Professional Documents
Culture Documents
¾ Introduction
¾ Pitfalls of Traditional Maintenance Programs
¾ Aspects of World Class Maintenance Programs
¾ Risk-based Maintenance (RBM)
¾ Understanding and Utilizing RBM Methodology as a Key
Element in:
¾ Routine Maintenance Programs
¾ Reliability Maintenance Programs
¾ Utilizing RBM in the Continuous Improvement Process
CONFIDENTIAL 1
Introduction
CONFIDENTIAL 2
Fundamentals to Success
CONFIDENTIAL 3
Typical Pitfalls to Successful
Maintenance Programs
¾ View maintenance as a cost center versus a technical resource for
improvement.
Improving maintenance costs is important.
Improvement in operations can often bring higher returns.
CONFIDENTIAL 4
Characteristics of
World Class Programs
CONFIDENTIAL 5
Risk Based Maintenance
CONFIDENTIAL 6
Risk = Consequence x Probability
¾ RBDM is not about taking risk, but how to recognize, understand, and
manage risk.
¾ Risk Management consists of:
Developing a process to consistently determine what we should do and when we
should do it
Understanding that we cannot afford, or have the resources, to do everything
Managing risk associated with work we are not doing at this time or at all
High A
Consequence
consequence and probability, Medium B
Illustrative
Risk Matrix
which must be considered
separately Low C
4 3 2
Low Medium High
Probability
CONFIDENTIAL 7
Applying Risk Based Decision Making
CONFIDENTIAL 8
Risk Matrices in Practice
High A
Miderate- A
HIGH RISK
Consequence
High B
Potential Consequence
B
Low- MEDIUM-HIGH RISK
Moderate C
C
MEDIUM RISK
Low D
D
4 3 2 1 LOW RISK
Low- Moderate-
Low Moderate High High
E
Probability
5 4 3 2 1
Extremely Unlikely Possible Somewhat Very Likely
Unlikely Likely
Likelihood (Probability)
CONFIDENTIAL 9
RBM Requires Broad Input and Participation
CONFIDENTIAL 10
RBDM Process
CONFIDENTIAL 11
Example Risk Matrix
Potential Consequence
Health/ Safety/ Environment, Business Impact
Fatality, serious impact to public
Major uncontained environmental incident, with offsite impact
Explosion or major fire with impact on neighboring community A
Total plant shutdown >10 days ($30)
5 4 3 2 1
Likelihood (Probability): Extremely Unlikely Possible Somewhat Very Likely
(Assessment time frame ) Unlikely Likely
< 0.1% 0.1% - 1% 1% - 10% 10% - 80% 80% - 100%
HIGH RISK -- Work always justified
MEDIUM RISK -- Work usually justified
LOW RISK -- Work normally not justified. Is mitigation possible?
LOWEST RISK -- Work not justified
CONFIDENTIAL 12
Routine Maintenance Programs
CONFIDENTIAL 13
Improved Work Selection
CONFIDENTIAL 14
Reliability Maintenance Programs
¾ Reliability improvement programs can be categorized into two areas:
Proactive - Equipment care programs
Reactive - Defect elimination programs
¾ Techniques such as TPM®, TQM®, were developed to:
Perform detailed analysis of equipment and systems
Develop routine maintenance tasks that would improve equipment performance
¾ These are excellent practices and principles, but can be time
consuming and provide minimal return in some areas,
¾ Companies can spend countless hours conducting analysis of
systems that have:
Little opportunity for improvement.
Failures, whose consequences have little impact to plant operations or safety.
Existing practical equipment care programs that can easily be utilized.
¾ Reliability practices have shifted to risk-based approach to:
Identify critical machinery based on consequence of failure to the system.
Optimize asset care programs based on equipment criticality analysis.
Prioritize equipment failures based on risk, focusing efforts in areas with the
highest impact and return.
CONFIDENTIAL 15
Proactive Reliability Maintenance
CONFIDENTIAL 16
Optimized Asset Care Programs
CONFIDENTIAL 17
Reactive Reliability Maintenance
CONFIDENTIAL 18
Foundation for Continuous Improvement
CONFIDENTIAL 19
Continuous Improvement Process
CONFIDENTIAL 20
Key Element to World Class Maintenance
CONFIDENTIAL 21
Getting Started
PRODUCTION MAINTENANCE
CONFIDENTIAL 22
QUESTIONS
CONFIDENTIAL 25
Baker & O’Brien, Inc.
CONFIDENTIAL 26
Contact Information
Dallas Houston
Headquarters Office
12221 Merit Drive 1333 West Loop South
Suite 1150 Suite 1350
Dallas, TX 75251 Houston, TX 77027
Phone: 1-214-368-7626 Phone: 1-832-358-1453
Fax: 1-214-368-0190 Fax: 1-832-358-1498
London
41 Queens Gate Terrace
Suite 4
London, SW7 5PN
Phone: 44-207-823-8967
Fax: 44-207-823-7223
www.bakerobrien.com
CONFIDENTIAL 27