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Asset Management Council 1005 Maintenance Execution and Shutdowns Best Practice
Asset Management Council 1005 Maintenance Execution and Shutdowns Best Practice
Asset Management Council 1005 Maintenance Execution and Shutdowns Best Practice
AGENDA
Introduction
The Importance of Maintenance
Execution
Maintenance Execution process steps
Maintenance Workflow
Maintenance Events
Shutdowns Process
Worked Example (Risk Analysis)
Questions
THE IMPORTANCE OF
MAINTENANCE EXECUTION
GOOD MAINTENANCE IS
GOOD SAFETY
New legislative
requirements
Increased stakeholder
scrutiny of safety
performance
Risk Management
strategies
ZERO HARM
Good Safety is Good
Business
MAINTENANCE EXECUTION
JOB SCREENING
SCOPING
Replace
Repair
Patch up
Defer work
Do nothing
PLANNING
People
Materials
Tools
Equipment
Cost Estimate
Risk Assessment (PPA)
Safety Requirements (JSA/JHA)
SCHEDULING
EXECUTION
Do the work
CLOSE-OUT
WORKFLOW
Putting it all together
MAINTENANCE WORKFLOW
Routine Work
Flow
Review and
Approve
Requests
Plan
Jobs
Authorize
Costs
Prioritize
Work
Schedule
Allocate
Jobs
and Do the
for the
Work
Next Period
Unplanned Jobs
Collect
Costs &
=
Job
Feedback
Accommodate
Interrupt
Schedule
Continuous
Improvement
Types of Work
INITIATION
Different Work Types
SAP Notification
PM Schedule
Injected Work (E&SB)
SAP Notification
For a Corrective job
Acceptance required
before work proceeds
Approval by
Maintenance Manager,
etc.
PM Schedule
Automatically
generated
Pre-Approved
Injected Work
Emergency & Schedule
Breakers
For Breakdowns
Immediate approval
PLANNING
Planned Job
Planned Jobs will
require an Estimate
Can then go off to be
Approved
Before detail
planning job, get
approval to proceed
(avoids spending
time on job that may
not go ahead)
PM Schedule
Job already planned
Breakdowns
This process shows
no planning step for
breakdowns
Best practice is to
have some templates
available for
breakdowns
SCHEDULING
WORK LOG
Planned Jobs & PM Schedules
go into common backlog of
work
Jobs that can be deferred are
identified
SCHEDULE
Jobs are scheduled according
to business requirements
Schedule for all available hours
BREAKDOWNS
Breakdowns are not scheduled
They get injected during
Execution phase
EXECUTION
Daily & Weekly Schedule
Jobs are executed according to
priority and business requirements
Deviations from schedule managed
by Operational Personal
Breakdowns
Breakdowns are injected into daily
schedule
Pre-identified backlog jobs are
deferred
Breakdown work orders should
have a sunset clause on them
(suggest 48 hours)
HISTORY
All Jobs
Failure data added to CMMS
Hours recorded
Update library plans (or create new
ones)
Breakdowns
Reliability analysis
Is a library plan required?
Is a PM required?
PMs
PM data updated
Recommend that PMs do not get
rescheduled based on Completion
Date
Increased reliability
Increased planning efficiency
BREAKDOWNS
CORRECTIVE WORK
Project Work
Major Maintenance
Re-Engineering
FOUR PHASES OF
SHUTDOWN MANAGEMENT
Initiation
SHUTDOWN STEERING
GROUP
FOUR PHASES OF
SHUTDOWN MANAGEMENT
Planning & Preparation
SHUTDOWN CRITERIA
Shutdown criteria
DUR
SYN
Duration
Can only be done while equipment is
disassembled for other shutdown work
Synergies with doing work in conjunction
with other shutdown work
UTIL
HAZ
OTH
DIS
Jobs to be
reviewed
for their
operational
impact if
not done
Risk Matrix
Likelihood &
Consequenc
e
Extreme
High
Almost Certain
(Over 30%)
$0
4
Likely
(10% to 30%)
$0
$0
18
27
Moderate
12
$0
$0
$0
$0
36
34
26
$105
$96
13
21
3
Possible
(3% to 10%)
35
79
$0
29
33
30
37
22
39
32
10
$271
23
$512
1
6
14
24
7
31
28
25
20
15
$443
$539
$0
$0
$0
17
38
Unlikely
(1% to 3%)
$0
$28
$97
Moderate
High
Rare
Low
(up to 1%)
$0
$0
$0
$0
Low
Minor
Moderate
Major
Critical
<$25k
$25k - $250k
$250k - $2.5m
$2.5m - $25m
>$25m
Probability of
Event Occuring in
2005/06 Financial
Year
$0
Environmental Impact
Operational Impact
$000's
GANTT CHART
DEVELOPMENT
RISK ANALYSIS
FOUR PHASES OF
SHUTDOWN MANAGEMENT
Execution
MEETING STRUCTURE
Consistent meeting
times
10:00 AM Morning
Area Meeting
3:00 PM Managers
Meeting
Schedule Updates
EARNED VALUE
SHUTDOWN
COMMUNICATIONS
Email is a problem
Reply All
Mass Distribution lists
Not everyone has email access
FOUR PHASES OF
SHUTDOWN MANAGEMENT
Close-out
Consolidate issues
Feed-Back into Management Plan for future shutdowns
PREVIOUSLY WORKED
EXAMPLE
SHUTDOWN PPA
WATER SUPPLY TURNED OFF
DURING SHUTDOWN
PPA PROFORMA
Potential Problems
Likely Causes
Preventive Actions
Contingent Actions
Triggers
QUESTIONS