1. Reliability and Maintenance Management as a Part of Asset Management

2. 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

3. Reliability vs Time Mileage Reliability prob. of Failure 1,000
1,500
2,000
2,500

4. Reliability Engineering Illustration
PM : Assume 20 USD
CM : Assume USD
Assume : cars
By 1000 miles, expecting 1 engine to fail
If I were to perform a PM at miles, my total cost :
PM = $20 x = $ ,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 miles, my total cost :
PM = $20 x = $ ,720
CM = $3000 x 64 = $
Total = $20,190,720
CM cost only =
$3000 x 64 = $ 192,000

5. 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..

6. Adikari Wisesa Indonesia
Operation and Maintenance
Strategic Maintenance Strategy
Predictive Maintenance

7. 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

8. 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

9. 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)

10. 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

11. Asset Register LTRO - RCM.xls

12. Criticallity Ranking

13. 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.

15. Task Workshop All (1).xlsx

16. 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

17. 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

18. Manhours per Month

19. Requirement and Capacity

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

21. 3 MONTHLY – ENGINE GENERAL INSPECTION

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

23. Dashboard CMMS

24. Experiences

25. Experiences

26. Experiences

27. Thank You