The A-PRO suite of services
helps companies to make the transition from a reactive organization
to a highly proactive one by addressing the core competencies of
asset reliability. This is accomplished by drawing upon the best
practices of reliability-centered maintenance techniques. PCA does
this by implementing three modules, each distinct yet integrated.
Each of the modules features three distinct levels of training and practical application. The process begins with a thorough gap analysis of existing conditions followed by an interactive leadership workshop. This provides the opportunity to understand each plant site’s goals, objectives, and reliability requirements. Additionally, it allows us to develop a comprehensive process tailored to these specific needs and culture.
Since the process impacts both the maintenance and operations departments, it is important to enlist the active participation of your leadership team, giving them enough understanding of the process so that viability and continuity are maintained. Checklists are provided to management to gauge effectiveness and performance.
It’s important to note that these are not “canned” training programs. They are highly interactive workshops followed by one-on-one, hands-on field training.
There is not just one way to achieve success in asset reliability. PCA’s consultants will provide you with very specific—and sometimes unique—solutions based on our over 27 years of experience and practical application of asset reliability and optimization.
Module 1 - Reliability Focused Maintenance (RFM) is the core track. Here we establish the improvement process and organization to identify, monitor, analyze and optimize business reliability initiatives. Organizational requirements vary but we always strive to develop them from within. The three principal tools used are:
Statistical Process Control (SPC)
Root Cause Failure Analysis (RCFA)
Failure Modes and Effects Analysis (FMEA)
A seven step process improvement model provides the structured approach to problem identification, solution and implementation. PCA’s Reliability Focused Maintenance service provides you with a proven methodology to launch and sustain the reliability function without the substantial overhead burden found in other reliability centered maintenance programs. Successful implementation of the program typically takes 60 days of PCA time spread over six to eight months. This is accomplished by a three-level training and implementation process:
Level 1. Activities begin with an assessment of current reliability efforts, a “gap analysis”, a four-hour leadership workshop, and the preparation of a detailed plan/schedule for correction of the “gaps” as well as recommendations and strategy for development of the RFM process.
Level 2. Three specific activities are part of this level. The first activity is to select the people who will lead and participate in the reliability process. The Reliability Core Team is typically comprised of PPM coordinator, mechanical and electrical engineers, and the manager. The Reliability Support Group includes a cross-functional group of people from throughout the plant who are utilized periodically to participate in the Root Cause Failure Analyses (RCFA) and Failure Modes and Effects Analyses (FMEA). The second activity is to provide detailed training for the Reliability Core Team and Reliability Support Group. And the third activity is to setup the code tables, data collection forms, reporting and associated procedures.
Level 3. Activities at this level are aimed at applying all the training, data and other gap improvements to specific equipment at the client’s site. PCA provides benchmark information to help target and measure specific opportunities at your facility. Our database is extensive and encompasses many businesses and equipment types. Two pilot efforts are undertaken to improve the reliability of specific equipment and reduce maintenance costs. Savings and improvements are tracked and reported. In addition, Level 3 includes implementation of the A-PRO Reliability System, allowing the plant to track and report the benefits and cost savings generated by the RFM process
Module 2 - Preventive/Predictive Maintenance Optimization is a fundamental asset care process. PCA begins by analyzing core competencies as they relate to process and equipment functions. Operator, maintenance and engineering functions are addressed as they currently and potentially affect business reliability. This runs the gamut from housekeeping to vibration routes.
Our service provides the training and direction needed to asses, modify and optimize a plant’s repetitive, preventive and predictive maintenance activities. Intrusive maintenance inspections and services are minimized through reliability improvements. Studies have shown that over 30% of overhauled machines fail at start up, often causing collateral damage. In many cases, these machines were not in need of overhauling, or the need to overhaul could have been eliminated through more effective Preventive/Predictive Maintenance. Our focus is to provide the optimal level of asset care which typically includes the reduction of non-value added work and scheduled/unscheduled downtime.
This entire optimization process typically takes 40 days. The required time may be longer if there is no existing Preventive/Predictive program, and PCA’s assistance would be required in establishing one.
