Carlo Scodanibbio presents:

Lean Maintenance
Lean Plant Management
We are what we repeatedly do.
Excellence, therefore, is not an act, but a habit

a training event organised by

What is Maintenance?
the work of keeping something in proper condition; upkeep
upkeep
Maintenance is the management, control, execution and
quality of those activities which ensure optimum levels of
availability and overall performance of plant are achieved to
meet business objectives.

Nothing lasts forever

approaches to maintenance
main types of maintenance operations

reactive maintenance

preventive maintenance

STUDY 2000
>55% Reactive

predictive maintenance

reliability centred maintenance

31% Preventive
12% Predictive
2% Other

others

REACTIVE MAINTENANCE
Advantages

run it till it breaks

Low cost (until equipment fails)

Less Maintenance Manpower

Disadvantages

Increased and incremental cost due to unpredicted downtime of equipment
equipment

Increased labour cost, especially if overtime is needed

Cost (possibly very high) involved with repair or replacement of equipment

Possible chain reaction: secondary equipment or process damage
consequential to equipment failure

Inefficient use of resources (in the long run)

PREVENTIVE MAINTENANCE

PREVENTIVE
MAINTENANCE
PREVENTIVE MAINTENANCE

PREDICTIVE MAINTENANCE

PREDICTIVE
MAINTENANCE
PREDICTIVE MAINTENANCE

about RISK & RELIABILITY

FMEA
(Failure Mode and Effect Analysis)
FMECA
(Failure Modes, Effects and Criticality Analysis)

about RISK & RELIABILITY

FTA
(Fault Tree Analysis)

RELIABILITY CENTRED MAINTENANCE

RELIABILITY CENTRED
MAINTENANCE

RELIABILITY CENTRED MAINTENANCE

RBM RISK BASED MAINTENANCE

RBI RISK BASED INSPECTIONS
RBI has been applied in industries such as oil/gas industry, power
power
generation, refineries, petrochemical plants and pipelines.
RBI can be applied for static equipment such as pipepipe-work, pressure
and atmospheric vessels, heat exchangers/coolers, filters and other
other
static equipment.
RBI is used in calculating both the consequences of possible failures
and the likelihood with which those failures are expected to occur.
The product of consequences and likelihood is used to identify which
which
equipment poses the greatest risk and therefore warrants the most
inspection attention in order to manage that risk effectively.
RBI makes use of a broad range of technologies including
consequence modelling, reliability and failure frequency analysis
analysis and
limitlimit-state approaches to provide industry with a riskrisk-based method
for evaluating and developing inspection plans.

IPF INSTRUMENT PROTECTIVE FUNCTIONS

definitions:
Developed originally by Shell, the IPF methodology refers
specifically to automated responses to abnormal situations as
detected by instrumentation (typically alarm and trip
functions).
The process entails the execution of a risk assessment for
each protective function by a multidisciplinary team,
accomplished by consideration of the instrument failure
probability and the associated consequences.
The result of the classification enables specification of the
most appropriate implementation and maintenance strategies
for the IPF.

SHUTDOWN (TURNAROUND) MAINTENANCE

& (PLANNED) OUTAGE MAINTENANCE
definitions:
Shut Down: scheduled downdown-period for a plant for scheduled
maintenance for an extended period of time
"Turnaround" is intended to encompass all types of industrial
projects for existing process plants including I&Ts (Inspection
& Testing), shutdowns, planned outages, debottlenecking
projects, revamps, catalyst regeneration, etc. where an
operating plant must be shut down until the work is completed
and then restarted - thus "turning around" the unit/plant.

The terms: shut down

down and turnaround
turnaround have, in
practice, the same meaning. However, turnaround
maintenance may imply works which are not only of
maintenance nature (for instance, plant revamping may be
much more than just pure scheduled maintenance).

FORCED (UNPLANNED) OUTAGE MAINTENANCE

definitions:
Outage: an out
out-ofof-service
service condition of a plant

(or part of it) that is unwanted, unplanned and

unpredicted
Forced Outage Maintenance is maintenance directed
to bring back the concerned Plant to a in
in-service
service
status as fast and reliably as possible

An unplanned outage can be dealt with:

in the absence of any plan = panic management
with a sufficiently or, preferably, well structured plan to
manage the (any potential type of) outage

T P M
TOTAL PRODUCTIVE
MAINTENANCE

equipment: OK
surrounding waste
CC+desbro

efficiency,
effectiveness, losses
OVERALL EQUIPMENT EFFECTIVENESS - PRESS
X - MONITORING CHART
100
50
0
Date 1

OEE
Date 2

Date 3

Date 4

Date 5

Date 6

LOSSES AND EQUIPMENT EFFECTIVENESS

LOSSES AND EQUIPMENT EFFECTIVENESS

continuous process equipment & some construction equipment

exercise????

