3.07 Asset Operations

This presentation is a case study on the Maintenance Journey for the Simcoe Muskoka Catholic District School Board guiding participants through the transformation of the school board's maintenance department which originally consisted of an informal program focussed on breakdown maintenance and reactive work, and to the current state of a formal maintenance program.The journey includes leveraging resources to baseline maturity and establish focus areas for evolving practices and adding structure. I will speak about specific initiatives completed and are in process which have established the organisation's programs, engagement, clarity, and purpose. It's a good news story which will also share how the tools and practices inherently part of the PEMAC community and body of knowledge have assisted in modernizing this team and organisation.

The City of Winnipeg faced challenges with the condition of their Return Activated Sludge (RAS) piping within the North End Sewage Treatment Plant. Non-destructive and destructive condition assessment techniques were used to determine that the critical process piping was life expired, and required replacement or rehabilitation to maintain process level of service until the plant is upgraded. Replacement of a RAS piping system is akin to major heart surgery on a sewage treatment plant. To manage the process risk, in situ structural renewal using an engineered Carbon Fibre Reinforced Polymer (CFRP) external wrap system to encapsulate the original carbon steel piping was chosen. Selection of the rehabilitation method reduced the schedule by two years compared to the replacement option and minimized operational risk, as process outages were reduced to a few short-term events. Offline testing of mock-ups and emphasis on environmental and quality control further managed the risks associated with CFRP installation. The project faced unique challenges due to the complex configuration of the RAS piping, which was located inside a congested plant gallery with surrounding equipment, piping, and electrical services in continuous operation. To effectively convey information during planning, design, tender, and construction, a digital 3D model was developed using laser scanning to capture the detailed configuration of the piping and surrounding physical constraints. The 3D model was embedded with data to define the rehabilitation scope, locations of existing pipe leaks requiring immediate repair, rework of pipe supports to accommodate the CFRP installation, and other aspects relevant to the work. This model was a highly effective tool used for collaborative review by all project team members throughout design and construction, leading to successful completion of the RAS piping rehabilitation.

Reliability and maintenance teams in all manufacturing plants have a common goal; that is, to plan and execute initiatives that will help sustain the inherent reliability of the physical assets and increase the availability of the plant. Productivity and profitability of the manufacturing plant and overall organization are highly dependent on the reliability and availability of the plant. A thorough understanding of the importance of reliability has made the top management of major corporations invest in reliability and physical asset management. When the top management invests in reliability, they typically set the corporate strategy and directions for reliability through a road map for all the manufacturing plants that operate under the corporation. When the commitment or support from the top management is available for reliability initiatives, the onus is now on the individual manufacturing plant to develop a reliability plan that aligns with the corporate strategy and/or reliability road map and the current needs of the plant. The reliability and maintenance teams typically build all the strategic, tactical, and operational reliability plans that have initiatives that would make the biggest impact on continuous improvement in reliability and bring the desired benefits for the site. This presentation will explain the systems thinking approach, along with the seven golden rules and seven key factors, that will help reliability and maintenance teams to build an effective reliability plan. In addition, this presentation will also address the top three challenges in building a reliability plan and how to overcome those challenges through two case studies. The first case study is about developing a three-year reliability plan, and the second case study is about developing an annual reliability plan. Both the case studies will explain the application of the systems thinking approach, seven golden rules, seven key factors, and top three challenges that were dealt with and solved.

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.  

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.

Presenting Tactical Asset Management deployment and case study overviews implemented at the Regional Municipality of Halton, Water and Wastewater Treatment Division. Demonstrating how collaboration between Maintenance, Operations and Capital can effectively optimize asset value and promote innovation to how municipalities generally view asset management in an industrial setting.Sharing a vision to rebrand the function of Maintenance to “Tactical Life Cycle Management” when aligned with Municipal asset management plans and how this can be achieved through Assessment based Maturity Mapping of the maintenance function.

Do those that manage the performance, understand the measures?

2020 was a challenging year for everyone, but in our facility, we were able to sustain the site reliability through the successful implementation of Total Productive Maintenance. Total Productive Maintenance allowed us to minimize equipment downtime throughout the year through the combination of keeping equipment in its base condition and producing clear operational and maintenance triggers to catch problems before they become in-process failures. The talk will go through the initial implementation phase (pre-lockdown) and how we navigated through internal and external challenges in 2020 to sustain the TPM and Reliability activities.

Let us look at an ordinary omnipresent part of Asset Management: bolting and fastening the machinery or structure. This single vital activity turns out to be remarkably neglected with undesirable consequences for reliability. Motion Amplification®, a new technology has the capacity to show machinery and structural movements, and so naturally brings out looseness or unnatural behaviors. Fastening errors seem to be one of the most prevalent occurrences and it is therefore important to look at what we can learn and how the technology can drive improvements and uses of best practices. A variety of problems are shown, such as forgotten difficult to access bolts, rusted/corroded fasteners, improper tension, improper washers, bolt grade or size and custom modifications such as a bunch of small shims. Some of the issues can be attributed to design errors, some to lack of asset information provided, some to installation errors, lack of training and proper tools or a culture of installation and maintenance excellence. Sometimes and improvement push comes with the integration of more advanced tools, for example tools exist where the torque can be properly managed. This requires that many other items come into place, such as the missing information, correct parts, training and cultural to get the job done properly.

New technologies regularly enter the world of asset management (AM), often leveraging new inventions, which, in turn, are driven or supported by other advances such as computing power and big data handling. Such is the case for Motion Amplification, a new technology impacting crucial aspects of vibration analysis, machinery and structural troubleshooting, root cause analysis, and communications. This presentation will outline which areas of AM are impacted so we can have a road map facilitating the integration of the new tool into a global strategy and get an overall picture of the impacts it will have. We’ll also provide a brief technical introduction and some practical illustrations.Originally presented at MainTrain 2020