FORUM: Design for Maintainability CII Construction Project Improvement Conference September 11-13, 2005 Austin, Texas George Conner Richard Danks Robert Post

Presentation Agenda Making the Case & Concept Overview NASA Implementation D for M Implementation Model Chevron Texaco Implementation Benefits of D for M Rohm & Haas Implementation

Design for Maintainability: Making the Case & Concept Overview Richard A. Danks Deputy Chief, Facilities Division NASA Glenn Research Center Cleveland, OH

The Case for Design for Maintainability

Life Cycle Cost — 30 Year Period Land Acquisition, Planning, Renewal, Revitalization, & Disposal 5%-35% Design & Construction 5%-10% Operation & Maintenance 60% - 85% Source: Stewardship of Federal Facilities, 1998 The Case for Design for Maintainability

Productivity Prod Eff / Utilization Production Losses Equipment Criticality Availability Uptime Improvements OPEX & CAPEX $$$$ Asset Economics (Differential NPV) Landscape of Interrelationships Reliability Sys Configuration Equip Performance Maintainability Factors affecting ability to perform Maintenance Total MTTR Operability Operational Flexibility Degraded Performance Chevron Pre-Operations Impact to Asset Performance

CII Research Project D for M research project CII Guidebook CII Education module

Research Results Defined “levels” of implementation Common approaches to implementation Common attributes of success Model implementation process

Maintainability Principles Reduce or eliminate wrench time Optimize Safety, Accessibility, & Ergonomics Reduce Complexity or Task Difficulty Optimize Standardization, Interchangeability, and Modularization

Process Characteristics Integrates downstream knowledge early in design process Model process provides implementation structure Long-term perspective – Reduces life cycle costs Short term perspective – Integration into existing processes Alignment Start up

Early implementation = Greatest impact Suite of tools to expedite implementation Continuous improvement carries over to future projects D for M Process Highlights

NASA Implementation Engineering & Construction Innovation Committee –D for M selected as best practice for implementation Development of week-long course –Presented at Field Centers –D for M material presented in Sustainability course Centers implementing sustainable projects

NASA Implementation Interdependent concepts D for M integrated with –Sustainable (Green) design –Commissioning –Safety & security Supports other NASA programs – Reliability-centered Maintenance – Reliability based equipment acceptance

Implementing Design for Maintainability George Conner Staff Reliability Engineer Chevron Corporation Houston, Texas

Approaches to Implementation Standard design practice Contract specification Cross functional participation Pilot program Integration into existing programs Formal maintainability program Comprehensive tracking

Model Process Source: CII Implementation Resource Page 16

Model Process Elements Milestones Milestones are achieved through maintainability practices Practices Maintainability practices are implemented using tools Tools Tools basically document process steps in a checklist format

Assemble cross-functional proj team Formal maintainability reviews Design to project maint. strategy Consider maintenance staff skills and training requirements Implementing D for M

Implementation Resources Implementation guidebook –22 Maintainability Practices –16 Implementation tools Implementation suggestions – Establish a champion – Pilot program – if a new start

Chevron’s Application Post Startup Performance unacceptable Developed Operations Assurance Process Team approach to selecting, developing, assessing and executing specific pre-operations activities, throughout the course of a project, that impact asset performance. Project development and execution is based on a structured phase gate approach: Identify, Select, Develop, Execute, Operate Maintainability is part of the Operations Assurance (OA) process.

Chevron’s Application OA Foundational Philosophies OA Reliability Maintainability Operability BID Specifications Qualified Vendors Standardization Reliability Modeling RCM Performance Indicators Human Factors Assmt Maintenance Strategy Mobilization Delays Resources & Competency Shift/Spares Constraints Mechanical Handling Plan Production / Utilization Operations Strategy Resources & Competency Operational Flexibility Work Environment

Implementation Summary CII has developed a robust D for M process. Milestones Practices Tools Milestones Practices Tools Early commitment / implementation is critical The implementation can be customized based on current state and ultimate goals. For Chevron, D for M is not a standalone effort Specific D for M applications adapted for the OA process generally reference: Milestone 4: Plan Maintainability Implementation Milestone 5: Implement Maintainability Process

Design for Maintainability Benefits Robert Post Technical Fellow Project Engineer Rohm and Haas Company Bristol, PA

Project Benefits Smoother project startup Less project rework Less costly maintenance Lower life cycle costs Metrics & Continuous Improvement Supports CII Best Practices

Long Term Benefits Eliminate the need for maintenance Increased task efficiency Reduced accidents Decreased downtime Access & ergonomics Standardization/modularization Task simplification

Experience at Rohm & Haas Domestic US Projects: “ Reliability Design” Functional focus Looks at reliability issues first Minimize failures and maintenance Identify/Resolve maintainability issues Mostly done prior to execution

Experience at Rohm & Haas Domestic US Projects: but…. Superior FEL definition yields faster/cheaper execution Everyone knows this, but…… Getting Front End schedule time & resources Actual results vary US work is limited these days anyway…

Experience at Rohm & Haas Overseas Projects: difficulties Engineering Processes Vary Owner processes Contractor processes O&M processes Cultural Viewpoint / Values differences Language Safety Quality What does “Yes” REALLY mean?

Benefits Summary The know-how exists! Domestic: Must get commitment of management and engineers Overseas: Much steeper learning curve

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