...oh, yes!!!

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homework????

...oh, yes!!!

Associating the Six

Sigma Methodology with
the TPM approach

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TAKING THE TPM WAY..

EQUIPMENT
RANKING

chronic

chronic losses
chronic

losses

losses
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THE GENERAL TPM APPROACH

FOR REDUCING AND
ELIMINATING CHRONIC LOSSES

REDUCING AND ELIMINATING CHRONIC LOSSES

5 Approaches or combination, as applicable:

a) IDENTIFYING AND ESTABLISHING OPTIMAL
OPERATING CONDITIONS
b) RESTORING THE EQUIPMENT TO
ORIGINAL/OPTIMAL OPERATING CONDITIONS
c) PREVENTING DETERIORATION
d) INCREASING EQUIPMENT RELIABILITY
e) ELIMINATING (ALL) SMALL DEFECTS

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The
P-M ANALYSIS

exercise????

...oh, yes!!!

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CHRONIC LOSSES FINAL REMARKS

WHEN CHRONIC LOSSES (ESPECIALLY
QUALITY LOSSES) ARE NOT ORIGINATED
BY (HIDDEN) DEFECTS IN THE EQUIPMENT
BUT RATHER BY INADEQUATE METHODS,
METHODS A
P-M ANALYSIS MIGHT BE INAPPROPRIATE
THE PROPER APPROACH IS THROUGH
TOTAL PROBLEM SOLVING TECHNIQUES
LIKE TPS AND CEDAC

ELIMINATING
ELIMINATING
THE 6 BIG
LOSSES
THE 6 BIG
ELIMINATING THE
6 BIGLOSSES
LOSSES
ELIMINATING THE 6
BIG LOSSES

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PREVENTIVE MAINTENANCE
AUTONOMOUS MAINTENANCE
the 2 hearts of TPM

The new relationship between

Maintenance and Production

MAINTENANCE ACTIVITIES
IMPROVEMENT ACTIVITIES
MAINTENANCE ACTIVITIES
---> Prevent Breakdowns and repair faulty
equipment. Combination of :

Autonomous Maintenance
Preventive Maintenance (daily-periodic)
Predictive Maintenance
and

Corrective Maintenance (sporadic, ad hoc)

IMPROVEMENT ACTIVITIES
---> Extend Equipment Life - reduce Maintenance
time - avoid the need for Maintenance.
Combination of :

Reliability Improvement
Maintainability Improvement
Maintenance Prevention
MaintenanceMaintenance-free Design

COMMON TARGET:

MAX OEE
basically by means of:

DETERIORATION
PREVENTION

DETERIORATION
MEASUREMENT

RESTORATION OF
OPTIMAL CONDITION

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MAINTAINABILITY IMPROVEMENT

improving equipment
maintainability increases
the efficiency of
maintenance work and
reduces repairs time

Maintenance PREVENTION
Maintenance Prevention targets at
eliminating/reducing the need for Maintenance
It is a TPM goal to reduce the need for maintenance
(especially costly Preventive Maintenance) and,
where possible, eliminate that need altogether.

the marriage TPM/RCM

contributes substantially
to the target

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HOW TO GO INTO
A TPM PROGRAM
HOW TO GO
PROGRAM
INTO
A TPM

assignment????

...oh, yes!!!
MEASURING TPM EFFECTIVENESS

TPM
SELF-EVALUATION

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MEASURING TPM EFFECTIVENESS

TPM STATUS:
SELF-EVALUATION

MEASURING TPM EFFECTIVENESS

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PLANT MANAGEMENT
IN A TPM ENVIRONMENT

SPARE PARTS
MANAGEMENT
MANAGEMENT
"....everyone has a favourite horror
story about large production losses
caused when an essential part was
missing in a store full of ununnecessary materials and spares ...."

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PLANT
MANAGEMENT
ECONOMICS

PLANT MANAGEMENT
ECONOMICS
PLANT
MANAGEMENT
ECONOMICS
PLANT
MANAGEMENT
PLANT MANAGEMENT
ECONOMICS
ECONOMICS

REDUCING OVERALL COSTS OF

MAINTAINING EQUIPMENT
Targets and strategies:
a. Review Periodic Maintenance intervals
b. When appropriate, switch from outside
contracting to in-house facilities
c. Audit Spare Parts Management
d. Identify idle equipment and use it effectively (f.i:
in Cell Production activities)
e. Reduce energy use and service resources waste
f. Eliminate Equipment Losses

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MEASURING
MAINTENANCE
EFFECTIVENESS

OVERALL EQUIPMENT EFFECTIVENESS (OEE)

OPERATIVITY RATE (OR)

