3.06 Reliability Engineering

Asset Criticality is an important input to production system design, maintenance strategy definition and short term work execution management processes. The value the supporting FEMA exercises provide in determining these categorizations is well understood in the Reliability Community. Less common is the extension of this analytical rigor to the spare parts required to maintain equipment. Establishing and maintaining robust part criticality values can be an invaluable link between operations and the supporting supply chain, helping to set stocking strategies, inform alternative material management approaches and quickly flag when expediting is required. Despite the value, part criticality values (or Risk Priority Numbers) are rarely objectively derived and even less frequently maintained. This presentation is intended to: 1. Establish the link between asset health and spare part availability 2. Illustrate common item criticality practices 3. Provide an overview of a robust item criticality assessment approach 4. Highlight the benefits to be gained from an enhanced approach to item criticality determination.

We know that reliability has value to your business, but many of us with technical backgrounds struggle to present a good business case to decision-makers. We are very often held back by budget constraints and we are not in a position to make decisions involving financial risk-taking. Most of us don't have a business background, nor do we speak "finance". It is a whole different language than maintenance and reliability, yet we all want the same things for our business. This presentation will give you some ideas on what you will need to determine in order to show what reliability is worth, and how to present that to decision-makers.

Sharing a recent mandate with a mining client where we assessed the maturity of maintenance management. The webinar will also cover the findings and our actions for improvement.Approach   1. After dozens of interviews from trades to maintenance manager, from operators to supervisors, we started to gather an understanding of the situation.   2. Then, a thorough analysis was performed on work order history, PM percentage vs total available work hours, schedule compliance and production KPIs to help pinpoint several recurring issues.   3. The analysis was concluded with on-site shadowing of supervisors and trades. We selected key dates to execute day-in-the-life-of exercises (i.e., shutdown days) to assess the quality of shutdown management and observe the execution effectiveness. Actions in partnership Tool time is a powerful metric because it helps to expose the majority of the teams’ shortcomings: engagement of the team, respect of processes, communication between departments and productivity of all the maintenance members. After the assessment and analysis, we got to work:   1. Work management process   2. Maintenance tactics review     3. Maintenance execution   4. Spare parts analysis Results With a SWAT team approach, we reduced maintenance backlog by 20%, which allowed us to focus on high criticality assets. In less than 8 weeks, we started to see a reduction in major breakdowns of equipment. We started performing root cause analysis on each breakdown and defect elimination workshops to achieve better reliability. By reducing waste related to maintenance activities in planning & execution, the team managed to transfer the work hours toward preventive tasks. The actions got translated into an improved plant availability and higher engagement

