefore. RIMSys is designed as a stand-alone software. gone are the days when you "can't find that piece of paper" or when you cannot respond in seconds on the status of a specific investigation. The new feature is designed to integrate data from remote or isolated areas quickly and simply. RIMSys software is an e-mail based notification system. You can purchase or rent the full version of RIMSys via internet download and credit card transaction. Now with RIMSys at your service. Current version 10. Advanced 'What if ?' exploration capabilities enhance decision making in SOS. Heidelberg 3084 Phone: 03 9455 2211 45 . searching. Estimates the mean life and other distribution parameters. The Spares Optimisation System (SOS) continues to address this in a unique manner. or a combination. and archiving of equipment failure incidents. telephone +61 419 540 113 or go to www.com Software Details . random or wearout. A cost/risk analysis is also applied to expensive items or capital/insurance spares. The new RIMSys software guides you through defined investigation. by fitting the Weibull and/or bi-Weibull distribution. New features allow user to include notes on specific failures and to flag specific failures in or out of analysis. From nuclear power plants to pet food processing operations. require investigation to prevent these incidents reoccurring. Site license $4400. taking into account economic order quantity and safety stock calculations. Runs on IBM-PC. the principles of RCM are applied using RCM Turbo to the generation of maintenance regimes that lead to minimisation of failure consequences. A criticality assessment is applied to establish the importance of a spare to continued plant reliability. can be customised to suit the needs and structure of your organisation. RIMSys is specifically designed to target equipment failure incidents which cause unexpected down time and production loss. Works from direct data entry. Reliability Incident Management System. RIMSys is designed to take the administrative headache out of investigation. and including photographs in recording and investigations.ReliabilityAssurance. implementation and archiving processes. It includes a configurable Risk Assessment calculator and can be an attachment of any type of file to each incident for archiving formal reports. which details screens for specifics.reliabilityassurance.Functionality: Statistical analysis of failure and successful performance data. from spreadsheet data. OMCS has added a new feature to its Reliability Incident Management System software. the issue of spare parts required to sustain the maintenance practice is an important one. while striking the optimal balance between equipment reliability expectations and total annualised cost. filtering. facilitates the recording.01. Through Microsoft Outlook it can be configured to notify individuals and groups of certain events in the investigation resolution process. resolution. It can also be purchased as part of the PMO2000™ software allowing quick retrieval of planned maintenance tasks associated with the equipment being investigated. appealing to most maintenance professionals. At the same time. Each incident is assigned a ‘status’at every step along the way and user definable consequences can be assigned to each incident to assist with prioritising. RCM based maintenance schedules. and archiving of equipment failure incidents Company Information: Name: Address: Contact: Phone: Fax: Email: Web: OMCS International Steve Turner 1 Slough Road.com Strategic Corporate Assessment Systems Pty Ltd PO Box 427.Functionality: RIMSys. RIMSys is a simple process which guarantees that records. Detailed information on both these methodologies can be downloaded from Strategic's web site www. It records all incidents. XP) application provided on CD-ROM for standalone or network use. the system provides a sophisticated interface to structure definitions and control the workflow and approval process. Masterpiece enables each line of your data to be cleaned in the most cost effective way. Humble. 2136 Stephen Young [email protected]. Software Details . SIMLOX is ideal for capability assessments. web-based solution to a long standing problem of poor quality data in large inventory databases. Through a criticality assessment taking consideration of a combination of technical and business implications. A final decision will be a direct reflection of current maintenance practice. These tools facilitate data organization. Knoxville. for unlimited users. 2 Culdees Road.com. Strategic also offers spares optimisation services through its affiliate Sparesoptimization.com http://www. It will simulate how performance varies over time given certain operational profile. SOS will make a holding recommendation ready for export to the existing computerised maintenance management system.se Software Details . Software Details . lateral support. Masterpiece provides a cost effective solution to cleaning ‘dirty’ data. battle damages.Functionality: Masterpiece is sparesFinder’s award-winning automated system for cleaning large engineering inventory databases. complex organisations. SOS is an optimising tool. TN 37923 Edward Skompski 865-539-2139 865-539-4335 Skompski@taproot. SE10245 STOCKHOLM. 3084 Chris Kelly 03 9455 2211 03 9455 2233 chris. auditable platform for deciding whether or not to hold a spare part. Software Details . particularly where improving and then maintaining data quality to a common standard will allow them to properly leverage their ERP software investments.Functionality: SuperSMITH softare is a bundled package of WinSMITH Weibull and WinSMITH Visual reliability software. scheduled transfers (of systems.systecon.Survey 2005 Special Maintenance Applications Software analysis of complex operational and logistic support scenarios.com http://www. The system has been designed to address the needs of large. allowing you to get data cleaned in the way which gives you most business benefit. and Gumbel analysis of corrosion data to provide objective evidence for failure modes when censored data is included in the dataset. where the cost and risk of stockout is graphically compared to the holding costs of the item. evaluation for root causes. TapRooT® System Software Root Cause Analysis and Cor rective Action Development software for the evaluation of equipment and human performance related failures. Inc. BURWOOD. This functionality can clarify the path to new.se www. thus it can be applied to new equipment spares and equally to slow moving items. The sophisticated cleaning tools. WinSMITH Weibull software makes probability plots to organize the chaos of failure data into X-Y plots that are understandable to engineers by performing Weibull analysis of failure data. in what max/min quantities Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Strategic Corporate Assessment Systems Pty Ltd P. actual vs requested mission time etc. WinSMITH Visual software provides reliability growth plots of mixed failure modes to provide objective evidence of improvements.com Software Details . bottlenecks and shortages before real world operations are compromised. batched transports. Accurate simulations will identify and correct problems.com Company Information: Name: Address: Contact: Phone: Fax: Email: Web: Barringer & Associates.strategicorp. pattern recognition capabilities and inventory dictionaries automate the task wherever 100% certainty of output is possible. NT. SOS does not rely on the mathematical manipulation of movement history. vendor arrangements while quantifying the effects.Functionality: SIMLOX is a powerful and versatile tool for simulation and analysis of complex operational and logistic support scenarios.com www. cleans and manages large engineering databases. Developed by and for maintenance engineers. expensive and capital/insurance items. SOS will clearly indicate the implications. NSW. A cost/risk module is provided for the assessment of contentious. Masterpiece operates independently of private cataloguing schemes and standards. resource utilisation. and the 46 . If the decision is to hold. Users can explore the effect on recommended holdings based on alternative lead times. Masterpiece delivers a cost effective. SOS is a 32 bit Windows (9x.com sparesFinder Masterpiece Award winning software Masterpiece. or will justify the introduction of new items to the store. SIMLOX handles any technology or organisation.com www. Spares Optimisation System (SOS) Unique expert decision support methodology for establishing whether or not to hold a spare and if so.sparesoptimization.kelly@strategicorp. Where the business is exposed to risk through insufficient holdings. and reliability growth software for plots to predict future failures. Peters Road. not a 'slash and burn ' approach.com Company Information: Name: Address: Contact: Email: Web: SYSTECON AB BOX 5205. Company Information: Name: Address: Contact: Email: Web: The Asset Partnership Pty Ltd Suite 1. TX 77347-3985 Paul Barringer 1-281-852-6810 1-281-852-3749 hpaul@barringer1. Suite 301. Company Information: Name: Address: Contact: Phone: Fax: Email: Web: System Improvements. SWEDEN Oskar Tengo systecon@systecon. Hardware required is Pentium level or better. See www. then SOS will recommend an appropriate max/min quantity. lognormal analysis of repair times.com SuperSMITH with WinSMITH Weibull and WinSMITH Visual Probability software for Weibull analysis to objectively find failure modes. items or resources) and more. spares assortment and maintenance resources. Box 427 Heidelberg.Functionality: SOS is a Windows based software application which provides users with a consistent. Costings including training.taproot. or no change in reliability growth plots to predict future failures. support structure. and allows you to choose the approach which best suits your business needs. SOS is unique in that it utilises an expert approach to the decision making process. Where manual intervention is required.assetpartnership. usage and repairability implications. implementation and corporate licences are provided on application. As well as a multi-lingual user interface. the system is designed to process legacy data supplied in many languages to produce a descriptive output in the desired language and format. 238 S. Inc. Licences are provided on a perpetual basis. SOS is also a 'what if ?' tool.Functionality: TapRooT® System Software provides a database and suite of data collection and evaluation tools that assist the investigator in understanding the root causes of equipment related and human performance related problems. PO Box 3985. Masterpiece encourages a focus on value. SIMLOX provides graphs on system availability. deterioration.barringer1. It will accommodate for “robbing”. Work order interface directly loads PM tables. Dundee DD5 2ND. aids the investigator in understanding the symptoms and causes of equipment related failures. Priorities and Predecessors o Scheduling based on Resource and Equipment availability o Drag and drop task linking o Flexible sorting and filtering of work tasks o Printing of Schedule in Gantt format o Flexible project hierarchy o Manage stand alone projects o Integration with CMMS applications (optional) The Wells Wok Scheduler will vastly improve most maintenance scheduling applications and. tasks. Suite 110 Camphill Road. our equipment troubleshooting tool. Scotland Mr. Arvada. The Gantt based graphical view of the work schedule clearly shows the automatically generated task schedule and resource utilization. doc) • Integration to major asset management software such as MINCOM Ellipse. Trim aka RCMtrim Trim™ reliability software quickly builds equipment preventive maintenance (PM) programs using templates to load directly into computerized maintenance management systems. Company Information: Name: Address: Contact: Phone: Email: Web: CORE. Equifactor®.com Software Details . pdf. Wells Work Scheduler Advanced scheduling application that links Maintenance and Operations so that maintenance work can be easily scheduled around resource and equipment availability. and point & click speed use.com www. Ideal for shutdown planning to efficiently schedule and allocate work packages based on a user definable work breakdown structure. Purchase options include single-user through enterprise solutions. NSW Steve Sydenham 0419 413 139 02 9402 4532 [email protected]. pre-developed reports. Wizards. which can be easily imported into a word processing package (gate suppression facility).Functionality: This advanced scheduling application integrates with CMMS applications to provide a seamless environment for generating maintenance tasks and then optimizing the maintenance schedule around task priority.com Software Details .com/reliability-maintenance-optimization-software. Frenchs Forest.com. August (+1)303-425-7408 Fax: (+1)303-425-0861 [email protected] www. Critical parts. • Incorporating parts lists to manuals (html. Melbourne. thereby increasing the reliability of the root cause analysis and providing data for trending and analysis. Wells Work Scheduler includes the following features: o User Defined resource calendars o Scheduling based on Constraints. 3000 Hakim Mentes 03-8687 8000 03-8687 8111 [email protected]: Main Capabilities • Easy identification of parts by linking items on parts list to call outs on drawings.5 or higher Software Details . as a result. See http://www. Industry-specific templates. Failure effects document work basis reducing ad hoc field decisions. Inc. Effects and Criticality Analysis (FMECA) • Maintenance Task Analysis (MTA) • System lead step-by-step decision process • Automatic calculation of failure mode criticality. Broughty Ferry. 5915 Braun Way. It provides: > A simple and logical tree input method that enables tree logic to be verified.000+ equipment tags efficiently maximizing work planning productivity.au Software Details .au TTREE Address: Contact: Phone: Fax: Email: Web: Broadhaugh Building. minimize equipment downtime. 2000 or XP • 64 MB of RAM • 20 MB of space on hard disc (60 MB space for Publisher) • Microsoft IE 5. Software turnkeys at $10. > Facilities for one-shot probability such as human error. SAP. Company Information: Name: Address: Contact: Phone: Fax: Email: GHD Level 8. Lees +44 (0) 1382 803070 +44 (0) 1382 737736 kenny@M2K. Melbourne 3000 Nicholas Phillips 613 8687 8000 613 8687 8111 maintenance_engineering@ghd. etc • Web based viewer or stand alone viewer • Comes in two parts. resource availability and equipment availability to maximize resource utilization and 47 . 2086. 180 Lonsdale St. Call our office for pricing and system specifications. maximize resource utilization and minimize equipment downtime.com www. > The Technis Beta + method for taking account of common cause failure. CO 80004 USA J. schedule intervals and workhours block strategy and scope.Functionality: Capabilities • Reliability Centered Maintenance (RCM) • Failure Mode. Company Information: Name: Address: Contact: Phone: Fax: Email: GHD Level 8.Survey 2005 Special Maintenance Applications Software development of effective. fixed-price PM program conversion and optimization at lowest cost. measurable corrective actions to prevent reoccurrence. and custom output formats at nominal cost.M2K. > Clear outputs providing cut set ranking by unavailability and failure rate (six measures of cut-set and event importance). 180 Lonsdale St. Simple features manage 10. dropdowns. > Clear graphics. MINCOM LinkOne LinkOne is an illustrated parts catalogue and documentation software which allows users to identify parts and maintain the equipment quickly and efficiently.thesoftwarewell.Functionality: Template-based Trim™ develops PM plans to load directly into the CMMS. Concurrent procedure development lowers cost. Failure risk simplifies selecting equipment PM. CORE guarantees turnkey.htm for further functional details and costs.K. ME Analyst ME Analyst is a maintenance engineering software suite that assists maintainers to conduct various maintenance analysis methodologies such as FMECA and RCM.Functionality: TTREE is a straightforward and fast Fault Tree Analysis package that caters for the majority of Fault Tree sizes encountered in practice. LinkOne Viewer and Publisher System Requirement • Windows ME.com. K. Manual overrides can be used to tweak the schedule as required. limits.au Company Information: Name: Address: Contact: Phone: Fax: Email: Web: The Software Well 47 Epping Dr.m2k.rcmtrim.com. item criticality and task intverval • Complete history of original and subsequent analysis • Training is available Software Details . Crafts people are often not in a position to know whether the failure was due to lack of lube. Picking good codes means that you will have information that is useful for continuous improvement activities. “All that data but no information” One of the most common complaints I hear from companies with CMMS’s is that they keep putting data into the CMMS. Picking inadequate codes means that crafts people will soon grow tired of carefully entering codes that are not perceived to generate value for the organization.48 Generating Failure Codes Using FMEA And Functional Analysis Bill Keeter (USA) This paper was presented at the Computerised Maintenance Management Summit 2005 (Indianapolis. Figure 1: Failure Code Example for a Gearbox . In most cases a craftsperson would not enter Maintenance Error as the cause of the failure. See the advertisement on the CMMS . This paper explores how to use Failure Modes and Effects Analysis (FMEA) or Equipment Functional Analysis methods to generate useful failure codes. Failure Coding Example One of the most frequently used methods for arriving at failure codes is for a group consisting of maintenance engineers and crafts people to sit down and think of the codes based on their memory of what has failed and how. USA). Functional Analysis to the Rescue By focusing on the function of an item of equipment and developing the failure modes associated with the loss of function we can create data coding schemes that will enable us to use statistical analysis tools such as Weibull to get useful information for making Reliability Improvements. Normal Wear and Tear (NWT).2005 to obtain the Conference Proceedings. More often than not. etc. the root cause of this problem is that the failure codes used to gather reliability information are not well devised. The result is often something like what we see in Figure 1. but they hardly ever get useful information for maintenance improvement back out. One of the most important parts of Computerized Maintenance Management System (CMMS) implementation and CMMS usage is the generation of failure codes for the craftsmen to record. In many instances maintenance personnel are asked to make judgments about the root causes of failures when it is impossible for them to have the information they need at the time failure codes are entered. Failure codes such as these do not lend themselves to useful data analysis. piping. The loss of these functions is typically what an operator sees and might be the basis for the initial comments in a work order generated for a failure. and fans. The failure modes are simply the failed equipment parts that cause the loss of equipment function.49 The functional analysis structure is much like the structure in the CMMS. There are levels of indenture that are developed based on how facility equipment is constructed to perform the facilities overall function. Figure 3: Item Functions and Functional Failures Failure Modes or How I Learned to Troubleshoot in Advance The next step in the functional analysis is the development of the failure modes or causes associated with the loss of desired function. . It starts at the top level and works its way down to individual maintainable items within the facility such as pumps. Figure 2: Equipment Hierachy We next describe the functions of the various pieces of equipment. The functional hierarchy is developed using the equipment hierarchy as its basis. gearboxes. It might look something like what we see in figure 2. These codes can later be exported from the CMMS to a spreadsheet so they can be manipulated to produce useful information for Weibull Analysis.50 Figure 4: Equipment Failure Modes/Causes The failure modes now become the basis for CMMS Failure Coding. The first being the failed component. It is helpful to break the failure mode into two parts. and the second being the description of the failure. 