INDICES

MEAN TIME BETWEEN FAILURES (MTBF)

A non-TPM factory

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A non-TPM factory
adf

TRADITIONAL
PROJECT MANAGEMENT
basics

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PLANNING
PROGRAMMING
SCHEDULING
CONTROLLING

LIFECYCLE OF PROJECT WITH

POOR PLANNING
Project initiation
Wild enthusiasm
Disillusionment
Wild chaos
Search for the guilty
Punishment of the innocent
Promotion of nonnon-participants
Definition of the requirements (Planning)

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PERT
(PROGRAM EVALUATION and REVIEW TECHNIQUE)

CPM
(CRITICAL PATH METHOD)

PROJECT
PROJECTRISK
RISK
MANAGEMENT
MANAGEMENT

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CONTROL
ADEQUATE PLANNING

=
EASIER + MORE EFFECTIVE CONTROL

CONTROLLING PROJECTS
yesterday

today - tomorrow
objectives definition by mutual consent

giving orders
being at the head
directing
supervising
inspecting
controlling

clear definition of tasks at all levels

planning & scheduling on the basis of
necessary and really available resources
Progresses, Costs and Quality
Measurement Methods based on a clear,
clear
precise,
precise prepre-defined system, known by all
relevant members of the project team, and
agreed upon by mutual consent
At all levels:

continuous monitoring of actual results
versus estimates and budgets

adequate and timely rere-scheduling

regular rere-assessment of time and cost
to
to completion
completion in a continuous
projection process

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.then the world changed.

why enterprises dont perform...

.the root causes of poor performance date
back to over 2 centuries ago
ago..

.we have gone into the

21st century, with
enterprises designed in the
18th and 19th centuries to
perform well in the 20th..

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WORLD-CLASS PERFORMANCE

the world-class enterprise

operates per process

VAM
VALUE ADDING
MANAGEMENT

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SEW
SYSTEMATIC
ELIMINATION OF WASTE

WASTE

VALUE!
LEAN MANUFACTURING
and FLOW PRODUCTION

continuous flow
the target:

pipeline flow

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LOT (BATCH)
PRODUCTION
VS.

FLOW
PRODUCTION

fake flow production

the conveyor method
eureka_conv1
eureka_conv2

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batch production vs.

one-piece flow
one-piece flow
one-piece-flow_longer
one-piece-flow_foi

analysis

LEAN
THINKING
what is it?

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are Lean Thinking

and Flow Process
principles and
techniques suited
to all industries?

The answer is always:

yes!!
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introducing:

LEAN
PROJECT MANAGEMENT
basics

Lean Project
Management
foreword
dehli_construct

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spot the waste!

Construction Industry 1
EXAMPLES
cpt_sme_construct_short

any correlation between what you have seen and your work of every
every day?

Any similitude?
 Moving
 Filing
 Answering
 Attending
Attending
 Reporting
 Preparing
 Waiting
 Observing

Check list:

Meetings spot
spot meetings in the passage
passage

Giving instructions Receiving instructions

Doing things in case

case or why not?
not?

Ordering things SettingSetting-up things Making sure..

Checking Inspecting - Supervising

Talking Clarifying Explaining Illustrating

Illustrating

Chatting - Phoning Taking this

this call
call

Putting pressure Chasing - Expediting Dealing

Dealing

Managing Authorising, approving Getting right

right

Does all this create

value for your clients?

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LEAN PROJECT MANAGEMENT

taking the lean way

taking
the lean
way

specific tools/techniques for:

LEAN PROJECT MANAGEMENT

the PPC and its intelligent use

the Last Planner approach

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Lean Project
Management in
Multi-Project
situations
the TOC approach
multitasking

projecttoc

can construction
become different?
look at this!!
san diego

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a world-class
project-driven
enterprise
aea_wcp
or
aea_wcp_longer

Lean
Maintenance
what is it?

37

Lean Maintenance
definition

Lean Maintenance is the

systematic deployment of
Lean principles in all
maintenance-related activities
in Maintenance of all kinds

spot the waste!

Maintenance World
EXAMPLES
maintenwaste

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CONCURRENT
(SIMULTANEOUS)
ENGINEERING

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CONCURRENT ENGINEERING

...another Terminator of
Adam Smith theories...

Lean Plant
Management
what is it?

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LPM and PEOPLE

Lean Maintenance &

Lean Plant Management
A course presented by Carlo Scodanibbio
Organised by
CREDITS: the documentary material of this course is based on papers
papers and works of
K.Arai
M.Baldini
N.Bodek
W.F.Christopher
T.Conti
E.del Turco

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Lean Maintenance &

Lean Plant Management
a cultural revolution

Lean Maintenance & Lean Plant Management

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