heckettmultiservmaintenancedraftblueprin(编辑修改稿)

heckettmultiservmaintenancedraftblueprin(编辑修改稿)内容摘要：

ls • Scored pistons • No stops • Use 5Why’s to determine root cause (., machine dirty, missing filter cap) Implement solutions • Alterations to preinspection checklists • Revisions to planned maintenance service intervals • Introduction of condition monitoring • Change in SOPs • Change of supplier • Determine designout remendations * Operational changes must also be implemented to realise full OEE analysis benefits • Reduce idling time • Use shorter routes • Ensure pots are cleaned and fully loaded for each trip 020606JHHMF006KS_P1 15 EPC FLEET OEE ANALYSIS WORKSHOP ESTIMATE Fleet of 3 Issues to resolve • What is the ideal operating time? • What can be done to reduce maintenance downtime? • What can be done to reduce idling time and inefficient use of time? Annual hours (fleet of 4) 0 24 390 18 684 ? ? 5 706 26 280 Calendar hours Holidays and unscheduled time Planned and unplanned hours Available hours Time not used Actual operating time Idling time and inefficient time use Ideal operating time 35 040 2 718 32 322 13 638 Apparent OEE = 53% Availability = 92% Taking 1 unit out of fleet will increase OEE to 71% 020606JHHMF006KS_P1 16 VANDERBIJLPARK POT CARRIER OEE ANALYSIS WORKSHOP ESTIMATE Opportunities to improve OEE • Track and monitor equipment operating time to identify and eliminate inefficient use of time • Reduce maintenance downtime by up to 2/3 by reducing actual equipment operating time • Aim to extend equipment life by approaching ideal equipment operating times Annual hours Calendar hours Holidays and unscheduled time Planned and unplanned hours Available hours Time not used Actual operating time Idling time and inefficient time use Ideal operating time Availability = % Actual unit OEE = 12% Fleet OEE = 6% 0 4 7 52 2 4 41 0 8 03 3 2 48 2 8 54 9 6 18 7 6 0020606JHHMF006KS_P1 17 COST BREAKDOWN BY EQUIPMENT TYPE R 000 . Pot carriers Downtime Parts Labour Issues to plete before workshop • Complete analysis for the 6 key sites • Break costs down for the top 5 to 6 equipment types • Analyse costs for parts, labour and direct downtime impact Metal recovery plant Columbus steel plant DUMMY Front end loaders Downtime costs calculated by assigning an opportunity cost of downtime per operating hour Parts costs are based on costs of repair parts purchased Labour costs are based on works order labour hours assigned to the specific ponent failure 020606JHHMF006KS_P1 18 EQUIPMENT STRATEGY DEVELOPMENT – POT CARRIER EXAMPLE Equipment type Pot carrier Hydraulics Electrics Engine Other Cylinders Hoses and fittings Oil pumps Other Broken clevice Seal failure Bent rods Scored pistons Other Functional ponents Maintainable items Failure mode • Breakdown the equipment into functional ponents and maintainable items • Use 80/20 principle to identify the ‘big hit’ functional ponents and maintainable items • Determine the failure modes for the ‘big hit’ maintainable items and use ‘5 why’s’ to identify the root causes • For each of the ‘big hit’ items, develop a maintenance strategy to optimise the equipment OEE 020606JHHMF006KS_P1 19 COST BREAKDOWN BY FUNCTIONAL COMPONENT R 000 . Hydraulics Issues to plete before workshop • Determine highest functional ponent spends for the top 2 to 3 equipment types • Rank spend from highest to lowest • Use 80/20 rule to make sure that 80% of the functional ponent costs are covered Electrics Pot carriers Engines DUMMY 020606JHHMF006KS_P1 20 COST BREAKDOWN BY MAINTAINABLE ITEM R 000 . Cylinders Issues to plete before workshop • Determine maintenance spend for all high cost functional ponents • Ensure 80% of total costs are covered Hoses and fittings Hydraulics Pump DUMMY Prioritise maintainable items to determine where to start looking for failure modes and root causes 020606JHHMF006KS_P1 21 FAILURE MODE ANALYSIS Equipment type Issues to plete before workshop • Determine failure modes for 80% of spend • Rank the % of failure time for each failure mode Functional ponent Maintainable item Failure mode Equipment history % of cost Pot carriers Hydraulics Cylinders Broken clevice Seal failure Bent rods Scored pistons Other 10 50 15 5 20 DUMMY Key input data sources • Work orders • Maintenance records • Operator, artisan, maintenance supervisor and planner opinions Definition Failure mode: problem/fault that causes a maintainable item to stop operating or perform below rated capacity/quality specifications Tip: interviews of knowledgeable operators, maintainers and engineers provides a good validation for maintenance records, and, in the absence of such records, can provide an accurate fact base 020606JHHMF006KS_P1 22 5 WHYS ROOT CAUSE ANALYSIS Why 5 Why 4 Why 3 Why 2 Why 1 Equipment history % Failure mode Cylinders Broken clevice Seal failure Bent rods Scored pistons Other 10 50 15 5 20 Overheating Worn Wrong seal Bad workmanship Hot oil Wrong oil Hot operation Wrong seal Friction Blocked coolers Cavitation Exposed reservoir Wrong oil Dirty oil Blocked tubes WORKSHOP EXAMPLE Dirty heat exchangers Dirty machines Unfriendly environment Not maintained It was agreed that the 5 why system of root cause analysis。