1: Component Code Examples Component Code DEBRG NDEBRG BLT SFT GR Component Drive End Bearing Non Drive End Bearing Belt Shaft Gear 2: Failure Type Code Examples Failure Code SZD BRK LS BRNT CRK Failure Description Seized Broken Loose Burnt Cracked . beta.. We put the times to failure into the software. eta. Shape Factor . Symbol η Description Characteristic Age . and to see if our data set makes any sense to us. number of cycles. Weibull Analysis was invented by Waloddi Weibull during the 1930’s to describe the bathtub curve that is so often associated with failures in aging populations. operating hours. Beta Gamma β γ Figure 5 shows the bathtub curve and the different points for various values of eta.The point in time at which 63. Weibull Parameter Eta . Weibull Analysis allows us to use small amounts of data to make powerful decisions about maintenance strategies. and a time zero for the installation or overhaul of the component. Location Parameter . etc. Analyzing the Data There is not much use in collecting failure data unless we can analyze it to determine what sort of maintenance strategy we might use to improve overall equipment performance. The key thing to remember is that Weibull is really only valid for a single failure mode such as seized bearing. or loose belt. and gamma. and gamma rapidly. The Weibull equation describes each portion of the bathtub curve using three parameters.2% of items in service are likely to have failed. and gamma. With only a small amount of training we can improve the decision making process so that overall reliability can be improved. beta.Marks the beginning of each of the three regions of the bathtub curve. All we need is some basis such as calendar time. beta.51 By developing codes in this way we eliminate the huge laundry lists of codes that often lead to overuse of the “other” code because it is so hard to find the right one. low pressure not working correctly oil pressure low oil pressure low comments Filter blocked cleaned filter cleaned the filter cleaned filter blocked filter cleaned and unblocked filter filter was blocked filter badly blocked . 3: Example of Time to Failure Data item blocked filter blocked filter blocked filter blocked filter blocked filter blocked filter blocked filter time to failure 22712 15503 22962 22398 21167 20106 23616 work order description Alarm low oil pressure low oil pressure low oil pressure moving too slow. Figure 5: The Bathtub Curve Weibull Software Weibull software now allows us to analyze failure data to determine eta.Represents which portion of the bathtub curve we are on. and then simply interpret the results. These are unreliability values which we can use to decide when we might want to change the filters. Time based replacement or overhaul depending on the level of acceptable cost or risk. or Constant Condition Monitoring. Weibull only gives us a probability of success. Potential for time based replacement or overhaul at just before the point where Wearout begins to occur. F: Combination May require different strategies depending on where in life cycle. Interim stage parts and personnel if repairs required. At B10 we could expect a 90% probability that we would not suffer a failure due to blocked filters. It does not give us all of the information we need for making the best business decisions. Predictive Maintenance or Constant Condition Monitoring. Figure 7 shows some various Weibull shapes and the potential maintenance strategy for dealing with them. or 20% of the filters are likely to become blocked. Potential Maintenance Strategy Root Cause Failure Analysis to determine causes of infant failures. E: Random Failures with constant failure rate Run to Failure. Predictive Maintenance. Do not implement time based maintenance. Root Cause Failure Analysis if residual failure rate is too high. D: Constantly increasing failure rate. B: A long period of gradually increasing or constant failure rate followed by a rapid wear out period.52 Figure 6: Weibull Curve Generated From Sample Data The B values shown in Figure 6 represent the times at which 10%. The maintenance strategy we use will be very dependent on the business impact of the failures. Curve Description A: Infant failure followed by a long period of gradually increasing or constant failure rate. Root Cause Failure Analysis if failure rate is higher than desired or required to meet cost and risk needs. C: Very few initial failures followed by a short period of rapidly increasing failures then a long period of gradually increasing or constant failure rate. 15%. Root Cause Failure Analysis if Wearout is occurring earlier than desired or required to meet business obectives. Figure 7: Weibull Shapes and Potential Maintenance Strategies . Structured Problem Solving for IP Business Systems. The Role Of CMMS In Support Of An Improvement Initiative. Unlocking The Secrets of CMMS Data. Selecting the Right Maintenance Information System. Functional analysis allows us to focus on the failure items that prevent the business from achieving its goals. maintenance and asset management. Benchmarking Best Practices Maintenance. environmental criticality. Mastering Computerized Maintenance Excellence.FAX: 800-350-4449 Conference Proceedings CD For Sale: Aus$ 220 CMMS 2005 Indianapolis. Understanding Plant Maintenance Effectiveness. Price includes postage anywhere in the World.A Critical Component to Your EAM Strategy. Payment may be by Credit Card. Computerized Asset Management for Public Works Departments. Purchase Order or Direct EFT. Managing Maintenance Training with the CMMS or EAM. Value Driven Maintenance® . We can improve the Reliability Centred Maintenance (RCM) process by integrating these factors with Weibull to reach decisions that make the most business sense. Strategies and Tactics for Achieving Results. safety criticality.What is Important The final decision for a maintenance strategy has to be based on the business impact of the failure in terms of cost. Improved CMMS and Asset Management Systems. Bonus article: CMMS Best Practice To purchase these important CMMS 2005 conference proceedings Fax 61 3 59755735 or Email mail@maintenancejournal. Take control of work. President. CMRP. Contact Information: Bill Keeter. Leveraging Enterprise Information to Enhance Asset Management. Application Service Provider (ASP) model for CMMS/EAM. Using CMMS to Optimize its Inventory Management Practices. 6 steps to selecting a CMMS. Phone: 888-673-8360 x3 . Making Your Existing CMMS Successful. Industrial Lubrication and CMMS.com Cost of the CD of the CMMS 2005 conference proceedings is Aus$ 220. Smart training: Implementation Leading to CMMS training. Reducing the Cost of Parts and Inventory Stores Using EAMs.Creating shareholder value . and operational criticality. EAM Versus Best of Breed CMMS. USA Papers are formatted in Acrobat PDF. The use of Weibull Analysis to analyze the data from the coding will significantly improve the decision making process with just a few simple guidelines. Inventory Management-. Conclusion Using functional analysis of equipment to generate failure codes for the CMMS can significantly increase the value of the information we get back.A Maintenance Inventory Savings Model. Generating Failure Codes for CMMS Implementation. Maintenance Inventory and Purchasing. Getting the most from SAP-Enterprise Asset Management. Key Elements To Successful CMMS Implementations. BOMs . 53 . Some papers are in PPT slide format and some in text format.53 The Business Decision . Internet delivered CMMS to build improved equipment reliability. The use of two part codes significantly reduces the size of the code list and helps improve the likelihood that people responsible for entering the codes will do so. 54 The Business End Of Maintenance Deryk Anderson Oniqua Enterprise Analytics (Australia) deryk. Moderate improvements in maintenance performance can have a significant impact on the “bottom line” results of business. as it always has been. • A statement of the functional objectives of an organization. • To operate safely with regard to the environment. .” Most businesses declare their purpose and objectives in a number of published statements that are available to employees. The challenge for maintenance is to quantify its value to the business in a measure of organizational management effectiveness. the purpose of business is to return a profit to owners and investors. narrow in outlook. is. and instrumental in behavior is rarely successful business. INTRODUCTION Asset intensive organizations in both the private and public sectors rely on assets to provide products and services. There are similar common objectives identified in the statements of asset intensive businesses: • To operate profitably or economically. organization and control. Kay [ii] observes: “… this view of business as necessarily selfish. which contains more distinct goals that may have performance criteria associated with them. Often the cause of a poor corporate view of maintenance lies in the difference between executive and technical stakeholder views. and economically or profitably is dependent on the effective maintenance of these assets. efficient operations capable of sustaining competitive advantage. Effective maintenance requires planning. vision and values of an organization (e. narrow and instrumental. The ability of these organizations to provide desired service levels. These objectives can be seen in the following statement by Rio Tinto [iv]: “Rio Tinto is a world leader in finding. These may include: • A statement of the purpose. Mission Statement). in other words management. of the maintenance function. Business which is selfish in motivation. mining and processing the earth's mineral resources. This paper explores the relationship between maintenance and business outcomes and the contribution of the maintenance function to the business “bottom line”. social and environmental requirements of sustainable development.anderson@oniqua. shareholders and the public. • To operate safely in terms of consumers. Greater understanding of the relationship between maintenance objectives and organizational goals and objectives will enable the maintenance practitioner to deliver new levels of service to the organization. Being trusted to meet societal expectations is essential for long term profitability. The maintenance function of organizations has an essential purpose directly related to the assurance of asset capability [i] and the achievement of organizational objectives. The conclusion that business is focused only on making money to the exclusion of all other concerns is not popularly supported.g. • To provide desired or agreed levels of service.com S UMMARY Many organizations fail to see the Maintenance function as part of their competitive advantage. OBJECTIVES OF BUSINESS In fundamental terms. function safely (with regard to personnel. Maintenance is more often regarded as a mystery to many decision makers and is frequently seen as an easy target for budget cuts. nonsense.” Hutton [iii] reports an excerpt from Shell’s annual report from Sir Mark Moody-Stuart: “Profits are an important part of our ability to contribute to society. the public and employees. Shell companies also accept that their responsibility is to help deliver the economic. public and the environment). In order to deliver superior returns to our shareholders over many years. we take a long term and responsible approach to exploring for first class orebodies and developing large. This paper explores the impact of maintenance improvement initiatives on the Return on Assets and Return on Equity of business. we help to meet the global need for minerals and metals which contribute to essential improvements in living standards as well as making a direct contribution to economic development and employment in those countries in which we invest. Accordingly. personnel and the environment. . • Safety of consumers. For this reason. and ensure transfer of benefits and enhancement of opportunities. and strive to respect laws and customs. MEASURING BUSINESS PERFORMANCE The outputs of business management are demonstrated in the model of Figure 1. This list considers business performance in terms of managerial performance and financial performance. the public. safety and the enhancement of the skills and capabilities of our employees is second to none in mining. The financial performance of a business is considered to be much easier to measure. As maintenance is intended to assure asset capability. These assets are designed to achieve levels of safety. we aim to work closely with our hosts.55 In this way. As the capability of assets deteriorates.” Asset intensive organizations rely on assets (plant and equipment) to achieve their outcomes. Wherever we operate. derived from [vi]. employees and the environment. This model shows business management responding to a set of operational and environmental constraints to produce performance in terms of profit. we set ourselves high environmental and community standards. Our commitment to health. Assets may behave in a way that is unsafe or uneconomical. maintenance objectives often emphasise attention to: • Maintaining assets to a functional standard of performance such that they will achieve their desired capacity and availability (assures required service levels and economy / profitability of operation). this means that maintenance is a significant consumer of human and financial resources in business. We believe that our competitiveness and future success depend not only on the unrivalled quality and diversity of our assets but also on our record as good neighbors and partners around the world. The effectiveness of the performance of assets in asset intensive organizations impacts on the ability of these organizations to meet their objectives. in particular to the organizational objectives of profitability (economy of operation). risk and cash flow. output and economy. minimize adverse impacts. The loss of asset capability through degradation or failure can impact significantly on the ability to meet these objectives. these outcomes are put at risk. while risk is less quantifiable. means that maintenance should be considered a vital function within the business. We seek to make lasting contributions to local communities and to be sensitive to their culture and way of life.Influence of Organisational Management on Share Price A more detailed appraisal of business performance can be seen in the following list derived from work by Freibert [vii]. Maintenance contributes. and safety of consumers. PROFIT Operational Environment / Constraints Organisational Management RISK CASHFLOW SHARE PRICE Figure 1 . agreed levels of service. public. The objectives of the maintenance function must be complimentary to the objectives of the host business. the purpose of maintenance can be generally described as to assure the safety and profitability (or economy) of the host business. OBJECTIVES OF MAINTENANCE Thomas [v] reports that maintenance accounts for up to 40% of an organization’s costs. The role of maintenance in preventing the consequences associated with asset failure. These outputs are considered to be both tangible and intangible. • Meeting objectives of safety and capacity at a minimum total resource cost. The financial categories of Figure 2 are defined as follows: • Current Assets are assets of a business that are expected to be converted to cash. • Management Team. • Innovation. Current Assets (CA) TA=CA+FA Total Assets (TA) ROA=OP/TA Return On Assets (ROA) Fixed Assets (FA) SE=TA-TL Total Liabilities (TL) Shareholders Equity (SE) ROE=OP/SE Return On Equity (ROE) Sales Revenue (SR) OP=SR-OC Operating Profit (OP) Operating Costs (OC) Figure 2 . • Operating Profit is profit before tax and is calculated by the difference between Sales Revenue and Operating Cost. • Leadership. sold. • Dividend Payout. • Employee Relations. The model of Figure 2 shows the relationship between finances and ROA and ROE. • Fixed Assets are assets such as plant and equipment. these measures are defined as follows: Return on Assets (ROA) .56 Managerial Performance • Strategic Direction. taxes payable. • Sales Revenue is the income from all sales. ROE is calculated by dividing operating profit by shareholders equity. For the purposes of this paper. The calculation of ROA and ROE is demonstrated in the model of Figure 2.A ratio of the net income a business is able to earn with its total assets. • Market Share. machinery and furniture and fittings. Risk management is part of the social responsibility of organizations. • Regulatory (statutory) Compliance.A ratio of the net income a business is able to earn with its total shareholders' equity. and are ultimately reflected in the financial performance of the business. Return on Equity (ROE) . • Board Relations. • Investor Relations. and inventory including maintenance spares. derived from Higgs [viii]. • Shareholders Equity is the capital invested from shareholders and from retained profits and is equivalent to Total Assets minus Total Liabilities. It is argued that the managerial performance measures relate to risk. • Succession Planning. or consumed during the normal operating cycle of the business (normally one year) and include cash.Calculation of ROA and ROE . etc. • Return on Equity (ROE). ROA is calculated by dividing operating profit by total assets. Financial performance is a tangible outcome that reflects the true performance of business and one against which the contribution of maintenance can be easily measured. • Community Relations. Financial Performance • Return on Assets (ROA). • Total Assets are the entire assets of an organization and are calculated by the sum of Current Assets and Fixed Assets. Primary measures of financial performance for asset intensive business are Return on Assets and Return on Equity. • Stock Price Performance. labor including maintenance labor and materials. Calculations of these measures vary between sources. receivables. • Risk Management. • Book Value Performance. bank loans. • Total Liabilities are what a business owes to others and includes wages and salaries payable. • Capital Provision. • Operating Cost is the sum of all costs associated with sales and includes raw materials. but is ultimately measured by the viability and profitability of the business. 