Project showcase

Preventative Maintenance Management Improvement Program

Project goal

To deliver an efficient and effective preventative maintenance programme designed to assure safety, reliability and plant uptime.

Client:

Ethanol Producer

Location:

North America

Why Add Energy Were Contracted

The majority of the maintenance executed on site was reactive maintenance triggered by breakdowns, which was impossible to plan for, incurred additional costs and excessive downtime due to lack of spare parts being available.

To overcome these challenges, the client required support in moving from a reactive maintenance approach to a proactive preventative maintenance regime which required a complete overhaul of their maintenance strategy, CMMS data and implementation tactics.

The Initial Review

In order to identify and prioritize the elements that required enrichment and optimization, the Add Energy project team conducted an initial CMMS Gap Analysis. During this study, we identified:

  • Significant gaps in the asset register data when compared against the tags in the engineering drawings
  • An extreme lack of preventative maintenance assigned to equipment in the asset register
  • Inaccurate criticality rankings allocated to the equipment

What We Did

To enrich and optimize the data for transformation to a preventative maintenance management regime, Add Energy then:

  • Developed CMMS Master Data Standards and Processes
  • Conducted a Physical Asset Verification (PAV) using Add Energy’s ePAV™ app
  • Completed a functional location hierarchy build of the asset register
  • Conducted equipment criticality analysis and allocation
  • Delivered a full planned preventative maintenance strategy library, and complete planned maintenance task lists to upload into the CMMS

The Findings

  • Upon completion of the PAV, we identified:
    • The original asset register only contained 17% of the actual assets on the plant
    • Critical name plate data was missing from the asset register
  • During the PAV we identified:
    • Over 5000 tags that were missing from the asset register
    • 950 tags that were missing from the engineering drawings
    • 25,670 new equipment attributes that were missing from the asset register, such as the manufacture, make/model, serial number, size, pressure rating, etc.

The Deliverables

  • CMMS master data standards and governance documentation
  • Criticality assignment process
  • CMMS load sheets with the updated asset register, which increased the number of tags within asset register by 611%, and held the following information:
    • Description
    • Location
    • Criticality
    • Equipment type
    • Hierarchy
    • Equipment attributes, such as name plate data and size
    • Maintenance allocation (task lists)
    • Photographs of equipment
  • Red line marked up engineering drawings detailing where changes were required
  • Library of planned preventative maintenance strategies
  • List of recommendations required to successfully implement the newly adopted preventative maintenance strategies

The Benefits

  • Assurance that all equipment on the plant is accounted for in the asset register, enabling equipment to be managed and maintained, helping to ensure productivity and safety integrity of the plant
  • Accurate criticality rankings will enable maintenance and spares to be assigned, prioritized, and stocked effectively
  • A structured hierarchy enables the maintenance team to navigate through the data easily, and inter-dependencies of equipment to be clearly defined, which is a crucial success factor for efficient maintenance planning and scheduling
  • Up to date and accurate name plate data is now readily available, assuring that the maintenance team have the correct information about the equipment, in order for BoMs to be assigned/developed
  • Able to avoid wasting money buying and storing the wrong parts, through accurate name plate data which details the correct equipment specifications
  • Increased reliability through optimized preventative maintenance, enabling the asset team to intervene at the right time, to avoid known failure modes

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