MainTrain 2021 Panel DiscussionModerator: Susan LubellAuthor of "Root Cause Analysis Made Simple", Susan specializes in asset management and reliability strategy, cost effective lean maintenance programs and operational excellence. She brings over 25 years of practical experience to drive asset management, maintenance and operational business improvement opportunities. Susan currently serves as National President for PEMAC Asset Management Association of Canada, Chair of the World Partners in Asset Management (WPiAM), and teaches for both the Maintenance Management Professional (MMP) and Certified Asset Management Professional (CAMP) programs. Panelists:John Hardwick, Executive Director, Sydney, Roads and Martime Services NSWRepresenting: AMC - Asset Management Council, AustraliaWith extensive Executive Management and Board experience and a background over the past 30 years in asset management within the electricity and transport industries. A passionate leader of organisational improvement in asset and operational risk management, and has implemented world class asset management strategies implementing effective asset management strategies and systems to manage risk and provide value for customers and communities.John is co-author of Living Asset Management.John has a desire to make a difference and explore new ways of solving wicked problems. John is the past Chair of multiple not for profit organisations the World Partners in Asset Management, Global Forum on Maintenance and Asset Management and the Asset Management Council.João Lafraia, President, Fábrica Carioca de Catalisadores S.A.Representing:  ABRAMAN - Associação Brasileira de Manutenção e Gestão de Ativos, BrazilOÃO RICARDO B. LAFRAIA is MSc by the Cranfi eld Institute of Techonology, in England. MBA by the Pontificia Catholic University/State of Paraná. He taught in the graduation and post graduation about Quality Assurance, Reliability and Organization in the Federal University of Paraná and FGV Rio. He is author and co-author of the books of Reliability Handbook, Mantenability and Availability and Strategic Management and Reliability, Creating the Habit of the Excellence. Author of several articles and lectures about Excellence in Management of Reliability and Health, Environment and Security.Lafraia has acted as General-Manager in 5 Refineries around Brazil. He also headed the Operational Excellence Department for all refineries at Petrobras Headquarters in Rio de Janeiro. Executive Director for the FCCSA Chemical Company. He served as board member for 4 chemical companies. At present moment, he has the position of General-Manager in the Exploration and Production Santos Basin Business Unit and Chairman of the Deliberative Council of ABRAMAN.Johannes Coetzee, Managing Director, Machine Assessment & Reliability Technology (Martech)Representing:  SAAMA - The Southern African Asset Management Association, South AfricaJohannes Coetzee is the MD of Martec and Chairman of the Global Forum on Maintenance and Asset Management (GFMAM), the umbrella body for professional associations in the field of maintenance and assets management across the world. He is the past-president of the Southern African Asset Management Association (SAAMA) and also serves on the Advisory Board of the Industrial Engineering Department at the University of Pretoria, South Africa. Johannes is an Industrial Engineer, holds an MBA and has been in the field of asset management for more than two decades. Naoki Takesue, Mitsubishi Research Institute Inc.Representing:  JAAM - Japan Association of Asset Management, JapanMr. Naoki Takesue is a Professional Engineer and has more than 30 years experience in the field of construction management and asset management for public and private sectors.  In MRI, he is engaged in research and consulting works for developing government policies of infrastructure management.  Also, as a director of JAAM, he is  actively involved in the introduction of ISO55000s into Japan.  

The “Power Panel” is comprised of reliability and asset management professionals in the electricity industry and will speak to their experiences within the industry that can be applied to outside of an electricity utility. They will cover a roadmap to ISO55001:2014 certification, asset maintenance strategies and mitigation of risks for capital assets.  Moderator:Daniel Gent, Director of Analytics, Canadian Electricity AssociationDan leads CEA’s Reliability Programs, the only national industry program that leverages reliability data analytics on behalf of member and participating utilities. Dan is a Certified Business Analyst Professional with Certification in Business Data Analytics with over 10 years of experience in the electricity sector working in reliability and asset management, and over 15 years in the telecom industry working in business intelligence support. Rounding out his work at CEA, he also oversees several other committees from Technology to Data Strategy and Finance, Tax and Accounting.Panelists: Erin MacNeil, P.Eng, Asset Management Operations Manager, Nova Scotia PowerErin MacNeil is a Mechanical Engineer with experience in both the Utility and Alberta Oilsands industries.  As the Asset Management Operations Manager for Nova Scotia Power, Erin leads a team which designs and administers processes, programs and technologies which enable, sustain and optimize asset-centric maintenance strategies, and advance initiatives with respect to operations and maintenance excellence.  Erin has worked with NS Power's Asset Management Office for 8 years, and is a Professional Engineer (Mechanical) as well as having attained IAM Certification.  Nova Scotia Power’s AM team has been the recipient of a number of awards including a 2019 Game Changer Award (Connected Plant Conference), and a 2018 GE Digital Innovator Award.  Kyle Smith, Supervisor, Maintenance and Reliability, Hydro OttawaKyle Smith, P. Eng. oversees a team of engineers dedicated to keeping Hydro Ottawa’s distribution system assets functioning, reliable, and cost effective for customers. He leads the development and operation of routine maintenance and inspection programs, as well as processes and initiatives to improve system reliability. Prior to joining Hydro Ottawa in 2019, he gained experience in various technical roles with Nova Scotia Power, Inc. and held leadership positions with both the Canadian Electricity Association and Engineers Canada. Kyle holds degrees in Mechanical Engineering and Engineering Mathematics from Dalhousie University.Ehsan Abbasi, Ph.D., P.Eng, SMIEEE, Senior Reliability Engineer, Lifecycle Maintenance Engineering, AltaLinkEhsan has been with AltaLink as Senior Reliability Engineer – Lifecycle Maintenance Engineering since 2015. He has been active in electrical power industry and academia for more than 12 years with experience on reliability assessment of power transmission and distribution networks, power assets lifecycle, reliability centered maintenance, risk based asset management, condition monitoring along with power system SCADA and IED management solutions. Ehsan received B.Sc. from Amirkabir University of Technology and M.Sc. in Energy Systems Engineering from Sharif University of Technology, Tehran, Iran in 2005 and 2007 respectively. He received M.Sc. and Ph.D. in Electrical and Computer from University of Calgary, AB, Canada in 2010 and 2018 respectively. He joined IEEE in 2009 and is currently a Senior Member. He has been a committee member of CEA Transmission Consultative Committee on Outage Statistics (T-CCOS) since 2015.