The optimization process requires three levels:
Level 1. Activities include a “gap analysis”, a four-hour leadership workshop, and the preparation of a detailed plan and schedule for optimization of Preventive/Predictive Maintenance activities and correction of gaps. Programs such as Process Safety Management, MSHA, and ISO are included as required.
Level 2. At this level, activities will involve the definition of the individuals who will be part of the Preventive/Predictive optimization process. Once this organization is established, detailed training is provided, current technology gaps are corrected, and the data and reporting network and procedures put in place.
Level 3. Activities involve the hands-on application of the Preventive/Predictive optimization principles, tools and data collection to the actual plant equipment. During this step, the Master Maintenance Schedule of repetitive tasks is developed and actual Preventive/Predictive routes are established or modified. These are then integrated into routine work schedules for daily and repair-day (outage) work. The feedback loop is established and actual data is collected and analyzed for continuous optimization of Preventive/Predictive activities. PCA will assist in the assessment and application of Preventive/Predictive technologies to include lubrication, vibration monitoring, shock pulse, thermography, ultrasonic emission, etc. Basic PM Templates are provided to initiate or enhance a proactive asset care process. These templates are designed to be applied against generic families of equipment for industries such as manufacturing, mining, petrochemical and pulp and paper, or they can be adapted to be more specific if needed.
Module 3 - Continuous Monitoring and Precision Maintenance expands the reliability process in the areas of data acquisition and analysis coupled with precision maintenance. PCA determines opportunities to combine business information systems to monitor the most critical equipment and processes. Process and maintenance management systems are combined to provide real-time condition monitoring and analysis. It is important to fix problems reliably when they first develop and not wait for the end of the month. Quality, compliance and safety, for example, cannot wait.
PCA’s Continuous Monitoring and Precision Maintenance service provides a method to enhance typical condition based monitoring and preventive maintenance. These activities are normally provided on an agreed upon timetable and assumes there is enough information to predict failure, and enough time to address it. Many times equipment is not accessible and cannot be effectively or safely monitored manually while running.
Critical processes and equipment require “real-time” information that monitors many functions to determine overall capability and reliability. The needed system often already exists in the form of DCS or other PLC monitoring of process parameters.
PCA engineers will work with your information technicians in expanding this monitoring to include machinery condition. Real-time alarms can then be established that trigger the work management system to initiate corrective actions. Of equal importance is the installation and repair of equipment reliably.
Precision maintenance opportunities are primarily focused on critical rotating equipment. Asset care techniques such as static and dynamic balancing, shaft alignment, bearing fit, lubrication, etc., are assessed for performance and effectiveness by PCA engineers. This entire optimization process typically takes 20 days. The process involves the following levels:
Level 1. Activities include: gap analysis, four-hour leadership workshop, and preparation of a detailed plan/schedule for optimization of continuous monitoring and precision maintenance activities, and correction of gaps. PCA reliability engineers conduct a complete critical equipment review.
Level 2. Activities include the identification of the people and equipment that will be involved in the Continuous Monitoring and Precision Maintenance process. Once this step is completed, detailed training is provided, current technology gaps are corrected, and the data and reporting network and procedures are established. This includes assistance with developing the process of continuous monitoring, and precision maintenance standard tasks for targeted critical equipment.
Level 3. The hands-on application of the continuous monitoring and precision maintenance principles and data to the actual plant equipment is the chief activity at this stage. During Level 3, the standard procedures of routine data collection and precision maintenance tasks are established, and actual monitoring of alarm conditions are initiated or modified, and integrated into work schedules for daily and repair-day work. In addition, the feedback loop is established, and actual data is collected and analyzed for the continuous optimization of the condition based and precision maintenance activities. Calibration requirements are also determined to ensure that hidden protective devices are not in failed states, which would inhibit alarm conditions of critical equipment.
To learn more about how PCA’s Reliability Focused Maintenance Model can improve your company’s bottom line, then please complete the request more information form and one of our consultants will contact you shortly.
A-PRO™ Asset Performance Reliability Optimization