737 Figure 3 -Example Calculation of ROA and ROE THE CONTRIBUTION OF MAINTENANCE The cost and performance of maintenance contributes to the ROA and ROE.867.250.152 $ 215.658 Return On Equity (ROE) 5. ultimately increasing ROA and ROE.01%. Every dollar reduction in inventory has a multiple impact on increasing business profitability. • Increased equipment uptime can lead to increased revenue.250.737 $ 144. reduce operating costs. and increase operating profit.241.988. The degree of contribution of the maintenance function to ROA and ROE can be explored by considering the influence of improvement in maintenance performance on ROA and ROE.34% Fixed Assets $476. .598. • Reducing the incidents of undesirable equipment failure consequences and increasing inventory service levels can reduce risk and lower insurance premiums (either external coverage or self insurance). These figures are derived from the annual report of the business.905 Sales Revenue 428.521.000 Total Liabilities $215.356.728.728. This indicates current financial performance of the business with an ROA of 3.610. The relevant financial figures for the business are shown in Table 1.57 The financial performance of a medium sized manufacturing business is shown in the following example.494 Shareholders Equity $429.598.643 $ 406.34% and an ROE of 5.643 Operating Costs $406.241.152 $ 476. This model shows the following Operational and Financial benefits of maintenance improvement: • Lower maintenance costs. • Lower inventory costs decrease operating costs AND decrease assets increasing ROA and ROE. Category Current Assets Fixed Assets Total Assets Total Liabilities Shareholder Equity Sales Revenue Operating Costs Operating Profit $ 167.000 $ 644.610.123 Table 1 -Financial Figures The application of these figures to the model of Figure 2 is shown in Figure 3.988.658 $ 428.152 Total Assets $644.494 $ 429.152 Return On Assets (ROA) 3. Every dollar that is not spent on maintenance has a direct impact on increasing company profitability.356. increasing gross profit and profit after tax. The model of Figure 4 shows how maintenance improvement initiatives can impact on ROA and ROE. Current Assets $167.01% Operating Profit $21. • Material cost reductions are deducted from operating costs.330 $ 125.667 $ 5.00% Annual Savings $4.00% 4.00% 4. To achieve equivalent improvements through sales would require a 24% increase in sales ($104.000 $ 50. This shows a net increase of 24% and 25% in ROA and ROE respectively.00% $0 $ 4.00% 3. quality and rate Labor Resource Excessive Labor Resource Cost Overtime Material Resources Excessive Maintenance Inventory Excessive Purchasing Transactions Reduce Number of Invoices Reduce Number of Payments Reduce Expediting Costs Overheads Annual Budget Over / Under Run $ 13.133. The figures from Table 3 are applied to the existing figures in Figure 3 on the following basis: • Increased production is added to sales revenue. Operating Uptime Losses due to downtime.643 Recoverable Loss 1.000 $ 1.500 $ 6.282.00% $ 206.00% 10.667 $ 82.700 Annual Cost / Income $428. • Inventory reduction is deducted from current assets.000 $ 50. These figures represent a significant improvement in the business “bottom line”.250 $ 8.000 0.670 $ 827.875). The results of these alterations are shown in the model of Figure 5.000 5.250.000 $ 25.00% 25.506 Table 2 -Moderate Improvement in Maintenance Performance . • Labor cost reductions are deducted from operating costs.000 10.266.00% $ 826.046. Moderate improvements in maintenance performance are arbitrarily applied to the categories of Figure 4 in Table 2.58 Analyse Equipment Failures Improve Equipment Design Increase Equipment Uptime Increase Production Output Improve PM Effectiveness Reduce Failure Impact Decrease Labour costs Improve Inventory Service Lvls Reduce Unplanned Maintenance Decrease Insurance Premiums Decrease Operating Costs Increase Operating Profit Increase ROA / ROE Reduce Unnecessary Maintenance Decrease Materials Costs Reduce Excessive Inventory Reduce Materials Inventory Decrease Asset Improve Supplier Performance Reduce Procurement Costs Initiative Impact Operational Benefit Financiall Benefit Figure 4 -Impact of Maintenance Improvement Initiatives on ROA and ROE The quantification of maintenance improvement is considered in the following example.000 $ 2. The financial impact of these improvements is summarized in Table 3.227. Maintenance particularly impacts the following objectives of asset intensive organizations: • To operate profitably or economically. 2001.plantmaintenance. Retrieved from http://www. Western Banking Magazine. University of Adelaide School of Commerce. Retrieved from http://www.pdf vii Freibert G.shtml vi Author Unknown..com/about/default.A Business Centered Approach. the public and employees.59 Category Improved Uptime / Rate / Quality Labor Cost Reductions Materials Cost Reductions (15% Holding Costs) Inventory Reduction Overhead Reductions Savings $ 4.html ii Kay J. August 2000 .commerce. AUTHOR’S NOTE Portions of the content of this paper are extracted from Central Queensland University (CQU) course notes “Establishing the Maintenance Strategy” written by the Author.149 + 24% Operating Profit $26.610. Corporate Citizenship.529 Operating Costs $405.au/courses/bf2/slides/TOPIC6-2001. 3 February 1998). The Role of Business in Society (Inaugural Lecture.riotinto.781.15% Fixed Assets $476. Western Independent Bankers.494 Shareholders Equity $429. REFERENCES i Murray M et.506 $ 909.edu. 1995. Portfolio Theory.Summary of Maintenance Improvement Initiatives Current Assets $167. • To operate safely in terms of consumers.667 $0 Table 3 .282.au/engineering. al.773. A World Leader in Mining. Retrieved from http://www.991 + 25% Return On Equity (ROE) 6.149.ac. The quantification of benefit to the business provided by maintenance can be considered to include tangible and intangible measures.485 + 24% Return On Assets (ROA) 4.uk/Education/ETGACE/ukworkshop-ChrisH. Maintenance .adelaide.367 $ 45. Retrieved from http://www. • To operate safely with regard to the environment.asp v Thomas C. When tangible.doc iv Author Unknown.24% Sales Revenue $432.759.Changes to ROA and ROE after maintenance improvement CONCLUSION The outputs of the maintenance function have a direct impact on the objectives of private and public organizations.surrey.620 Figure 5 .391.241. Quantifying maintenance improvement in terms of business measures is an effective tool for demonstrating the power of maintenance improvement and the cost effectiveness of investment in the maintenance function. • To provide desired or agreed levels of service.485 Total Assets $644.533. financial measures of business performance are considered.000 Total Liabilities $215.com/in_action/133 iii Hutton C. Maintenance Engineering Society Of Australia Capability Assurance: A Generic Model of Maintenance. Retrieved from http://jeeves.mesa. Advent User Conference. Retrieved from http://www. moderate improvements in maintenance effectiveness can be shown to impact significantly on the business “bottom line”. Permission of CQU to reproduce this portion in this paper is acknowledged. The Economic Value of Inventory Improvement.com/articles/BCMaintenance. Evaluating the CEO. October/November 2000 viii Higgs J.750 $ 206. The Maintenance Engineering Society Of Australia.johnkay.org. They typically gear their organisational structures and management practices to suit this responsiveness . from Dupont.i.e. planned.i. assessment.i. some companies may choose to remain reactive. • I am a highly skilled tradesperson (sic) in that I have to display all of my trade savvy to trouble shoot the breakdown and then fix it.people need me to fix the plant and get it back on-line as soon as possible. such as: • I am personally rewarded . etc. from Dupont) The model nominates five (stable) domains in which manufacturing organisations may choose to either remain within one. • I am financially rewarded when I work overtime and am called-out. Operations.) claim that this is certainly a stable domain and one that has served many an organisation well for a long time and become the paradigm of good maintenance performance. predictive and proactive? Answer. Dunn (n. The maintenance department within these companies typically have a relationship with their operations department which is one of “when you break it. prioritisation. very little work is planned and/or scheduled. Themselves and others judge their effectiveness by how quickly they can respond. Blann (2003). • Information systems / CMMS would not be effectively utilised hence rendered (almost) useless for future analysis and decision making purposes.d. Australia here do organisations start in terms of the journey of moving an organisation from one that is reactive to one that is preventive.e. strive for maintenance excellence and move through the domains. • Maintenance resource structures are top heavy in terms of labour allocation to address the first line / reactive work. job initiation. improve it Fix it before it breaks Planned Predict Plan Schedule Coordinate Cost Focuse Fix it after it breaks Reactive Don’t Fix It Proactive Eliminate Defects Improve Precision Redesign Value Focus Figure 1 Journey from reactive focused to reliability focused culture (from a diagram by Ledet. Some would call this having a customer focus. • Equipment maintenance plans would either not exist or be incomplete and not adhered to. Federal Behaviours Strategic Alignment (shared vision) Integration (Supply. we will fix it”. if we were to put ourselves in the position of a tradesperson in a reactive domain there are a number of personal incentives and behaviours associated with being in this domain. • Breakdowns take precedence over preventive / planned work which inevitably results in more breakdowns and the cycle continues.e. Marketing) Differentiation (System Performance) Alliances W Don’t just fix it.i.e. 4) claims that this question is best answered as per a diagram by Ledet. detailing scopes of work. For example. p. held outside of the normal store’s inventory system in satellite stores. From a different perspective. at the start. . • Discipline is poor in relation to work process flow . • Have no need for planners and schedulers .d. given that they are reactive they: • Carry lots of spares which are normally poorly controlled .. who plans. albeit the repair may only be a “band-aid” and exacerbate the situation.60 Moving From Reactive To Proactive Rod O’Conner OneSteel. part of which is shown in Figure 1. and Dunn (n. or based on their strategic business direction and organisational leadership. Current maintenance best practice. procedures and rules. A more stringent view of reactive maintenance is work you didn't foresee or plan to do on a Monday morning. Total Productive Maintenance (TPM). . KEY PROCESS Leadership & Organisation Root Cause Problem Elimination Planning & Scheduling Skills Development Preventive Maintenance Stores Management Technical Database Engineering Interface with Maintenance Facilities. or whether they should have all of the processes in working progress. Engineering Interface ORGANISATIONAL Training LEADERSHIP Inventory & Procurement Work Flow System Information Database Proactive Maintenance MAINTENANCE PLAN/STRATEGY Figure 3. it is not hard to envisage why initiating / leading a change from one to the next is a very difficult task. The reactive domain is very different from the next domain of planned. one can appreciate that there is no single process that will deliver the silver bullet that some seek to find and apply. plus propose a strategic implementation of each of the key processes.). tools and workshops). Business Centred Maintenance (BCM). from the same trade person’s view. avoiding failures. MAINTENANCE PLAN / STRATEGY Wireman (1998. who may have lived in the semi-chaos of a reactive environment for possibly all of his working life. Pyramid of key maintenance management processes (Wireman) .Element (n. as defined by Wireman (1998. Tools. depicted in Figure 2. how hard it would be to adjust to this planned domain. When you move into the planned maintenance phase there is more of a focus on systems. The rewards and behaviours in the reactive domain disappear and are replaced with routine inspections. Through the above dot point.refer to Figure 3. specify that maintenance shall be doing all of the processes right . These methodologies are based on teamwork and relationships and are absolutely vital to a reliability focused culture.from figure “Assessment of element Current Best Practices (CBP)“ (Ref.61 • I am motivated and enthusiastic because I enjoy the variety and challenge associated with not knowing what (and when) I will be working on next.refer to Figure 2. outline the relationships between each of the processes so as to raise an awareness of the value of implementing the key process in a specific order. p. One can appreciate.Proposed Maintenance Definitions: E . Its common characteristics are that it is unplanned and urgent. methodologies such as Reliability Centred Maintenance (RCM). WHERE TO START? Maintenance management. but had to do before the next Monday. for example. Once the foundation is laid the pyramid is constructed by completing one layer at a time. Put simply this domain requires the rigour and discipline associated with striving to understand plant and equipment condition so as to enable tasks be both planned and scheduled and then executed at a time suitable to both maintenance and operations. Key Processes . Within all constructions a solid foundation must first be in place otherwise the structure will topple over. WHY CHANGE? Reactive maintenance is typically characterised by practices such as run-to-failure. coupled with the above plethora of choices. & Workshops Figure 2. 1) is ‘the management of all assets owned by a company. Similarly all constructions require mortar to bind the construction. referring again to Figure 1. p. Each of the key processes form building blocks within the pyramid. will need to be embraced if the journey is to progress. and levels in excess of 20-30% should be avoided. The bottom line is reactive maintenance costs more . as nominated in Proposed Maintenance Definitions: E .d. The objective of this paper will seek to discuss each of the key processes (excluding facilities. If you compare the reactive to the planned domain. no surprises and no challenges. breakdown and emergency maintenance.typically (and conservatively) between two and four times more than being planned due to its inefficiencies. If organisations choose to continue on the journey and move on from the planned domain. based on maximising the return on investment in the asset’. it is not difficult to understand the confusion faced with some (if not most) maintenance leaders and practitioners as to what processes to focus on initially to deliver the maximum impact before moving on to the next area of focus. To realise this statement. 8) likens the structure of the key maintenance management processes to (building) a pyramid .Element ) Upon reflection of the initial question of where to start on the journey to build reliability. i. once a month for example. The key to selecting the right action (and frequency) lies in: • An understanding of the equipment’s criticality . The solution here may still be to let it fail but to carry a spare so as to ensure its timely replacement. X AGE FIGURE 2 Figure 4.i. Figure 4 depicts the traditional wear out profile that most people would relate to (Moubray 1991. safety implications. etc and in the marine field where age related failures are associated with fatigue and corrosion. then have a new one ready to install after it fails. and hence the overall business plan. we basically have a period of trouble free running and at some point in time it wears out and we replace it. p. etc to ensure equipment reliability meets the customer’s requirements in the most cost effective way.i.i.e. listen. minimise and/or mitigate the amount of preventable unplanned failures hence minimising the behaviours and practices associated with being reactive (which have been discussed earlier). adjust. do nothing.e. p. if the effects and/or consequences of the failure are negligible.e. safety and environmental. inspect (look. studies completed on civil aircraft showed that only 2% of items typically fit the pattern of wear out / age related failures as depicted in Figure 4. this profile indicates that reliability is a function of age . clean. Or put another way. operations. overhaul. To help in the selection of the correct maintenance action. To explore this a bit further. trades. Coupled to this is the effectiveness of the strategy . we firstly must understand the different ways in which equipment can fail. • The varying pattern or frequency in which the item of equipment will fail. crushers. For example. Alternatively. one can appreciate that changing the light bulb based on fixed time . furnace refractories. product quality. It should seek to formally select the appropriate maintenance action and frequency. replace.i. further damage to the equipment. If this was simply the case and through our extensive library of equipment history we could indicate the “when” then all we have to do is perform some kind of preventive (fixed time) maintenance such as overhaul or replace just before it fails. A B C FIGURE 3 D E F Figure 5. At our disposal are a number of maintenance actions for selection such as lubricate. etc. the strategy to do nothing / operate an item of equipment until it fails would be the correct strategy in the case of say a light bulb given that the random pattern of failure is not predictable and there would be no effects or consequences as an outcome of the failure. The maintenance strategy selection should directly reflect the maintenance objective. In the case of the later. Traditional wear out failure profile In reality. This pattern of failure is more predominant both where equipment comes into direct contact with the product . if the light bulb was of a more critical nature for whatever reason. age related failures can account for up to 17% of failures. • An understanding of the consequences of the failure in terms of a flow on affect .e. hopper liners.e. etc.e.examples include. coal chutes. would not ensure its reliability. contractor. Put simply. 