Ian Flood, Asset Manager at Northwest Territories Power Corporation, is a recent graduate from PEMAC's Asset Management Professional program. His AMP Course 6 Capstone Project was nominated by his instructor, and selected as this year's AMP Capstone Award winning project. The AMP Capstone Award encourages and recognizes excellence in the Asset Management Professional (AMP) program final project, the Capstone. During this presentation, Ian will share more insights into himself, his organization, his award winning AMP capstone presentation and how his learnings in the AMP program have impacted his organization.

Maple Leaf Foods has embarked on a journey to be the most sustainable protein company on earth with a mandate to relentlessly eliminate waste and improve efficiency. As the World’s First Major Carbon Neutral Food Company, the company is undergoing a cultural, operational, and digital transformation in various functions including Asset Management, Reliability, and Maintenance. The keynotes provide insights into how Strategic and Behaviour-Based Asset Management enables Environmental Sustainability to raise the good in food at Maple Leaf Foods.

Do those that manage the performance, understand the measures?

As maintenance and reliability professionals we often get caught in the detail of appropriate reliability techniques and can sometimes lose sight of the bigger picture and organizational goals.  This presentation will provide an indication of the place of reliability engineering in asset management and business planning.  We will also touch on some of the tools in the toolbox of reliability engineers and maintenance professionals such as asset modelling (deterioration and failure modelling), risk assessment, prioritization and inspection.  The presentation will indicate how these tools relate to business planning and when is appropriate to use during an asset lifecycle.  The presentation will show examples of application through case studies in treatment plants, infrastructure, and building facilities and highlight what we have found to be some of the key issues and challenges and how they can be overcome.  To conclude we will highlight some of the key lessons learned from application of these tools and approaches.

Through the introduction of online monitoring technologies in the field, including substation monitors capable of providing near-real-time data and readings on power transformers, switchgear and circuit breakers, along with line monitors for overhead conductor and monitors for underground cables, organizations now possess novel opportunities to integrate this data into their asset management frameworks such that decision-making can be enhanced. This presentation will examine recent efforts to develop Asset Performance Management (APM) frameworks, leveraging available near-real-time data that is being retrieved from online monitoring devices. This presentation will touch upon the emerging field of analytics that can be applied to this data, including machine learning techniques, in order to detect specific signatures within the data that can be correlated to specific failure modes. Robust APM frameworks are able to leverage this near-real-time data for the purposes of delivering dynamic health index results based upon the newest readings, as well as operational alerts that can detect possible failures that will occur in the next few weeks or months, providing organizations with enough time to take action. For complex substation assets, an APM solution can allow plant managers to manage and mitigate significant risks within their system. This presentation will also present the results from specific case studies, where near-real-time data from field sensors was successfully leveraged and integrated into an APM such that the organization was able to enhance their risk management and asset management decision-making approaches.