PMO2000™ 1 Improved Reliability through PM Optimisation Project Team: Electrician Planner Mechanic Operator Reliability Engineer Facilitator: Steve Turner

PMO2000™ Why investigate the Residue Cell C’s u PM Optimisation will fall in line with the business plan for the Site. u The only cost centre in the plant consistently over budget. u Opportunity to improve reliability as Cell C’s have highest failure rate in the area. u Opportunity for more consistent performance to meet plant expansion plans. u The experience is that there is more work in the area than there are people assigned.

PMO2000™ Objectives u Better focus of PM schedules. u Increase the quality of maintenance. u Understand the rationale behind each PM task. u To better manage the Cell C operation and maintenance. u Exchange information and increase understanding of each role ie mech,elect, process. u Understand equipment failure history. u Improve detection and rectification of failures. u Communicate findings.

PMO2000™ Objectives… cont u All of the previous will result in greater ability for us to meet the business plan.

PMO2000™ How we went about it u Started with the existing PM lists u Applied the process to the all schedules including: u SAP schedules u Maintenance and Process task lists u Check sheets u Created a new daily schedule for both operator and maintenance technicians. u Review failure modes and the PM’s which addressed these.

PMO2000™ How we went about it…. con’t u Review operating logsheets u Determined the most appropriate maintenance strategy. u What task (preventive, predictive or corrective) u Who does it u How often. u Develop implementation list/plan for approval.

PMO2000™ Opportunities identified u Numerous new PM tasks that should be done. u Task frequency could be more effective particularly in the mechanical area. u Some job descriptions were not specific or reflective of actual work. u Identified a opportunities for reliability engineering.

PMO2000™ Opportunities Identified… cont u Better utilisation of maintenance and operations resources by eliminating task duplication. u The maintenance strategy needs to be better documented so that it can more easily be reviewed and communicated. u There is an opportunity to transfer some of the knowledge to other processes and sites.

PMO2000™ Outcome PM Optimisation Analysis

PMO2000™ Outcome PM Optimisation Analysis

PMO2000™ Downtime Analysis-Mechanical

PMO2000™ Downtime Schedule

PMO2000™ Some interesting issues u Some valve failures could possibly be managed by condition monitoring rather than in breakdown. u Breakdown history was recorded incorrectly. This precludes any efficient analysis. u Some task were carried out too often…others not often enough. u The existing mechanical PM were difficult to complete but now broken into three PM’s. u Not all process tech inspections are recorded.

PMO2000™ Some interesting issues…. cont u Greater involvement of process tech’s in fault finding is possible for maintenance and operations problems. u The justification for each maintenance task is now documented. u The existing PMs are not all being completed. u Pizza Hut do not deliver on public holidays.

PMO2000™ Other benefits... Other benefits... u More knowledgeable and empathetic workforce. u More descriptive tasks with acceptable limits. u Improved team work. u Greater sense of ownership in the maintenance and equipment performance. u Better understanding of failure modes and objective of tasks u Planned downtime reduced (1hr per fortnight per unit). u Unplanned downtime will add to this.

PMO2000™ Benefits..con’t u Move to a less reactive environment by adopting more frequent inspections where warranted. u The PM program can now be achieved.

PMO2000™ What needs to happen now u Input changes to SAP (already started). u Implement the Process Tech check procedure. u Modify Elect Maintenance Tech check sheets. u Develop Mech Maintenance Tech check sheet. u Improve failure reporting in SAP. u Carry out some minor plant modifications. u Implement new tasks ie NDT and Structural inspections.

PMO2000™ 18 Improved Reliability through PM Optimisation Project Team: Electrician Planner Mechanic Operator Reliability Engineer Facilitator: Steve Turner