12). 11). quality assurance standards.62 The foundation of the maintenance management processes is the asset maintenance plan / strategy selection. the maintenance plan is similar to a car’s maintenance manual and is established to avoid. the effects of the failure in terms of impact on downtime. etc to name just a few. Figure 5 depicts the reality of what actually happens in terms of conditional probability of equipment failure patterns as a function of operating age for a variety of mechanical and electrical items (Moubray 1991. In other words we buy something new. Put another way. Failure profiles (Moubray 1991.i. the older it gets the more likely it is to fail. you would be both replacing a light bulb that most likely was still working and wasting labour to change it. feel and smell). monitor. p. categorised by disciplines . 12) . etc. screw conveyors. do the little things right and the big things will go away. In most cases the customer will be the operations department but this extends to include safety and environmental statutory authorities. This time is influenced by factors that include. more rigour and discipline around shut down and start up practices. depending on the equipment. days.random failure. is known as the P-F interval. access time to equipment.i. 3. but there is no identifiable wear-out age. AGE RELATED FAILURES Referring to Figure 5. It was in the past assumed therefore that just before this point that maintenance should intervene and apply the appropriate fixed time action to either overhaul the equipment or replace components so as to prevent or minimise the consequences of the failure. In actual fact the data suggests that the majority of equipment either: 1. lead time to procure parts. 2. performing fixed time maintenance can (and will) actually increase the overall failure rates by introducing infant mortality (this will be discussed further at a later time in the paper) into an item that basically may have had nothing wrong with it. which would more likely conform to the failure patterns of E and F. the patterns of failure as depicted in Figure 5 indicate that all failures are either age related or non-age related. B and C depicts the age related failure patterns . all age related failure patterns display a point in which there is an increase in the conditional probability of failure. As discussed earlier. One other factor to consider is the lead time requirement to take action. which is a key consideration when determining the monitoring frequency. organise labour. The same learning can be applied to the paradigm of thinking that suggests performing some kind of fixed time preventive maintenance such as scheduled overhauls. scheduled replacement of items. electronic. improved operations. once the potential failure has been detected. weeks.e. Put another way.e. patterns A. failures occur randomly throughout the life of the equipment. Pattern E shows a constant probability of failure at all ages . Based on the above data. motivation. It is the period between this point of potential failure and the actual failure of the bearing. Pattern B shows constant or slowly increasing failure probability. etc).i. known as infant mortality. Before discussing the different condition monitoring techniques at our disposal. the probability of failure increases. To coin an old phrase. This period. Generally speaking though. (Moubray 1991. . that enable action be taken. Moubray (1991. pneumatic and hydraulic equipment. Fails prematurely . as the item gets older. In most cases this will be sufficient to enable enough time to take action to avoid the impending failure. the P-F interval can vary quite considerably for different equipment. Pattern A is the well known bath tub curve. training. 119) suggests that the monitoring frequency should be half of the P-F interval.e. better storage practices. intrusive inspections of equipment. the objective is to select the most cost effective monitoring frequency (and technique) which will enable a reasonable lead time to take action. For patterns A and B in particular. and rolling element bearings which would conform to pattern E. less intrusive maintenance. Let us use the example of a rolling ball bearing: The initial point at which the bearing starts to fail may not be detectable. don’t fix it”. etc will ensure cost effective plant and equipment reliability. Pattern F starts with high infant mortality. these failure patterns are representative of complex items. 12 to 13). NON-AGE RELATED FAILURES Referring (again) to Figure 5. pp. For example. which drops to a constant or very slowly increasing failure probability. months. Based on this. If we take a minute to reflect back on the effectiveness of changing a light bulb based on fixed time. 2. Put simply this is folly if there is no dominant age-related failure mode. In actual fact the onset of failure. It is at some stage after this that the impending failure of the bearing will become detectable. Fails randomly . ending in a wear-out zone. E and F depicts that the majority of equipment conforms to these failure modes and more importantly have no correlation as a function of age (excluding an initial period for D and F). identified as point F. etc. Pattern C shows slowly increasing probability of failure. 5. Generally speaking. 4. followed by a constant or gradually increasing failure rate. In theory. 6. in which the impending failure usually deteriorates at an accelerating rate. “if it ain’t broke.63 1. improved workmanship (alignment and balancing practices. The key to selecting fixed time maintenance lay in reliable historical maintenance records.i. Pattern C however is more difficult to predict given the steady increase in probability of failure. then a wear-out zone. Pattern D shows low failure probability when the item is new then a rapid increase to a constant level. to name just a few. they will reach a point called the wear out zone where the conditional probability of failure will rapidly increase. operating conditions. we need to further explore the fact that a lot of items do not fail instantaneously. p. infant mortality or 2. can actually develop and take years. To this end one can appreciate that selecting fixed time maintenance for new equipment and/or in organisations that are reactive would (almost) be impossible. patterns D. etc until the item actually fails. In reality. information. It begins with a high incidence of failure. In the case of equipment that fails randomly: perform predictive maintenance / condition monitor. the best way to combat these type of failures is: 1. In the case of failure patterns E and F: improved design. • Hot spots within an electrical connection indicating poor connection. etc to fail once the onset of failure starts. etc. etc and the very thing that was set out to be achieved . whilst the equipment is either running or stopped but left in situ. but more importantly is non-intrusive hence minimising the reliability issues associated with infant mortality. p. He completes his inspection route and diligently raises a request for work to replace an identified leaking oil seal (at a later date). etc failure. from a timing perspective. • Wear particles in oil indicating imminent bearing. human senses (look. and supporting planning and resource structure. hence realising minimal improvements in terms of reliability. The key here is that predictive maintenance is usually very efficient. • The list goes on. It is not the intent to go into any great depth and discuss the hundreds of different condition monitoring techniques associated within each of the main categories. it is strongly recommended that the initial focus be on establishing a work flow system. the next layer within the pyramid of key maintenance management processes is ready for construction. • Metal / wear surfaces becoming thin indicating wear.e. if the maintenance plans are completed. gear. The benefits of predictive maintenance is that it is normally performed on-line . etc. temperature.i. listen. initially there will be a huge bow wave of additional work given that the equipment will have deteriorated. 1 to 6) . etc) and variations in product quality.e. WORK FLOW SYSTEM Once the foundation has been laid in terms of establishing the asset maintenance plans. condition monitoring programs. How many times will the same tradesperson diligently complete further monthly inspections and raise further requests for work if he sees no action time and again? As a result. feel and smell). Condition based (predictive) maintenance is the process by which we seek to identify this change in condition/s so as to enable action to be taken to prevent the failure and/or avoid the consequences. The importance of the work flow system will (hopefully) become obvious throughout this section and the remaining key processes will be discussed in order of priority. For example. • Cracks in welded connections indicating imminent failure due to fatigue. days. pressure. If there is no work flow system in place to accommodate this additional work then the request will most likely sit un-actioned until the next time that this inspection is due. a preventive / time based monthly inspection requests a tradesperson inspect a gearbox for oil leaks. etc. not only will the tradespeople (and others) place very little value in the maintenance plans. corrosion. and will need to be brought back up to a standard. reduction in reactive work. condition monitoring techniques (oil analysis. At a glance it seems difficult to ascertain which of the key processes to establish next or whether they should all be progressed in parallel. All of the upfront effort (and hence money) in establishing the maintenance plans will count for little. the worst case scenario is that the gearbox will ultimately fail due to no oil. this will create further work identified through formal time based inspections. As stated earlier. months. Examples of change in equipment condition include: • Vibrations indicating imminent bearing failure.e. It is during this period of decay that physical conditions within the equipment will change and this change will become detectable during the P-F interval. referring to Figure 3. which should be taken into consideration when selecting. Although there will be many a good debate proclaiming the importance of progressing all of the key processes (within the second layer) at the same time. variations in equipment running conditions (speed. weeks. JOB ORIGINATION JOB PLANNING JOB SCHEDULING JOB ALLOCATION JOB EXECUTION & CONTROL REPORTING Figure 6 Work flow process (Kelly 1999b. The objective here is to raise an overall awareness of their existence and the fact that each present their own advantages and disadvantages. will not be realised. To make matters worse. vibration analysis. power.i. flow rate. etc). increased reliability. engine. if the sum total of the additional workload is not managed and actioned in a disciplined and pragmatic approach and in line with budget constraints. schedule compliance in excess of 90%. current. The only way that this will happen however is if the maintenance plans are completed on time .64 CONDITION MONITORING TECHNIQUES Items can take years. due to the past reactiveness of the organisation. ingress of dirt.i. The four main categories of condition monitoring include. and completed properly. In what seems like a vicious circle. which in itself will be a huge addition in terms of workload. the successful implementation of the maintenance plans will realise a reduction in the reactive work. as this is key to the success of the journey. etc. • Pre-planning and executing the work in the most cost effective way. • Spares. Peters (2003b. • Cost to maintain. 3. 21 to 22) claims that the typical spanner time of trades in a reactive / unplanned environment is in the order of 30% to 40% (of an 8 hour day). etc. identified from the maintenance plans. pp. The information data base exists whether or not organisations choose to invest in a computerised maintenance management system (CMMS).work that has a longer lead time and can usually be held over to weekday shuts. 3 to 9) suggests that the key to managing the additional workload. pp. 2. pp. • Maintenance measures (MM’s) / Key Performance Indicators (KPI’s). pp.i. Third line . both planners and trades.i. Again. should be aligned to a dedicated planner/s (Kelly 1999b. Going back to the above example of replacing the leaking seal within the gearbox or as another example replacing a bearing or oil as a result of the condition monitoring programs. resources required (numbers. this is about the maintenance department’s organisational efficiency. • Maintenance plan / schedule. Put another way. isolation plans. WORK PLANNING AND RESOURCE STRUCTURE As stated earlier. p. Kelly (1999b. duration of shuts. drawings. 1-11 to 1-12). 2-23). • Documentation . • Failure analysis data. 8 -15). etc will determine the need for a dedicated planner/s as opposed to the second line planner/s planning the third line work. utilising shift trades as opposed to relying on call-ins (Kelly and Riddell 2000. work instructions. p. From the above is becomes obvious that the work flow system encompasses a number of steps and is not just about planning and scheduling. p. the shift tradespeople / shift supervisor should organise all necessary materials and information to enable a quick response to this work (Kelly 1999b.e. To realise this objective the design of both the work planning system and resource structure should be aligned so as to match the different levels of work. Similarly the resource structure should be aligned so that the dedicated trades group only execute the second line work (Kelly and Riddell 2000. put simply. etc but in the main both the first and second line resources should be utilised and (if applicable) topped up via the use of contractors (Kelly and Riddell 2000. pp. Wireman (1990) suggests that these jobs can only be completed in the most cost effective and efficient manner by completing the steps depicted in the work flow diagram of Figure 6 (Kelly 1999b. is by being both: • Effective in prioritising the list of outstanding work. 2-22). weekends. One of the pit falls of not being disciplined in relation to alignment of the different levels of work is that resources. etc. 2-5 to 2-6). the overall objective in the pre-planning and execution of all work is to ensure that all work is handled in the most cost effective and efficient manner. pp. The objective of a CMMS is.65 Kelly (1999b. size and type of work. the tool in which to transport each of the above functions so as to increase both the organisational effectiveness and efficiency (Kelly 1999b. The work planning system’s centre of gravity should be aligned to a dedicated planner/s (Kelly 1999b. 1-16 to 1-17) categorises all work into the following three levels: 1. this is about how effective the maintenance department is in terms of deliverables of the maintenance strategy and providing plant reliability. In saying this. locations and shifts. p.usually follows the production operating pattern and its characteristics are that it is typically reactive and maintenance is required to (and should) respond quickly. The third line work planning system’s centre of gravity. the duration of shuts. For example. INFORMATION DATA BASE / CMMS The information data base is the plant asset hierarchical library where all information should reside. 1-7 to 1-11). The resource structure for the third line work would again depend on several factors such as timing (total plant shutdown as opposed to sections of the plant). put another way. • History of all work performed. . like the second line work. 1-6).e. First line . Similarly the work planning system’s centre of gravity should be aligned to this resource structure . One reason for having dedicated planners is simply that it will increase the productivity (spanner time) of the trades by having the work planned and ready prior to execution. Kelly and Riddell (2000. 