Reliability and Maintenance Management as a Part of Asset Management

EQUIPMENT TROUBLE SHOTING ILLUSTRATION Technician arrive Trouble identification Spare part arrive Repair Main Pump Ready Main Pump Breakdown Half-day Half-day Few days A day A good technician can perform spare part replacement and quickly repair the equipment. But this only a small part of the whole troubleshooting effort. The big picture is on the failure overcome management. MTTR

Reliability vs Time Mileage Reliability prob. of Failure 1,000 0.99999900 0.00000100 1,500 0.99998860 0.00001140 2,000 0.99993600 0.00006400 2,500 0.99975600 0.00024400

Reliability Engineering Illustration PM : Assume 20 USD CM : Assume 3.000 USD Assume : 1000.000 cars By 1000 miles, expecting 1 engine to fail If I were to perform a PM at 1.000 miles, my total cost : PM = $20 x 999.999 = $ 19.999,980 CM = $3000 x 1 = $ 3000 Total = 20,002,980 If no PM, cost would just of the CM, $3000 By 2000 miles, expecting 64 engine to fail Thus, if I were to perform a PM at 2.000 miles, my total cost : PM = $20 x 999.936 = $ 19.998,720 CM = $3000 x 64 = $192.000 Total = $20,190,720 CM cost only = $3000 x 64 = $ 192,000

MAINTENANCE OPTIMIZATION BUSSINESS RISK MANAGEMENT Asset Management Asset Management is a systematic process which allows for the maintenance, upgrading and operation of our physical assets in a cost effective manner. OPERATION EXCELLENCE MAINTENANCE OPTIMIZATION ASSET MANAGEMENT BUSSINESS RISK MANAGEMENT ETC..

Adikari Wisesa Indonesia Operation and Maintenance Strategic Maintenance Strategy Predictive Maintenance

Reliabilty Centered Maintenance A method for defining the maintenance strategy in a coherent, systematic and logical manner. It is a structured methodology for “determining the maintenance requirements of any physical asset in its operation context” Primary objective of RCM is to preserve system function The RCM process consists of looking at the way equipment fails, assessing the consequences of each failure (for production, safety, etc), and choosing the correct maintenance action to ensure that the desired overall level of plant performance (i.e. availability, reliability) is met

RCM Development Steps Asset registering and validation Criticallity ranking FMEA dan Task Development Job Bundling and Levelling Check list development CMMS template development CMMS data upload

FMEA – Maintenance Task Check List Plant Register Criticallity Ranking FMEA – Maintenance Task Continuous Improvement Schedulling and Levelling Feedback and Measurement Execution Entry to CMMS (SAP Data)

Asset Registering and Validation Registering asset based on company and regulation standard Would be the backbone for strategic maintenance development Validation would be needed for ensuring that equipment is in place and on operation

Asset Register LTRO - RCM.xls

Criticallity Ranking

FMEA and Task Development We define possible failure mode based on the equipment. Every failure mode has failure defend task or maintenance task. Every maintenance task has detail information, such as : person in charge, interval time and work man hours.

Task Workshop All (1).xlsx

Job Bundling and Levelling Job bundling will unify the same tasks, tasks in same location or tasks for equipments that are attached to main equipment. Examples of job bundling : All vibration analysis will be done together in one campaign All valves and wellheads in one area Instruments that are attached on the main equipment

Levelling Levelling will distribute maintenance workload. Maintenance workload will be mathced with available resources. We will know whether maintenance resources is sufficient or not. Schedulling will benefit the most from levelling

Manhours per Month

Requirement and Capacity

Check List development Check list consists of points to be done during maintenance task. Check list development based on manual books, experiences and standards.

3 MONTHLY – ENGINE GENERAL INSPECTION

CMMS Data Upload Based on CMMS data template Asset register Task based asset Will be executed based on company need Review periodically

Dashboard CMMS

Experiences

Experiences

Experiences

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