Proactive maintenance has the purpose to detect damage and replace parts before they fail and cause production stop. At the same time this work has to be performed in ways that ensure efficient use of personnel and resources.
An important step towards this goal is to use a work process that focus on adapting preventive maintenance and inspection to the equipment criticality and condition. The preventive efforts need to be in balance with the importance of the equipment for production and safety. This is fundamental in efficient Asset Integrity Management.
Another important task is to identify and evaluate which of different possible preventive approaches that is best suited in different situations, for example condition monitoring, residual life assessment, periodic inspection and tests, periodic replacement, or well prepared corrective repairs. Alternative methods for condition monitoring and prognostics need to be evaluated.
Parts of the work process steams from Reliability Centered Maintenance (RCM), but the process has evolved for higher efficiency. Standards from ASME, NAVAIR, API, EN, IEC are used in the development of the work process and risk and reliability principles are applied for the prioritization.
The fundamental parts of the work process can be used as common process for all maintenance groups at the plant, in their work for planning of proactive maintenance, monitoring, inspections and tests. The work process is adapted to local needs and during the implementation our guiding principle is high involvement of the personnel.
Inspecta’s process and support
- Preparation of information - Item data, operating conditions, overall functionality, history and reporting to the maintenance system
- Criticality Analysis of each equipment - to classify their importance for production and safety
- FMEA based identification – applied to equipment of high criticality
- Identification of damage mechanisms and causes, failure patterns, the weakest links
- Identification of possible mitigation strategies
- Development of templates for different object types - provides large time savings
- Evaluation of preventive approaches
- Condition monitoring and prognosis, Periodic inspection, Periodic tests, Residual life assessment, Periodic replacement
- Cost/benefit assessment to decide use of condition/performance monitoring or run to failure
- Packaging and scheduling - work orders to maintenance system, packaging of tasks, instructions, spare parts
- Training – theory, work process and practical implementation
We can give support during all the different phases and steps in a project for implementation of preventive maintenance optimized to the equipment criticality. During the first implementation period we support to manage peaks in work load and with training.
The implementation of criticality analysis is fundamental and can be made as a separate first step, and it will in itself result several immediate adaptions and gains.
- Reduction of the number of failures and unplanned stops
- Focusing resources for early detection of damage in high impact objects
- Active evaluation for best choice preventive approach or run to failure
- Higher reliability and possibly decrease in maintenance work
- Common work process and concepts used for all maintenance groups