2-22 to 2-23). will naturally want to gravitate back toward executing the reactive work and the organisation will continue in the downward spiral of reacting as opposed to preventing the reactive work. skills requirements). Second line . p. 6-6 to 6-9) nominates that this information is inclusive of the following: • Manufacturers details (through Bills of Materials (BOM’s)).work that is required to be carried out during major and/or full plant shuts such an annual Christmas campaigns. This work should be resourced accordingly in terms of numbers. pp. A complete and accurate information data base increases the efficiency of planning and scheduling all work. in which the establishment of root cause leads to a change in the way in which the equipment is designed. etc so too should the data base be revised to reflect the changes.e. etc.e. it also plays an integral role in supporting and development of the future key maintenance management processes (within the pyramid). hence the need to carry satellite stores. there is an underlying appreciation within the organisation that things are improving due to an increase in uptime and a reduction in the amount of breakdowns and call-ins being experienced. the 80/20 rule. In terms of increased organisational efficiency. Time to roll up the sleeves as this will be an uphill battle all the way given there are no gains to be made here. the CMMS is utilised as the tool to increase both the organisational efficiency and effectiveness by facilitating the collection. the collection of all history of work performed and the cost of maintaining the process should reside no further down than the electric motor’s level given the benefits in tracking this information at the part’s level is a waste of time. • For zero based budgeting and/or historical budgeting. and then the automatic initiation to replenish the store stocked item. to establish root cause and hence prescribe a solution. Based on this and in relation to the pyramid of key maintenance management processes. • The list goes on. Put another way. as work is completed by the trades (and others) on a daily basis. • Inventory and procurement. Collection of information into the data base is off and running albeit most of the trades people. In terms of increased organisational effectiveness. or maybe maintenance plans have been developed for just one or two critical pieces of equipment within the process. • Un-controlled condition of parts . not fit for use due to poor storage practices such as allowing shelf life to expire. it enables the identification of the 20% of all (say) motors that create 80% of the issues . in excess of 70% (and climbing). With nothing else better to do it seems like an opportune time to address the issues associated with inventory and procurement. • In terms of financial optimisation so as to establish the true cost of manufacturing (life cycle costing). similarly the CMMS ‘s work order system should enable all history of work performed and the costs associated with maintaining be housed and made easy to retrieve at the electric motor level. every time the trades people go to the store to get something out it is never there. • Parts are not automatically flagged for reorder when used. such as a reliability engineer.i. Specifically information will be used in the following areas (and will be discussed further at a later time): • Proactive maintenance (as already touched on).whatever. • To justify the purchase of the most reliable and possibly the more expensive equipment as opposed to the cheapest. • To justify approval of capital expenditures. this could be achieved for example by linking the stores and purchasing functions when drilling down through the BOM to find and hence order the electric motor or bearing either out of store stock or to purchase externally. it can be appreciated how a tradesperson and planner would require the manufacturer’s details when ordering the electric motor’s bearing. operated. The information data base is a live and dynamic work in progress and there is no end to the amount of times that the data base will be updated over the life of the plant / process. Alternatively. The CMMS can then enable for example a Pareto analysis so as to identify a top five in terms of high costs and/or poor reliability.i. when new equipment is installed and conversely old equipment removed. be it from a business and/or bottleneck perspective. it is obvious as to why proactive maintenance (which will be discussed later) resides at the third level within the pyramid. processing and analysis of the data.e. • The list goes on.i. This whole new concept may actually be working. This information can then be utilised as the basis for a dedicated resource. . For example. The benefits of an accurate and dynamic information data base not only aids in the planning and scheduling of all work. team leaders / leading hands and some of the supervisors are still confused with what is history and what is shift log reporting.i. or maybe for the whole plant . The trades people know that satellite stores leads to the following but it is still a better option than handing back responsibility to the store: • Duplication of parts. An ongoing acceptable level of compliance to the maintenance plan’s schedule is being achieved . maintained or any combination of the three.e. when maintenance plans are revised to (say) reflect proactive maintenance. None of the trades people will ever admit to taking stock out of the store and not booking it out so it must be the store’s fault. just ask anyone! The trades people will tell you that they cannot give up their satellite stores and hand back responsibility to the stores people because they can never get it right . INVENTORY AND PROCUREMENT Reality check! Let us assume the following scenario: Suppose that maintenance plans have been developed for one of the more critical processes within the plant. relies heavily on accurate data.66 The information data base resides at the various levels within the process hierarchical library. The amount of work being planned and scheduled each week is increasing and the work flow system is being adhered to. As stated earlier. even though the CMMS indicates there is two in stock. All in all though. This example of proactive maintenance. In other words. Given that inventory generally represents capital that does not generate a return. labour. seeks to eliminate (altogether) and/or prolong the onset of failures. Now maintenance. like all of the key maintenance processes. predictive and proactive maintenance practices of the future such as laser alignment. The focus on the “planned” domain. similar to the story of goldilocks and the three bears. maintained and operated (or any combination of the three) and seek to work across these boundaries to improve reliability. to enable a quick response and hence avoid a potential more costly (to the business) loss of plant downtime. and without trying to over-simplify it.67 What about the stores department? For the past several years they have been engaged in an improvement initiative of driving down inventory to benchmark levels comparable with world class organisations. will be ongoing and only sustainable if key improvements are locked in. p. they would realise that in essence they are both working toward the same business goals. Their key driver for improvement being that typically the value of the spare parts held is equivalent to 25 . Reliability Centred Maintenance (RCM). wants to fill up the store with all of the parts that has appeared from nowhere and undo all of the good work of the past several years. • Lubrication practices. TRAINING Training of the maintenance personnel is similar to the preceding key maintenance management processes in that it is an ongoing and dynamic process. replaced with the preventative. or put another way. based on a prioritised approach. etc. It should be noted however that for the purposes of this paper. Six Sigma.i. • Correct start up and shut down practices. as determined by the maintenance department. Gone are the band-aid repairs of the past reactive world.e. not too many. The organisational culture within the proactive domain is one in which failures are viewed as losses to the overall business hence root cause is aggressively pursued with a view to eliminating these losses. etc).i. Total Productive Maintenance (TPM). again referring to Figure 3. in terms of the journey. whom the store’s department do not report to. this focus on improvement is depicted by the (next) domain of “proactive”. vibration analysis. Root Cause Failure Analysis (RCFA). which would have been completed during the maintenance plan / strategy stage. not too few. • The requirement to train supervisors. it is estimated that it costs a further 30% to carry the spares (floor space. This layer within the pyramid takes on a new approach in terms of reliability as opposed to the previous two layers. Referring again to Figure 1. Proactive maintenance practices include the following: • Root cause failure analysis (RCFA). If the maintenance department are to set the right inventory levels. If both departments were to take a step back from their respective narrow focused drivers and behaviours and assess their value add to the business. tidy. Kaizen. performing regular inspections. All work associated with the first two layers is related to basically “fixing it before it breaks”. They need to now work with the stores department and together trend inventory levels down as a strategic function of plant reliability. improve it”. as depicted by the “planned” domain in Figure 1. In addition. the various predictive technologies are also utilised to extend equipment life. One can appreciate for example: • The change required in terms of up-skilling the maintenance trades in the way in which they are now required to perform their work. clean. The third layer within the pyramid. These organisations know that reliability is a function of the way in which the equipment is designed. • The requirement to train the maintenance planners in areas such as planning. This process of improvement. to minimise and/or mitigate the more costly risks associated with ultimately stopping the plant and/or processes due to lack of spares. It should stock the right amount of inventory levels. balancing of rotating equipment. scheduling. tightly controlled and well organised. the CMMS. training of all personnel within the maintenance department is a necessity. The stores department may or may not understand that reactive organisations need to keep lots of spares. maintenance control (leading and lagging indicators). • Precision alignment and balancing. estimated to be a further 20% of world class organisations. maintenance practices and the engineering department interface. to name but a few. .e. PROACTIVE MAINTENANCE The next (and third) layer within the pyramid of key maintenance management processes is now ready for construction. The vicious spiral of conflicting KPI’s is alive and well. The objective of the store’s department should be to provide a service to the maintenance (and operations) department and run the store as a store should be run . guided by consensus management for the betterment of the overall business. builds on from the foundation work of the first two layers and takes the focus of reliability to the next level of “don’t just fix it. oil analysis. it is the intent to limit the boundaries of the proactive domain to within the key maintenance processes . hence the timing is now right. is about both preventing and/or detecting failures and then having a system in place to handle the resulting work. It goes without saying that given the focus on reliability. The overall prize / gains to the business are reduced cost of manufacture (sometimes offset by an increase in maintenance spend). but just the right amount.i.e. the emphasis here being on the right amount. In conjunction with this. then they need to be out of the reactive mode of the past. referring to Figure 3. insurances. the list goes on. 126).50% of the annual maintenance budget (Moore 1999. reliability engineers and middle management in the different (applicable) reliability functions of the future . To further emphasise this point. a function of the design of the plant and equipment so as to minimise the time it takes to carry out maintenance. will vary from individual to individual. To further explore the frame work for an effective training program. must change. most maintenance personnel can relate to becoming involved in projects when most of the preliminary decisions have been made and then being told it is too late for changes to be made . • Receiving instruction in a classroom environment. specify that the engineering department be in order if they (maintenance) are not. Mean Time Between Failures (MTBF). effort and skill. organisations that are reactive need to train more people in more areas as opposed to refining the training to a specific group/s . Measures would include: Mean Time to Repair Failures (MTTR). Kelly (1999a. The logic here is similar to the point made earlier with regard to reactive organisations needing to carry lots of spares. spares carried. Measures would include: uptime / downtime. and skills required. ENGINEERING / MAINTENANCE INTERFACE The interface between engineering and maintenance sits at the top level of the pyramid of key maintenance management processes. The relationship should be one in which the design. etc. 2. maintenance needs to firstly be effective and efficient in maintaining plant and equipment. • Plant reliability data . or loose it. The process of training in itself.i. 2-8) specifies that this would include data such as: • The true cost of maintaining a unit of equipment .i. life cycle costing.e. or the organisation. installation and commissioning of new plant and equipment is viewed. hence just another example of why (statistically) reactive maintenance costs more than planned maintenance. training and/or learning are mentioned. This should be a “win.e. . Put another way. the learning’s and skills development will be forgotten and/or never fully acquired given that they will not be put into everyday use in the work environment. attending lectures and/or “cramming” for an examination at the end of the course. p.i. The Training Process When the words educating. planners. • A workshop practice session whereby the learning’s can be applied in a situation so as to ensure a level of proficiency prior to it being used in the environment of the work place. Moore (1999. so as to justify future decisions at the preliminary design stage. The targeted audience. In both cases.too late in terms of not budgeted for. etc. procurement.e. there will not be a clear understanding as to whom should be trained and in which specific areas.e. etc. as the majority of maintenance personnel can relate to. coupled with requirements to close the gap between actual skills. factoring issues such as time. then how can they expect engineering. once the exam is completed. until the organisation is out of the reactive mode. master of none and use it. which includes the ongoing collection of accurate data. tradespeople. all materials and labour (including contract labour). The above point is why training of the maintenance personnel sits at the third level within the pyramid of key maintenance processes. The level of retention.e.68 A key objective in being successful in the aspect of training lies in: 1. These two sayings pretty much sum up the objective in terms of pitching the training to a targeted audience. most people would conjure up thoughts of sitting in a classroom. to perform the different tasks more effectively and efficiently. Put another way. for example to meet statutory requirements. If the maintenance department does not have the rigour and discipline to hence display accurate data such as the above. p. with the overall objective being the most economical plant and equipment to maintain (and hence produce) over its life . to support the purchase of anything but the lowest cost option? The relationship between engineering and maintenance therefore needs to be viewed similarly to the relationship between the stores and the maintenance department (discussed earlier) in that it needs to have a higher level focus rather than a departmental focus. the bottom line is that it is their only way of ensuring a quick response. The logic behind this is quite simple in that maintenance cannot expect. win” situation for both the person being trained and the organisation. with course notes. When this happens. Too often training programs are only a means for the trades (and others) to progress through their levels and attract further financial benefits with the learning’s never fully realised. • Plant maintainability data .e. and then a test at the end of the course so as to verify that the set objective has been achieved. supervisors.i. • The application of the learning’s on a regular basis so as to refine the skills. a measure of the time that equipment is available to operate at the rated capacity whilst repeatedly yielding the same results.i. but in most cases the majority of what has been taught will be forgotten if there is no process to firstly put into practice the new learnings and then secondly apply them in the work environment where they can be further enhanced over time.i. In other words. 339) suggests the following steps are a recommended breakdown for a successful process of learning: • The setting of clear objectives in terms of the outcomes of the training program. as a function of reliability and maintainability. or more strongly. etc. Too often there is a mismatch between the targeted audience and the training content. and hence measured. the way in which most engineering departments operate. For this to happen however. Targeted Audience As the two sayings go. • Refresher training (if applicable) . jack of all trades. Element n.Proposed Maintenance Definitions: C . whereby without the mortar. R. 4. R.30. & Riddell. Industrial Press.com/reliability/definitionE. S. pp.asp?docid=1G1:100543313 (accessed 21 July 2004). Stabilise the change. Without leadership to drive the transition of change. Rockhampton. 3.69 If a change is to be made in the way in which future projects are to be delivered. Making Common Sense Common Practice: Models for Manufacturing Excellence.Peters. 11. 2003.. T. improvement within the maintenance organisation will not succeed and revert back to its past reactiveness. ‘Maximizing Maintenance Operations for Profit Optimization: The Journey to Maintenance Excellence’.com/excerpts/excerpts/Repair_to_Reliability_Culture. Throughput and Profitability’. T. vol. The key steps in leading change are: 1. supervision / a verification process to combat poor practices. 4. 1999. 2. pp. infant mortality affects up to 68% of all new and overhauled equipment.idcon. 1998.pdf (accessed May 2003). pp. Understand the difference between leadership and management. specifications. R.com/reliability/definitionC. 16. 2. Oxford. 2000. one way to combat these early life failures would be to both specify a tolerance and then request a verification of actual settings. 2003b. the permanent maintenance employees will either install and/or supervise installation. D. Kelly. 2. Maintenance Journal. 16. Repeat the process from step 2 over and over (for each of the key maintenance management processes). 1999b. Reliability-centred Maintenance. 63518 Maintenance Systems and Documentation: Study Guide..htm# (accessed 10 September 2003).d.Wireman. Butterworth-Heinemann Ltd.reliabilityweb. Rockhampton. 1990. Houston. New York. Moving from a Repair-focused to a Reliability-focused Culture. 6. Besides.Component n. Based on this statement. Central Queensland University.idcon. Moore. just like within the construction process. who else is going to do it? Designing For Plant Reliability and Maintainability The reliability and maintainability of new plant and equipment over its life is influenced by the way in which it is initially designed. Articulate a compelling reason for change. post installation. 9. Blann. Maintenance Journal. 10. ‘Measuring Overall Craft Effectiveness (OCE)’. given that they will always be left “carrying the can” if they don’t. 63516 Establishing the Maintenance Strategy: Study Guide. 7. Maintenance Journal.11. procured. BIBLIOGRAPHY 1. 