Maintenance Excellence

Maintenance Excellence

Bernard Redmond (Director) ARM & Associates LtdMob: 087‐3104712

Email: [email protected]

Agenda Who we are Clients What is Maintenance Excellence The need for Change Success stories Our Approach

Bernard Redmond | Mob: 087‐3104712 | Email: [email protected]

ARM & Associates Ltd

• Over 23 years in Maintenance Management consulting

Clients Activities

Sanofi Genzyme ‐Waterford

Reliability Centred Maintenance (RCM) Studies

Janssen Biologics ‐ Cork

DePuy (J&J) ‐ Cork

Sigma‐Aldrich (SAFC) ‐ Arklow

Astellas (Kerry)PM Frequency Extension

Astellas (Dublin)

Astellas (Kerry) SAP Benchmarking Study


Doing the Right Maintenance at the Lowest Cost

What is Maintenance Excellence?


The Need for Change?Internal and External CompetitionMaintenance costs too high!

But we already have LEANLEAN is a Production process for reducing manufacturing waste.

LEAN is not a Maintenance process. Instead it recommends using other methodologies E.g. TPM, FMEA, RCM etc.

LEAN Maintenance JourneyNo evidence of cost savings!Still wasting time making all the mistakes, trying to figure out what works and what doesn’t?


The Need for change ............ Cont.

Reliability Maintenance EngineerPlaces additional strain on the maintenance budget.Can have difficulty showing evidence of success!Only gets involved after equipment has failed.Fully Tied‐Up carrying out Root Cause Analysis (RCA)Vibration Condition Monitoring Program not delivering any real cost savings.

Doesn’t have enough time for TPM, FMEA, RCM, Criticality etc

Operations dictate what they want him/her looked at …..


The Need for change............ Cont.Computerized Maintenance Management System (CMMS)Adds to the overall cost of delivering maintenance.Only being used to demonstrate PM schedule compliance to Regulators.

Underutilized in the effort to drive Maintenance Excellence.

Often Maintenance Costs andDowntime Costs are not recorded,preventing the Total Cost ofMaintenance to be measured andimproved.

What gets measured gets changedBernard Redmond | Mob: 087‐3104712 | Email: [email protected]

Our Approach toMaintenance ExcellenceSelf‐funding“Before you can spend money you have to save it”

PM Frequency Extension Analyze Work Order History for Failure Trends and MTBF Recommend extending PM Frequency where possible. Ours is a “No Win – No Fee” approach. Guaranteed cost savings; (we only get paid if recommendations are

approved by client). Requires login to CMMS

Astellas Kerry Savings = 340% reduction in PM maintenance. Astellas Dublin Savings = 430% reduction in PM maintenance. Annual Savings range between €500 and €833 per PM.


Our Approach to Maintenance Excellence …. Cont.“Only apply rigorous maintenance optimization methodologies to the critical few”

Carry out detailed System / Equipment Criticality Analysis.For High Criticality carry our RCM studies. Apply RCM results to similar equipment (standardized SOP)


Reliability Centred Maintenance (RCM) Study

(1)

Work

(1)Identify Work

(2)

Work

(2) Plan Work

( )

Work

(3) Schedule Work

( )

Work

(4) Execute Work

(5)Analyze

(6) Improve


Identify Case Study Equipment / System1. Selected by Company2. ARM & Associates (Data Analysis)

One Day Site Visit Site Tour One to Ones with:

CMMS Administrator Maintenance Manager, Supervisors and Technicians

RCM Study Session (At Site) Follow‐up RCM sessions (Remotely facilitated using WebEx)

Equip Failure Data SAP PEMAC MAXIMO INFOR

Our Approach to Maintenance Excellence …. Cont.“Fully utilize CMMS capabilities” Having a CMMS increases the overall cost of maintenance.Carry out a CMMS Benchmarking Study to identify Effectiveness

and Efficiency gaps in the Work Management Process.


(1) Identification

(2) Planning

(3) Scheduling

(4) Execute Work

(5) Analyze Work History

(6) RecommendImprovements

Our Approach to Maintenance Excellence …. Cont.“Develop your existing resources as much as possible”

Sometimes organizations already have potential individuals in‐house who could drive Maintenance Excellence.

All they need is easy access to professional Ad hoc Maintenance Excellence, Mentoring and Coaching support.


eMentoring & Coaching

Don’t know where or how to get started on your journey towards Maintenance Best Practices.

Wasting time making all the mistakes, trying to figure out what works and what doesn’t?

Wish you had an affordable way of accessing the professional help and support you need.

Want to receive the help and support you need at a time and place that suits you.

Want to be able to cancel the service at any time? Want to develop your career by becoming a Maintenance Best Practices

Champion?Bernard Redmond | Mob: 087‐3104712 | Email: [email protected]

LEAN TPM RCM FMEA Condition Monitoring

Training Reliability Availability Criticality

……….. cont Delivered through regular WebEx calls . No contract to sign. Cancel at any time. Applicable for Maintenance/Facilities Managers, Supervisors, Planners

and Reliability Engineers. Incudes CMMS training and template tools. Subjects covered include but are not limited to: ‐ Criticality

Assessments, LEAN Maintenance, TPM, RCM, FMEA, RCA, CMMS Data & User Competency Benchmarking, PM reviews, Condition Monitoring, Work Prioritisation, Competency Assessments and Productivity Studies. Work Flow KPI development and monitoring etc.


LEAN TPM RCM FMEA Condition Monitoring

Training Reliability Availability Criticality


Engineering

Maintenance Excellence