Reliability Centered Maintenance Strategies used in Manufacturing
Mary Gorczynski 1100006B54 firstname.lastname@example.org | | Tags:  assetmgmt maximo tivoli service-management software ibmeam asset-management eam manufacturing ibmontwitter ibmsoftware
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Today's blog posting is from Eric Luyer, Marketing Manager, Corporate Asset & Facilities Management, IBM Software Group, Tivoli, Industrial Manufacturing, including Life Sciences-Healthcare.
This blog is about the importance of working with reliable and safe physical assets and how a concept as RCM (reliability centered maintenance) can be leveraged working with Maximo Asset Software.
Perhaps one of the biggest challenges in asset-intensive industries is how to effectively manage all the different types of assets—without creating a huge management workload that erodes the bottom line. Companies have to constantly track, assess and manage an extraordinarily wide range of physical, technology and human assets. Also these companies must deal with continually aging physical assets—that require ongoing maintenance and repair, since asset performance and the resulting quality of the products are impacted by the reliability of the asset or equipment. Many organizations rely on their own experience, existing systems and of course an obvious safety margin. However the requirements today will put more pressure on the existing assets, to extend the asset’ life and also raise the bar on their asset management practices.
Specific supporting concepts are available today: Failure Modes, Effects and Criticality Analysis (FMECA), Fault Tree Analysis (FTA), Root Cause Analyses (RCA), Risk-Based Inspection (RBI), Reliability Centered Maintenance RCM). These concepts can provide answers on what-if questions and supports risk analysis necessary for better asset performance and optimization. RCM is a process to ensure that assets continue to do what their users require in their present operating context: it is generally used to achieve improvements in the field such as availability, performance, the establishment of safe minimum levels of maintenance, changes to operating procedures and strategies and the establishment of capital maintenance regimes and plans. Successful implementation of an RCM based working approach will often lead to increase in cost effectiveness, machine uptime, and a greater understanding of the level of risk that the organization is presently managing. It basically will try to provide answers on questions on:
Using data taken from the plant history held in the asset management system, RCM analysis can identify the main sources of loss and typical failure rates. By eliminating the recurrent failure stops and reducing changeover times, OEE can be increased significantly.
New available software capabilities allow companies to make various cost components and benefits more visible for better decision making. New solutions in new software often add tremendous insight to reliability, asset optimization and asset performance and can help organizations reach these goals by collecting, consolidating and analyzing information—and then putting information to use—across the critical assets.
Maximo Asset Management manages the day-to-day activity of maintenance work and has a specific role to play in supporting the identification and management of asset-related risks. As we know, Maximo Asset Management has a built-in formal structure for reporting on asset failures by individual asset and by asset type and location. This in turn supports the mean time between failure (MTBF) and mean time to failure (MTTF) types of analysis, and feeds key data into failure mode and effects analysis (FMEA), which is a key part of Reliability-Centered Maintenance (RCM).
Companies as Ivara, Meridium (both in the US) or MaxGrip (Europe) provide capabilities to integrate RCM capabilities with Maximo. At this moment MaxGrip offers a set of capabilities for reliability and maintenance engineers, fully integrating asset optimization information and asset performance management functionalities directly into the Maximo system, including FMECA on all locations as well as information around safety, cost, operations, etc to provide the ability to better determine the asset’s criticality in line with overall business guidelines. This combined solution supports all criteria of PAS 55 or ISO 55000 in terms of risk management. Learn more about Enterprise Asset Management alignment with PAS 55 here.
The concept of RCM and (embedded) integration with Maximo as described here is suited for maintenance managers and others looking to better understand how different strategies and approaches to maintaining their assets will impact costs, asset availability, performance and risk. In particular, asset-intensive industries, such as in discrete manufacturing, process manufacturing as oil and gas, chemicals metals and mining, utilities and transportation, would certainly benefit from this to deliver the best of breed tooling to lift your organization’s maintenance maturity to the highest levels possible. Making use of your assets in a better and smarter way….It’s worthwhile looking to these capabilities!
Thanks for reading and please look out to my next blog, which will be about the Maximo User Events we are planning in October 23 – 24: the Life Sciences Maximo User Group meeting, hosted at Cordis (Johnson & Johnson) in Miami, FL and October 25 a special Healthcare Customer Meeting, hosted at Johns Hopkins Hospital in Baltimore, MD.