6.highbeam. the pyramid’s blocks will crumble and fall. vol. if adhered to. ORGANISATIONAL LEADERSHIP As mortar is essential in binding the building blocks within constructions. Measure the results. H. so to organisational leadership is required to bind all of the preceding key maintenance management processes. no. 1999a. n. Involve the employees in the process. 3.htm# (accessed 9 September 2003). 1. 7.71. Moubray. then this will only happen if it is lead by the maintenance department. Moore. Kelly. 3. 5. J. www. Simple reason being that it is in their interest. . R. www. 8. Developing Performance Indicators for Managing Maintenance. A. no. 15. www. Moore (2003a) nominates that the following steps. New York. will enable the effective leader to lead the transition of change through each of the key maintenance management processes and deliver the benefits of improved reliability at reduced costs. 2003a.. World Class Maintenance Management. 14. Central Queensland University. Therefore. vol.Peters. Dunn.com/library/doc3. 13.Proposed Maintenance Definitions: E . www.Wireman. maintenance needs to raise an overall awareness of design reliability and maintainability practices by way of set objectives. 12. 16. Kelly. no. Rockhampton. Texas.d. Another way may be to specify that for all nominated critical equipment. 2003a. For example. Clearly communicate the strategy for achieving the change and the goals desired. A. Central Queensland University. ‘Reliability as a Strategic Initiative to Improve Manufacturing Capacity. A. installed and commissioned. 63517 Maintenance Organisation: Study Guide. 16 . 4 . represented within the pyramid of Figure 3. Managing Change. Industrial Press. 1991. 66 . Gulf Publishing Company. 5.d. projects. such as JCAHO. Aptools can used as stand-a lone or form a part of your ERP system. Apt-Spares & Stock: Justify min/max levels. the technicians can complete their work faster and increase accuracy with electronic transmission of data. shutdown scheduling frequencies. Apt Technology P/L Contact Ian Jones (0411193090) Tel: 02 9318 0656 Fax: 02 9318 0776 ianj@aptgroup. inspect. modifications. Identify cost/Risk/Performance plus impact and analysis of shuts. xmMOBILE for Healthcare can be used with a bar code scanner and supports a wide range of handheld devices using the Pocket PC operating system.au Maintenance Management Module for Pocket PC Aimed at Hospitals MicroMain Corporation has released MicroMain xmMOBILE™ for Healthcare. Apt-Inspection: Calculate the best inspection. and range-estimates can be used to test data sensitivity. deterioration management. maintenance requirements. reliability.maintenancenews Asset Management System Software Asset Performance Tools include the following: Asset Performance Tools (Aptools) software is now available through Sydney based Apt Group. safety. Maintenance technicians in a hospital’s facilities department and biomedical equipment technicians in a hospital’s clinical engineering department will both benefit from the xmMOBILE for Healthcare module. which includes ventilators. This add-on module is used with MicroMain XM™ for Healthcare. The UK developed Aptools is a flexible software tool that helps asset managers plan optimum maintenance strategies for all types of assets. It will optimise the associated costs and risks. process or procedure changes. a software module allowing hospital technicians to utilize Pocket PCs for their maintenance tasks and inspections. The software has the versatility to cope with any maintenance task individually or as a ‘bundle’ of activities. which generates reports used for regulatory agencies. DC and servo motors of all brands.com. Once hospital technicians upload their data from xmMOBILE. MicroMain XM for Healthcare allows each hospital to determine and assign maintenance tasks based on equipment risk assessment™ a numerical classification based on factors such as equipment function. Rockwell Automation motor repair for all makes As a result of a major expansion to its existing motor repair capabilities. 70 . the technicians upload their data into the main database. the remanufacturing centre is a hub for the company’s 26-strong nationwide distributor network--technical repair expertise for even the most remote locations. With xmMOBILE for Pocket PC. cardiovascular machines. At the end of their work shifts. Using this module with their Pocket PCs. Cost/benefit/risk screening & prioritizing of proposals. equipment risk assessment is associated with the work order in the main database. enter pertinent comments. technicians will easily access work orders. Apt-Schedule: Optimise work content planning. and nuclear magnetic resonance equipment. The software provides solutions based on fact and scientific calculation rather than subjective judgment. refurbishment and maintenance options. complete the tasks or inspections. and update the data at the point of work performance on the hospital floor. Rockwell Automation Australia’s Remanufacturing Centre is now servicing AC. using incomplete data if necessary. Compare vendors plus evaluate pooling options. and consequence of equipment failure to patient care. performance and lifespan. X-ray equipment. Apt-Maintenance: Calculate maintenance intervals. Biomedical equipment technicians install. service and repair this type of equipment. Based at the Rockwell Automation Australia headquarters in Melbourne. re-order jit. Aptools Modules Comprise: Apt-Lifespan: Determine the best life cycle for assets. repairs & construction. monitoring or test intervals and quantify the economics of riskbased inspection methods. Apt-Project: Determine the variability of projects. defibrillators. a computerized maintenance management system (CMMS) developed specifically for hospitals and healthcare environments. justifies costs and benefits of alternative replacement. Risk assessment is particularly important for clinical engineering equipment. It caters for multiple stores.au. Purchase Orders. phone +61 7 3392 4777 or email sales@mex. “The remanufacturing centre provides an important resource that each distributor can offer its customers. 17 technical and logistics experts are on-hand. You can start by simply using the basics. please visit www. It provides fast turnaround inclusive of a 12-month warranty agreement for all repaired products.” said Chris Baker.com. Users customise inspection applications by defining their specific sets of inspection questions and answers. Receivals.au. ensuring simplicity and efficiency. multi-select functions and conditional formatting. the MEX system gives users the power to take control. streamlined electronic safety permit approvals.000 pieces of equipment. inspection routines and standard jobs. including manufacturing plants. utilizing either MEX Access? or MEX Enterprise SQL Server?. Whether a maintenance operation services five or 50. Regardless of your level of spares. DC and servo motors. the remanufacturing centre does more than just reduce maintenance costs. building facilities and maintenance contractors. This new version also includes a ToDo list for task control.mex.freeing up capital. Longer lead times and critical equipment items contribute to the need to hold more spares. “Through growth and diversification.com.” said Baker. this company is providing solutions to virtually all industry sectors.500 system users across the globe. 71 . the remanufacturing centre has been recognised as a centre of excellence for the repair and maintenance of Allen-Bradley and Reliance products. ensuring that it delivers benefits to any size company . multiple suppliers. the MEX system gives users the power to take control. Invoice Matching and Stocktake. MEX Stores is a fully functional Inventory Management system that integrates with MEX and FleetMEX. Chris Baker. We’re hoping to ease the burden on our customers by providing one point of contact for all support needs. or to obtain a FREE demonstration CD or trial copy of MEX v11 software. MEX will allow you to create a maintenance plan to suit your needs. there is no paperwork and no separate data entry.au. Knowing who has booked parts out and why. MEX v11. Now with over 3. system regionalisation. Benefits of using MEX Stores: Knowing what spares are needed for planned work in time to order them. These questions and answers later guide the operator through the inspection runs and will automatically activate Work Orders based on results. MEX Stores module can only be used when you install MEX or FleetMEX. MEX will deliver benefits to any size company.au.000 pieces of equipment. we can now offer the same level of service and support on all AC. “Customers have been relying on us for this type of service for years.Since the commencement of its 25 year history. “By leveraging our established capabilities and associations with local and international technical service providers. For more information about Maintenance Experts and MEXv11. Rockwell Automation Australia Asset Management Business Manager. Whether a maintenance operation services five or 50. Knowing what equipment is consuming more parts than necessary. Issue & Returns. For more information about Maintenance Experts and MEX v11 software.mex. from stand-alone installations to multi-site regionalized organizations. utilising either MEX Access or MEX Enterprise SQL Server. “The distributor provides the key customer contact. or to obtain a FREE demonstration CD or trial copy of MEX v11.” According to Baker. MEXv11 is about simplifying routine maintenance.” said Baker.rockwell. This CMMS gives you flexibility in creating preventative maintenance plan that includes preventative maintenance policies. With the addition of palm devices. Rockwell Automation Australia Ltd E-mail: cbaker@ra. MEX CMMS simplifies routine maintenance Taking control of your Inspections routines is now even easier with the latest version of MEX. Maintenance Experts has been delivering maintenance efficiency to business operations since 1993. Reduced stockholding . Transaction History. we now have this capacity to service non-Rockwell brands. MEX Inspections provides effective centralised control over the equipment inspection process. It also enables the delivery of a mobile inspection system that guides operators through single or multiple inspections. phone +61 7 3392 4777 or email [email protected] MEX Manages Spares while Managing Assets Some users say that using MEX Stores brings them their largest cost savings. MEX Stores can reduce your stockholding and increase your level of control. simplified security.com. It provides comprehensive parts availability management and allocation of part costs to work orders and equipment. MEXv11 also includes new flexible functionality and expanded features. please visit www. preferred suppliers and various costing methods.com. and dedicated to providing a high level of support for repairable assets.from stand-alone installations to multi-site regionalised organisations. and when you are ready you can begin using the other functions.” An ISO 9001/2000 certified facility. Its functions include Parts Catalogue. TRU Energy Yallourn went with the CSI 4500 system to continuously monitor the critical FD and ID fans on the boilers used in their thermal power station. It has implemented the fleet management module of Datastream EAM which are specifically developed to fulfill the requirement of managing harbor hoisting machinery equipment such as the bridge hangs. Ltd. the wheel hangs and so on. The NEW 4500 with GT2 Technology and PeakVue enables powerful predictive intelligence. Worsley Alumina Collie and Millmerran Power Station. as well as manage the mechanism of reclamation. Oaky Creek also run a successful portable vibration program using the CSI 2130 portable vibration analsyer to monitor their coal shearers and longwall. Mediterranean Sea. Europe and the major domestic port’s interior branch routes. The system also provides specified tracking method to track the maintenance of large amount spare parts. So why not talk to Maintenance Systems Consolidated about the continuous vibration monitoring of your critical rotating assets. North America.CSI 4500 Online Vibration Monitoring System Maintenance Systems Consolidated P/L (MSc) have had continuing success with the CSI 4500 online vibration system as more and more companies look at continuous vibration monitoring of their critical fixed and rotating assets. senior engineer. the company responsible for implementing the system for the New Oriental Port. Hydro Tasmania. coupled with powerful diagnostic tools and Ethernet connected exceptions based reporting make the CSI 4500 the monitoring system of choice for a wide range of rotating machinery applications. Datastream's solution is our natural choice as it is highly effective and cost-efficient in maintenance operation. TRU Energy Yallourn and Xstrata Oaky Creek Coal. and is in charge of the entire business operation of 11 provinces’ economical centers. In addition. etc. Hydro Tasmania needed to continuously monitor their critical hydraulic turbines. covering Asia Pacific. BlueScope Steel Pt Kembla. Maintenance Systems Consolidated P/L info@maintsys. EAM has effectively helped the port company establish the related maintenance required.com. The 4500 systems are providing continual vibration data to BlueScopes condition monitoring and operational personnel on these critical items via wireless communication. Datastream’s newest GIS module is able to gather real-time information via a wireless device. “We strongly recommend an EAM system which addresses and anticipates the many problems faced in business expansion and modernization for the New Oriental Port. hence effectively decrease the breakdown rate of equipment. MSc’s ongoing support and training was also an important factor in the final decision to proceed with the 4500 systems. Shanghai Port Technology Engineering Service Co. The New Oriental Port is a specialized container port well known for its developed sea and railway transport network. Many port companies chose Datastream EAM for daily equipment management. The purchase of the Transient version of the CSI 4500 provided the solution which gave them days of continuous data and the capture of transient events. BHP Billiton (ex-WMC) Fertilizers Phosphate Hill. More importantly.maintsys. some further additions in recent months to the family of 4500 Online Vibration system users include BlueScope Steel Pt Kembla. “Datastream has a very comprehensive EAM solution especially designed for ports business requirements. and regulate the inspection planning and management of workflow. At present New Oriental Port has more than 10 international containers scheduled ship routes. New Oriental Port has become one of the most important East China container transfer ports in the world. BlueScope also purchased volume CTC accelerometers to aid in monitoring over 300 different points on the cranes. The Shanghai International Container Port. As well as longer term users like Australian Paper Maryvale. Datastream China Country 72 .” says Mr Jerry Tng. thus enabling the administrative personnel to make informed decisions in the shortest time. especially for those big scale key assets in port services.” says Zhu Tongshun.au Datastream Rejuvenates China’s Leading Port Company 13 September 2005 Datastream China announced today that Lianyungang New Oriental Container Port (currently known as New Oriental Port) would utilize Datastream’s asset maintenance software to optimize the IT infrastructure of the company. real time feedback to process control and real time transient analysis for turbines. With the advantage of peripheral developed highway transportation network. Along with increasing expansion of the shipping business.au www. such as the Pudong International Container Port. Continuous monitoring. it has become an important strategy to construct a transfer port with optimized asset management and decrease the cost of operations. the system enables the port to inspect vehicles operation based on fixed time and without ceasing its flows. And Xstrata Oaky Creek Coal had the need to monitor a critical conveyor at their Oaky Creek No 1 underground coal mine. Australia’s largest steel mill purchased twelve CSI 4500 Online Vibration Systems to permanently monitor the variable speed mobile cranes used in their steel making process. Datastream EAM (enterprise asset management) solution will provide the powerful safeguard to New Oriental Port by ensuring effective operations and ultimate performance.com. Manager. "I am confident that Datastream will help New Oriental Port in the harbor property management aspect, making substantial contribution to the construction of a modern transfer port.” www.datastream.net/singapore. Recognition for Excellence in Root Cause Analysis It is easy to recognise the people who help the plant out of a “disaster” but how do we recognise the people who prevent failure in the first place? A part of the answer is the quarterly recognition award for excellence in Root Cause Analysis conducted by RCA Rt. Participation in the awards provides companies with the opportunity to recognise and congratulate personnel who have been engaged in a methodical approach to defect elimination. The last edition of the Maintenance Journal announced that Golden Circle had won the award in the March - May quarter. The RCA team from Golden Circle, Kerry Gilliland, Glen Jacob, and Paul Whiting are shown receiving the recognition certificate and a cheque for $1000 from Bill Sugden of SIRF Roundtables. The “reward” of $1000 is made out to the team members personally. In this case the team elected to donate the money to The Australian Cancer Council. The winning submission in the June - August quarter is from the Mackay Sugar - Transfield Alliance. The RCA team members Terry Doolan, Russell Casanovas, Frank Forzatti, Anthony Toon and Anton Guinea demonstrated a methodical approach to the solution of a costly problem on a conveyor. A thorough understanding of the chronic problem allowed them to introduce procedural changes that have significantly reduced the likelihood of another failure. Individuals and organisations are welcome to learn more about the RCA Rt process for recognition of excellence in Root Cause Analysis at the RCA Rt web site www.rcart.com.au SoftSols Group Provides Agility To Maintenance Contractors SoftSols Group, a leading provider of maintenance management software solutions, has launched Agility, a browserbased maintenance management solution that provides a uniquely priced, completely flexible route for maintenance contractors and Facilities Management specialists to help their customers reap significant operational savings. Traditional maintenance systems are complex, costly to integrate and difficult to use. Agility addresses the core maintenance requirements in a very intuitive format. It is inherently flexible, enabling contractors to tailor the solution to how they want it to work, complete with customisable forms and style sheets to integrate smoothly with existing customer systems. Agility’s built in flexibility makes it much more cost-effective to run, with licensing costs at a price well below traditional systems. Value for money is a key factor in business today. More factories and plants subcontract their maintenance operation in order to reduce costs and improve productivity. Agility helps subcontractors to reap quick returns for their customers, by providing instant remote access so that they can gain a complete overview of enterprise assets. They are then able to streamline operations through more effective management of capital assets, better allocation of human resources and ensuring optimum performance from plant equipment. www.getagility.com The MX Series, Portable Maintenance Instrument, part of the Microlog® family of products Livingston, UK - The MX Series, portable maintenance instrument, part of the Microlog™ family of products, represents a new concept in vibration analysis instrumentation. The MX Series re-defines traditional approaches to vibration analysis and simplifies industrial maintenance, servicing and inspection techniques. It also offers new possibilities for manufacturers of rotating and reciprocating machinery. To achieve this SKF has combined the latest handheld computing technology with a flexible range of analysis modules to create a multi-functional tool for use by anyone, no matter what their level of experience. The MX Series was created to provide a simple, easy to use instrument for a wide range of applications. It is in effect, several instruments combined on a single, rugged hhandheld device. The MX Series gives users the flexibility to choose from a range of different testing and analysis applications. These modular tools include: • A conformance check module, to assess machinery health in accordance with industrial standards (ISO, BS, API etc.) or to allow users to define their own standards. • An easy to use FFT spectrum analyzer with on-screen phase vector readout • A stand alone balancer (static & dynamic couple, single or dual plane) • A bump test for determining resonance • A digital signal recorder 73 According to Product Manager Jim Fowlie “The key to the flexibility of the MX Series lies in its modular approach. By selecting just the applications they need, users can create an instrument tailored to their exact requirements.” He continues “Should their needs change, further modules can be installed at a later date, ensuring a viable upgrade path without the need to invest in new hardware.” The MX also has several unique features to ensure ease of use: • On-screen help & step by step instructions • Display images of actual machinery or transducer locations • Hardcopy printout to a field portable printer • PC based advanced reporting & analysis module At the heart of the MX Series lies an advanced mobile computer with the latest Intel 400 MHz Xscale processor. The result is a powerful instrument capable of taking fast, high-resolution measurements. The MX has a large color display that is readable in most lighting conditions and its use of Microsoft’s Windows CE.net operating system and USB communications provides seamless connectivity into the PC environment. The device has a large 64-megabyte internal memory plus the choice of digital storage options, ensuring access to ample data storage. Fowlie also notes that SKF understands the need for an instrument to be rugged, able withstand the daily knocks and abuse associated with industrial environments. The MX Series embodies this rugged design philosophy with a 6.5ft drop test rating and IP65 sealing to protect against dust and water ingress. The MX Series will be released in September 2005. For more information, visit www.skf.com/reliability ALL-TEST Pro™ Revolutionising Motor Testing apt Risk Management is pleased to announce exclusive distribution rights throughout Australia and New Zealand, for the full range of ALL-TEST Pro™ hand held instruments; covering off-line and on-line testing of motors, generators and transformers. Introducing the range: ALL-TEST PROTM 31 - an excellent pass/fail motor and winding troubleshooting tool. It detects all types of winding faults, incorporates a 500 M? meter and can perform a quick rotor test to detect casting voids and broken rotor bars. It is compatible with optional Condition Calculator 3.0™ and Condition Calculator PPC (palm top) diagnostic software packages. ALL-TEST IV PROTM 2000 - a motor circuit analyser for predictive maintenance and troubleshooting winding and rotor faults in motors and transformers of all sizes and types: Single and 3-phase, AC and DC, even traction motors and machine tool servos. The instrument has on board memory to store data and previous results; it has a PC interface and is delivered with TREND 2005™ software for 3-phase motor analysis and reporting. It is also compatible with EMCAT Pro 2005™ motor management software. ALL-TEST PROTM MD - provides for complete motor circuit diagnostics, both on-line and off-line. The kit combines Motor Circuit Analysis (MCA) and Motor Current Signature Analysis (MCSA), to diagnose and evaluate the health of virtually every component, both electrical and mechanical, in the motor circuit: Incoming power through the motor to the driven load. For existing customers, an exciting line-up of upgrades/enterprise licensing and NEW product is now available. Ask about: TREND 2005™ and EMCAT PRO 2005™ software. From a hardware prospective, the ALL-SAFE PRO test panel is for safe and fast testing of energised motor systems and power quality monitoring - the permanently installed connection box eliminates the need to open electrical panels when testing energised motors, removing the need for the operator to suite up in special clothing. In addition, Dr Howard Penrose’s newest book is now in stock and ready to ship. Motor Circuit Analysis: Electrical Motor Diagnostics is a supplement/companion book to the previous publication. Technical support, training tools and facilities, are readily available. As such, the next “Motor Diagnostic Workshop” has been scheduled 24-26 October 2005 in Sydney, Australia; course materials include a copy of Motor Circuit Analysis: Theory, Applications and Energy Analysis by Dr Howard W. Penrose, Ph.D. For more information (agents welcome) contact our offices: TEL +61 2 9318 0656 EMAIL [email protected] WEB www.aptgroup.com.au 74 Please complete this form or email the required details. This form may be photocopied Subscription Form The Maintenance Journal is a full colour quality journal of min. 76 pages. Published Quarterly. The Maintenance Journal is available in both a PRINT version and ELECTRONIC version (eMJ) Prices are in Australian dollars (approx. Aus$4 = US$3). For Australia prices are inclusive of GST taxes Please Tick Box PRINT Version Print Version subscription including postage is: Aus$150 1 year Aus$260 2 year Special Offer For the cost of a single subscription to the print version of the Maintenance Journal we will provide up to 5 copies of the journal in your name that you can distribute to other staff at your company. Please circle total No. of copies required per issue: 1 2 3 4 5 PRINT Version plus eMJ To add the Electronic Version (eMJ) to your above order for the PRINT Version of the Maintenance Journal: Extra Cost of eMJ Aus$50 Aus$80 ELECTRONIC Version - eMJ Download as a ZIIPPEDpdf file (approx. 6mb) Aus$100 1 year Aus$180 2 year eMJ Annual Subscription for Single Site Usage: May be distributed throughout your site intranet eMJ Annual Subscription for Multiple Sites: May be distributed to any sites within your world wide corporation Aus$300 Aus$580 Start Issue For new subscriptions please indicate when you wish to start your subscription Publishing dates are: Febuary, May, August and October (give month/year) Past Issues Past Issues of the MJ may be ordered from our web site: www.maintenancejournal.com Name Company/ Name Position Phone Email Method of Payment (Please $ preferred box) Fax FEE PAYA B L E AUS$ 1 2 3 Cheque enclosed made payable to Engineering Information Transfer P/L A.C.N 006 752 978 ABN 67 330 738 613 I would prefer you to charge my credit card. Card Number Signature Cardholder’s name American Express Mastercard Visa Card Expiry date: For electronic funds transfer - please email to obtain details from: [email protected] Engineering Information Transfer, PO Box 703, Mornington, Victoria 3931, Australia. P h o n e : (Int) 61 (3) 5975 0083 Fax: (Int) 61 (3) 5975 5735 E-mail: [email protected] Web: w w w. m a i n t e n a n c e j o u rn a l . c o m m. Activity-based costing o Fixed and variable cost elements o Direct labour. Past President.CAPEX o Engineering asset planning overview. condition monitoring o Outsourcing and insourcing o Cost control. Materials and Procedures The workshop format will encourage participant interaction. o Decision making. Nick Hastings. cash flow.OPEX o Budget structure. discounted cash flow. Day 1 Outline . auditing o Contingency allowances Who Should Attend o Maintenance managers and planners o Asset managers and strategists o Accounting and financial officers involved with capital asset and maintenance budgets o Engineering managers o Project managers o Facility managers Day 2 Outline . accounts. It will make use of numerical and descriptive examples. Adrian Stephan. mining. cost centers o Maintenance cost drivers o Traditional costing. Brisbane. feedback. net present value. Participants will receive a CD containing copies of related PowerPoint presentations and spreadsheets. supervisory & overhead costs o Consumables. Formerly Professor of Maintenance Engineering and Director. Queensland University of Technology. Organized by Albany Interactive Pty Ltd ACN 33006043965 . each day.albanyint. rotables. o Capital projects financial analysis. Capital rationing. Participants are requested to bring a calculator and/or battery powered computer and may bring their own data. refining the budget.com. Workshop Timings. spares. or visit www. return on investment. Dr. o Financial methods in engineering asset context. payback period. progress and performance. The workshop will run from 9 a. M. FIEAust.m. External lecturer. International Society for Logistics. o Lifecycle cost and economic life. tax. training. government and manufacturing industries. to 5 p. obsolescence o Budgeting for improvement.Mgmt. Sounds like you? Call (03) 9876 7188 to book your place. corrective action. or use the registration form overleaf. maintainability. inflation o Current equipment appraisal. Centre for Asset Management. depreciation. Your workshop leaders are experienced consultants to utilities. Monash University graduate program in maintenance management.au to register on-line. risk. reliability. for which solutions will be provided in printed form and as Excel spreadsheets. planning and budgeting for future acquisitions o Aggregate capital budget.OPEX and CAPEX A Two-Day Workshop Melbourne 24th-25th November 2005 Strategic Aim Create and justify financially and technically sound budgets for: o Maintenance expenditure o Capital expenditure To enhance: o Achievement of overall business objectives o Plant or service reliability and availability o Meeting regulatory requirements. o Replacement decision analysis. 4520 Credit Card: VISA MASTERCARD BANKCARD Card No:………………………………………………………. refreshments and full workshop documentation. Group Discount Send three or more delegates from the same organization and receive 10% off the registration fee for each delegate..au Registration Form Maintenance & Asset Budgeting Two-Day Workshop... Name of Contact Officer……………………………………. North Ringwood.. 24-25 November 2005 Please copy form if more than one delegate..... Name of Delegate……………………………………...interactive@bigpond. No cancellations will be accepted within 7 days of the event start date. METHOD OF PAYMENT Fee payable: $...com... Bank Transfer: Account name: Albany Interactive Pty Ltd BSB: 014-307 Account No: 253 251 158 Bank: ANZ Main Street.. Payment Terms Payment.…………..…………… Name on credit card………………………………………Signature…………..…………………….. Invoice Company on Purchase Order No:………………………………………………………….. Address…………………………………………………………. Purchase orders will be invoiced net 30 days..com How Do I Register? – Use one of the following options: FAX the completed registration form with payment details to Fax: (03) 9876 6138 MAIL the completed registration form with cheque or other payment details to: Albany Interactive Pty Ltd 16 Wellesley Road..………….Job Title…….. VIC 3134 EMAIL the details as per the registration form to Albany.Maintenance and Asset Budgeting Two-day Workshop REGISTRATION FEES Individual Fee GST TOTAL $1400 $ 140 $1540 MELBOURNE 24th-25th November 2005 Eden-on-the-Park Hotel 6 Queens Road..……………………………………………… Telephone………………………Fax…………………………Email………………….………………Job Title…... Cheque: Enclosed is our cheque for $... is required before the event..interactive@bigpond. Cancellation Policy All cancellations must be made in writing if you are unable to attend.…….made payable to Albany Interactive Pty Ltd. Once the registration is established your place is automatically reserved and a confirmation letter will be sent to you... but full seminar documentation will be sent to the delegate.Expiry Date: mm/yy…... . A substitute delegate is welcome at no extra charge.……………………………………….. Qld..……. Melbourne Registration fee includes lunches....………...……………………... You will receive a full refund less 15% administrative charge if cancellation is made in writing at least 7 days before the event..albanyint..com WEBSITE register via our website www.....…….. For Further Information Phone Albany Interactive Pty Ltd (03) 9876 7188 or fax (03)9876 6138 or email: albany.………. or an acceptable company purchase order...….. Company………………………………………………………………. Samford. Computerized Asset Management for Public Works Departments. Selecting the Right Maintenance Information System.37 slides.PPT SLIDES For the first time anywhere in the world we are able to offer for sale CD’s of hundreds of Power Point Slides from Terry Wireman’s series of Maintenance Seminars.00 This classic text has saved process plants millions of dolllars and is now in its 3rd edition with much new material.00 The detection.70 slides.Maintenance Publications The following Maintenance Publications. 2004.00 Achieving Zero Breakdown A Reality . Getting the most from SAP-Enterprise Asset Management. CMMS Implementation. Improv.00 Introduction to TPM . Practical Machinery Vibration Analysis & Pred.00 Successfull CMMS .256 slides. EAM Versus Best of Breed CMMS. CMMS Issues . available from EIT Pty Ltd. diagnosis and rectification of faults in reciprocating and rotating machinery when using vibration analysis. TOTAL PRODUCTIVE MAINTENANCE CD Version Aus $295. Industrial Lubrication and CMMS. Managing Maintenance Training with the CMMS or EAM. Making Your Existing CMMS Successful. Inventory Management-.Proceedings CD CD Version Aus $220.335 slides Building the Pyramid &The Future . Deterioration Prevention. 272pp $125. ERP and EAM.00 How integrating Lean Thinking and Total Productive Maintenance accelerates benefits delivered from continuous improvement activities. 5. The CD contains 30 papers. BOMs . Maintain Operating Standards. RCM Indicators. Inventory & Purchasing Indicators. MAINTENANCE PERFORMANCE INDICAT0RS CD Version Aus $295.A Maintenance Inventory Savings Model. plus using vibration analysis.125 slides Preventive Maintenance Indicators. 6 steps to selecting a CMMS. Internet delivered CMMS to build improved equipment reliability. Includes a route map for Lean TPM. Maintenance Inventory and Purchasing. Maintenance Planning.A blueprint For Change By SMcCarthy & Rich. 8. Zero Breakdown Strategies & TPM . Work Order Systems. 224pp $160. Preventive Maintenance.151 slides Organizational Considerations. Value Driven Maintenance® . Beyond the Basics. 10. Mastering Computerized Maintenance Excellence. Operations/Facility Involvement PI’s.33 slides.36 slides Improved Equipment Effectiveness . TOTAL: 468 slides 3. / PRICES for AUSTRALIA INCLUDE POSTAGE COSTS AND GST ADD Aus$40 PER TOTAL ORDER FOR ALL DELIVERIES OUTSIDE OF AUSTRALIA. 650pp $240. Improving Design Weaknesses Preventing Human Error. By Scheffer & Girdhar. location. Maintenance Scheduling. Improved CMMS and Asset Management Systems.18 slides CMMS Selection. Bonus article: CMMS Best Practice 1. Predictive Maintenance Indicators. TOTAL: 493 Slides 4. TOTAL: 350 Slides 9. 2004. CMMS 2005 CONFERENCE . TPM & CMMS.328 slides Financial Benefits of TPM .66 slides TPM Conclusions .100 slides Best Practices and TPM. 2004.00 Indicators for managing maintenance. Leveraging Enterprise Information to Enhance Asset Management.00 Introduction . TPM & Work Orders. ZERO BREAKDOWN STRATEGIES CD Version Aus $295. some in PPT slide format and some in text format: Unlocking The Secrets of CMMS Data. Reducing the Cost of Parts and Inventory Stores Using EAMs.60 slides TPM Organizational Considerations . Benchmarking Best Practices Maintenance. TOTAL: 863 SLIDES 2.MaintenanceJournal.53 slides Organizational Assessment . TOTAL: 591 Slides TEXTS: 7.Creating shareholder value . These CD’s are an invaluable training and learning tool for your maintenance personnel.455 slides Benchmarking Best Practices and Benchmarking Survey . The Role Of CMMS In Support Of An Improvement Initiative. BENCHMARKING MAINTENANCE MANAGEMENT CD Version Aus $295.com Web: www.A Critical Component to Your EAM Strategy. CD’S: WIREMAN SEMINARS . Structured Problem Solving for IP Business Systems. Performance Indicators for Maintenance 2nd Ed By Terry Wireman. PI’s . Training Indicators.Performance Indicators . TPM Indicators.00 Benchmarking Introduction and Generic Benchmarks .com ALL PRICES ARE IN AUSTRALIAN DOLLARS. TPM & Stores & Purchasing. Smart training: Implementation Leading to CMMS training. Maint.314 slides Introduction. Generating Failure Codes for CMMS Implementation.264 slides Cost Justification and ROI .00 The major Conference in 2005 on Computerized Maintenance Management Systems. Machinery Component Maintenance & Repair 3rd Edition By Bloch & Geitner. CMMS/EAM Systems Indicators. Education Problems. Application Service Provider (ASP) model for CMMS/EAM. This new edition also addresses further advancements in the managing of maintenance. may be ordered on: Fax: 03 5975 5735 Email: mail@maintenancejournal. . Work Flow Systems Indicators.32 slides CMMS. Understanding Plant Maintenance Effectiveness. The best book on this topic. Maintenance Materials . maintenance and asset management. Strategies and Tactics for Achieving Results. CMMS 2005 CONFERENCE Indianapolis USA 6.31 slides Maintenance Practice Assessment . Using CMMS to Optimize its Inventory Management Practices. Cont. Learn TPM . Preventive Maintenance & TPM. Take control of work. CMMS Usage . 2004. What Causes Failures? Understanding Basic Component Design Five Steps: Maintain Basic Conditions. 288pp $92. Statistical/Financial Optimization PI’s. COMPUTERISED MAINTENANCE MANAGEMENT SYSTEMS CD Version Aus $295. Key Elements To Successful CMMS Implementations. Develop. 320 pp. Optimising Maintenance and Replacement Decisions Optimising Condition Based Maintenance. providing proven strategies for regularly monitoring critical process equipment and systems. It provides valuable insights into current preventive maintenance practices and issues. Valve. $120. Coupling Torus. Fan Axial. 2003.00 Moving the maintenance operation well into its own lean transformation is a must-do-prerequisite for successful manufacturing plant .Quincy. It is required reading. Backstop. Presents seven real-world successful case studies from different industries that have profited from RCM. maintenance supervisors.Air. and implementation of an effective CMMS in any facility. Accessible pocketbook format facilitates on-the-job use. Piping and Pipe Hangers. Cylinder . Steam Trap Mechanical. Clutch Centrifugal. In this new edition. $330. while explaining how a transition from the current ‘preserve equipment’ to ‘preserve function’ mindset is the key ingredient in a maintenance optimization strategy. this unique guide is written in a language and style that practicing engineers and managers can understand and apply easily. Pump Vacuum Nash. Valve solenoid. Pump Gear. 115 pp [Colour].Lean Transformations. CONDITION MONITORING STANDARDS VOLUME II Torbjorn Idhammar. Bearing . COMPUTER-MANAGED MAINTENANCE SYSTEMS 2nd Ed. Heat Exchanger. Coupling . and Increase Market Share R Smith. $330. Coupling Thomas. Cylinder Hydraulic. This book defines the four principal features of RCM and describes the nine essential steps to achieving a successful RCM program. Bridge the gap between designers/maintainers and reliability engineers. Pillow Block. 130 pp [Colour]. LEAN MAINTENANCE Reduce Costs. INDUSTRIAL MACHINERY REPAIR Best Maintenance Practices Pocket Guide R Smith. Reliability by Operator: Total Productive Maintenance.Condition Monitoring Standards Motion Detector. Coupling Grid. 21. Feeder.00 Condition Monitoring Standards Universal Joint. 304 pp $120. predicting machine failures. Benchmarking Best Practices in Maintenance Management will provide users with all the necessary tools to be successful in benchmarking maintenance management. Bolts and Nuts.00 Section 1 . a practitioner-turned-consultant presents his field proven. Coupling Jar. adverse publicity. 12. Conveyor Belt. Maintenance Optimisation Models. Measurement in Maintenance Management. the authors have added a chapter specifically on the latest technology.Centrifugal. B Hawkins 2004.Fluid. Each CMS contains brief inspection points. Air Breather . MAINTENANCE EXCELLENCE OPTIMIZING EQUIPMENT LIFE CYCLE DECISION J Campbell & A Jardine 2001. but most of the currently available texts are written by theorists and involve complex approaches. Expansion Joint. With this.Diaphragm. Coupling Tire. Screen . and profitably. It presents an overview of the benchmarking process.Progressive Cavity. 16. 537 pp $90. Assessing and Managing Risk. Pneumatic Filter and Oil Most.00 Now you can have the ability of saving money immediately just from reading and using this unique guide! Managing Maintenance Shutdowns and Outages will provide a deeper understanding of how to effectively manage large maintenance jobs such as power plant outages.Vertical . Steam Trap Thermostatic. Reliability By Design: Reliability Centred Maintenance. 13.00 Providing readers with a clear rationale for implementing maintenance programs. this guide is sure to help businesses utilize their assets effectively. Improve Quality. Valve with Actuator [S=Shutdown].00 This second edition of An Introduction to Predictive Maintenance helps plant.Condition Monitoring Standards Motor AC.Preventive Maintenance Task List Section 2 . Mechanical Seal. 11. Steam Joint . 124pp [Colour]. 2003. Doctor Blade. EFFECTIVE MAINTENANCE MANAGEMENT Risk and Reliability Strategies for Optimizing Performance V Narayan 2004. Optimising Maintenance Decisions. Pump . MANAGING MAINTENANCE SHUTDOWNS AND OUTAGES Joel Levitt 2004. Application . Bearing. RCM . MANAGEMENT Terry Wireman 2003. CONDITION MONITORING STANDARDS VOLUME 1 Torbjorn Idhammar. Chain Drive. for every plant and facility that is planning. 17. Coupling Wrap flex/Atra flex.Air. Maintenance Management Methodologies.00 A comprehensive. 2001.Rotary Lobe. In CMMS: A Time Saving Implementation Process. Pump. 536pp $190. safely. II & III Condition Monitoring Standards [CMS] are the building blocks for setting up and running a preventive maintenance. 19. Screen Reciprocating. 23. a self analysis. and scheduling maintenance accordingly. Conveyor Screw. $180. Lubrication Reservoir. Check Valves. Motor DC. Effective Maintenance Management examines the role of maintenance in minimizing the risks relating to safety or environmental incidents. Pump Piston. users will have the increased ability to plan for and manage such projects. CONDITION MONITORING STANDARDS VOLUME III Torbjorn Idhammar. Packing. Screen . and condition monitoring [PM/ECCM] system. 288 pp $95. 15.00 Computerised Maintenance Management System [CMMS] is now penetrating moderate to small corporations on an international level. Hydraulic Motors. Centrifugal. Coupling Magnetic. Conveyor Drag. Reliability Management and Maintenance Optimisation: Basic Statistics and Economics. install and maintain electro-mechanical equipment in a typical industrial plant or facility which will keep equipment operating at peak reliability and companies functioning more profitably through reduced maintenance costs and increased productivity and capacity. 337 pp.00 As the only reference that provides vital information in a concise and easy-touse format. fully explained processes for each phase of Lean Maintenance implementation providing examples. $330. 208 pp $95. or even thinking of adopting ‘Lean’ as their mode of operation.00 The new standard reference book for industrial and mechanical trades. Pump . refinery refits and many more. Coupling Sure flex. Rope Sheaves. By Mobley/Cato 2001. 337 pp. Agitator/Mixer. Blower .Preventive Maintenance Task List Section 2 . Brake Disc. Pump . process. BENCHMARK BEST PRACTICES IN MAINT. practical guide that covers selection.Multistage. Screen . $225. These corporations need an efficient method to implement this effective but complicated system.Disc. Industrial Machinery Repair provides a practical reference for practicing plant engineers.Vibrating. 228 pp $105. 20.Oil Cooled. 200pp $140. Governor. 14. detail and practicality that no previous publication has even approached. 2001.00 Section 1 . V Belt Drive.Valmet 18. checklists and methodologies of a quantity.Condition Monitoring Standards Volume I. R K Mobley 2003. Steam Trap Thermodynamic. and loss of profitability.Air desiccant. and a database of the results of more than 100 companies that have used the analysis. Flinger. Dryer System . practical approach that can dramatically reduce the amount of time and cost needed to implement and maintain CMMS in any corporation.Des Case. Coupling Gear. Conclusion: Achieving Maintenance Excellence. Belt . Gear Reducer. Provides essential information on how RCM focuses your maintenance organization to become a recognized ‘center for profit’.00 Includes detailed instructions for implementing and sustaining an effective RCM program. AN INTRODUCTION TO PREDICTIVE MAINTENANCE 2ND Ed Keith Mobley 2002. Hydraulic Unit. and a required reference. Managing Equipment Reliability. condition monitoring as well as why and how each of these tasks should be executed. Fan Radial. Compressor Rotary Screw .or any process plant . Materials Management Optimisation. Tank. CMMS A TIME SAVING IMPLEMENTATION PROCESS Daryl Mather. It presents a logical step-by-step methodology that will enable a company to conduct a cost-effective benchmarking effort. Steam Turbine [Small]. Data Acquisition. justification. physical plant supervisors and mechanical maintenance technicians. 22. detailed instructions and suggested intervals for each on-the-run and shutdown inspection.Cog. step-by-step. Pump Vane. This Handbook provides detailed.GATEWAY TO WORLD CLASS MAINTENANCE A Smith & G Hinchcliffe 2003.00 Maintenance Management Fundamentals. Regulator .Multistage. Pump . The CMS documents have full color pictures to explain the function. maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program. It focuses on the skills needed to select. Safety Considerations. Human Factors Considerations. The inspection techniques are presented in the book together with inspection tools and examples of how to inspect a number of standard components. Maintenance Models. fans. R Haas & W Uddin. Numerous examples of the technologies available for various uses are included. as a manual for cost reduction. 25. ROOT CAUSE FAILURE ANALYSIS By R Keith Mobley 1999. Continuous Improvement. bearing. Maintainability Testing. Maintainability Management. validating the work scope. 333pp $186. explaining technical terms and jargon and handling the limitations of reliability parameters 30. David Smith 2001. chain.00 Must rate as one of the best texts ever published on Maintenance Planning. Maintainability Tools. Age Based Replacement Policy Analysis. Et Al. . A new appendix on Key Performance Indicators has also been added. MAINTAINABILITY AND RISK 6th Ed. planning the turnaround. 28. This text for the first time looks at those unique aspects of turnaround management. maintaining. electrical systems. ASSET MANAGEMENT AND MAINTENANCE . Case Study . Maintainability and Risk has been updated to ensure that it remains the leading reliability textbook . the turnaround organization. Cost Considerations. Clearly identifies the six basic principles of planning and the six associated principles of scheduling. 264pp $190. terminating the turnaround. updating the scope of applications and tools. parks. 33. 820 slides $180. It describes the methodology to perform Root Cause Failure Analysis [RCFA]. 1999. 476pp $172. 29. It deals with all aspects of reliability. Maintainability Measures. Sustaining life after pilot. PhD 1999. TPM in non manufacturing. It also includes detailed equipment design and troubleshooting guidelines. and performing in-house work sampling. TPM analysis. Reliability Centered Maintenance. seals. Maintenance. TPM for design. Asset Management Overview. hardware. the communications package. using work orders. HANDBOOK OF MAINTENANCE MANAGEMENT By Joel Levitt [USA] 1997. couplings. database management. $390. The book carefully explains how to set up and improve a preventive maintenance system or process in any industry. the safety plan. contractor packages. Provides how-to information on implementing a planning function. The book also discusses a host of high interest topics such as life cycle analysis of structures. a primer for the stockroom.00 This compact disk contains 19 PowerPoint presentations containing over 820 slides dealing with Asset Management and Maintenance. water and waste water facilities. PREVENTIVE MAINTENANCE. RELIABILITY. 416pp $150. Risk Analysis and Risk Management. ESSENTIAL CARE AND CONDITION MONITORING Idhammar. motors. Availability and Maintainability. Functions. Spares & Consumables Management. cleaning. Case Studies. building. maintainability and safety-related failures in a simple and straightforward style. Reliability-Centred Maintenance.THE CD By Nicholas A Hastings 2000. including issues of organizational structure. Contents include : Initiating the turnaround. alignment.MAINTENANCE PUBLICATIONS Service Providers [ASPs]. and networking technology along with Information Technology [IT] consulting services into an outsourced package. The TPM route map is updated to include the journey to zero breakdowns & beyond. 32. utilities. that has revolutionized the way computer-managed maintenance systems are used and the benefits they can offer to a business. and Models. buildings. as an introduction to maintenance for non maintenance people. conveyors. airports. 24.00 The principles and the overall concept of effective infrastructure management discussed in this book have never before been treated in such detail. Planning and launching TPM. Condition Monitoring. Demonstration. 31.00 This title builds on Peter Willmott’s earlier book. An excellent hands-on text and one of the few published on maintenance planning.00 This unusually comprehensive book is designed as a complete survey of the field for students or maintenance professionals. cost. ‘TPM the Western Way’. Total Productive Maintenance. managers and planners. Failure Mode and Effects Analysis. pneumatics. and as an element of a training regime for new supervisors. This information will therefore be invaluable to maintenance and plant managers wanting to increase their own knowledge. Reliability Data Analysis. 26. pumps. Specific Maintainability Design Considerations. which are needed to perform RCFA analysis on machinery found in most production facilities. compressors. lifting equipment. Reliability Statistics & Life Distributions. It also covers the management of maintainability efforts. Organisation & Control. 254pp $205.00 Reliability. the quality plan. Questions and problems conclude each chapter. Measuring and Improving Maintenance Effectiveness. ENGINEERING MAINTAINABILITY: HOW TO DESIGN FOR REALIBILIITY AND EASY MAINTENANCE By B S Dhillon.it has all its main elements. and Data. fasteners. 27. CONTENTS: From total productive maintenance to Total Productive Manufacturing. 1997. the cost profile. pre-shutdown work. It also has a number of features which make it unique. executing the turnaround. Preventive Maintenance/Essential Care and Condition Monitoring teaches the reader how to organize condition monitoring. and analysis and modeling methods. Life Cycle Costing. This sixth edition incorporates brand new material on the accuracy of reliability prediction and common cause failure. steam.00 Root Cause Failure Analysis provides the concepts needed to effectively perform industrial troubleshooting investigations.00 There are thousands of plants around the world that each require regular shutdown or turnaround maintenance but until now there has been almost nothing published in this specialized area. hydraulics. This book has now been established for over 20 years. pipes and valves. Turnaround management is project management . and planning processes. and fixing our nation’s roads. 183pp $170. 337 pp. and sports complexes are thoroughly examined. as a review of the most advanced thinking in maintenance management. This solution provides integrated software. TPM A ROUTE TO WORLD CLASS PERFORMANCE Peter Willmott & Dennis McCarthy 2000. one of the hottest topics currently in maintenance engineering. MAINTENANCE PLANNING & SCHEDULING MANUAL Richard D Palmer 1999. Designing the TPM umbrella. decision support systems. etc. 400pp $195. The TPM improvement PLAN TOOLBOX. This text enables maintenance managers and maintenance planners to dramatically improve the productivity of their maintenance plan. 336pp $135.00 It is a unique resource for improving maintenance processes and learning smart inspection and trouble shooting techniques on a wide variety of components including. plan or provide training [and use this book in doing so]. Contents: Introduction. lubrications. and other preventive maintenance systems into one orchestrated process. TURNAROUND MANAGEMENT By Tom Lenahan 1999. bridges. gears.Axle Bushes. lubrication. All the varied tools and techniques that are used in planning. standardizing best practice. and to operators needing to improve their skills.00 This book provides the guidelines and fundamental methods of estimation and calculation needed by maintainability engineers. TPM top down & bottom up roles. Job and Shutdown Planning. site logistics. Reliability of Systems. INFRASTRUCTURE MANAGEMENT By W R Hudson.cementing the book’s reputation for staying one step ahead of the competition. 26. 20. Maint. 4. PH: 61(3) 5975 0083 FAX: 61(3) 5975 5735 Email: mail@maintenancejournal. 12.00 $295.A Route to World Class Performance Asset Management and Maintenance .00 $172.the CD Preventive Maintenance.00 $295. 29. 2.00 $95.00 $120.00 $205.00 $190. 24.00 $240. 2.00 $190. MORNINGTON.00 $180.A blueprint For Change Practical Machinery Vibration Analysis & Pred. Life Cycle Decisions Computer-Managed Maintenance Systems 2nd Edition Reliability.00 $160. Title Benchmarking Maintenance Management Course PPTs .00 $225. 16. CARD NO: SIGNATURE: This form may be photocopied CHEQUE ENCLOSED PAYABLE IN AUSTRALIAN DOLLARS TO : ENGINEERING INFORMATION TRANSFER P/L CHARGE MY CREDIT CARD:: EXPIRY DATE: NAME ON CARD: . 32.00 $120. 8. 18. 11. 27. 5.00 $295. VIC 3931 AUSTRALIA Item 1. Performance Indicators for Maintenance 2nd Ed Condition Monitoring Standards Volume I Condition Monitoring Standards Volume II Condition Monitoring Standards Volume III Lean Maintenance Managing Maintenance Shutdowns and Outages Effective Maintenance Management Benchmarking Best Practices in Maintenance Management RCM Gateway To World Class Maintenance CMMS A Timesaving Implementation Process Industrial Machinery repair Introduction To Predictive Maintenance 2nd Edition Maintenance Excellence Optimising Equip. 9. 14. P O BOX 703. 21. 3. 30. 17.ORDER FORM All prices are AUSTRALIAN DOLLARS.CD Maintenance Performance Indicators Course PPTs .00 $125.00 $92.Proceedings CD Machinery Component Maintenance & Repair 3rd Edition Learn TPM .00 $150.CD Total productive Maintenance Course PPTs . Maintainability & Risk TPM . 28. ADD Aus$40 PER TOTAL ORDER FOR ALL DELIVERIES OUTSIDE OF AUSTRALIA. 33. 22.00 $180.00 $170.CD CMMS 2005 CONFERENFE . 23.00 $390.00 QTY NAME: ADDRESS: PHONE: FAX: COMPANY: Email: TOTAL FEE PAYABLE: AUS$ METHOD OF PAYMENT 1.00 $186. 25. 10.com ENGINEERING INFORMATION TRANSFER P/L.00 $295.00 $330. 7.00 $95.00 $330. 15.00 $330.00 $195. Develop. PRICES for AUSTRALIA INCLUDES POSTAGE & GST. 6.MAINTENANCE PUBLICATIONS .CD Computerised Maintenance Management Systems Course PPTs .CD Zero Breakdown Strategies Course PPTs . 19.00 $90.00 $140. 31. 13.00 $220. Essential Care and Condition Monitoring Engineering Maintainability: Design for Reliability &† Easy Maintenance Root Cause Failure Analysis Turnaround Management Maintenance Planning & Scheduling Manual Handbook of Maintenance Management Infrastructure Management Aus $ $295.00 $135.00 $105.