08 Material Resource Mgmt

How well is your MRO Stores system integrated with your maintenance requirements to ensure effective support of your organization’s maintenance efforts?Most of MRO stores efforts are to provide parts and materials to both Operations and Maintenance. For this article, the focus will be upon MRO stores support of Maintenance.

Enbridge Liquids Pipelines is at the midpoint of a multi-year journey to advance the M&R program for its electrical and mechanical assets. This presentation will share successes and challenges while aiming to apply M&R best practices to a midstream pipeline operator. Our initiative will improve M&R processes and culture, with a focus on improving multiple work streams. These include the planning, scheduling, and execution of preventative and predictive maintenance, information management, spare parts, and CMMS use.

The desert-bound city of Chandler in the American Southwest operates a municipal infrastructure that includes aging machinery assets at four water treatment facilities and dozens of potable water wells, recharge wells, and pumping stations. The city hired an expert— who happens to be an ICML-certified lubrication technician and oil analyst—to develop predictive maintenance programs intended to extend the reliability and service life of these assets. Though his proposed solutions will take several years to implement fully across the board, the benefits and efficiencies have been felt almost immediately. In this presentation,we’ll provide an overview of the main water treatment facility’s lubrication conditions prior to the expert’s arrival and describe the challenges he regularly faces with regard to environmental conditions, untrained vendors, and corporate culture—even as he harvests low-hanging lubrication fruit within the scope of his broader predictive maintenance mandate. We’ll also highlight his personal emphasis on the valuable role that training and certification play in his program’s success. You’ll understand that best lubrication and oil analysis practices can produce significant ROI for any machinery maintenance program; training and certification contribute greatly to the sustainability of culture change and new processes; and a strategic road map can make implementation more efficient and sellable from the outset.

Even today, many organizations see maintenance as a necessary evil neglecting the importance it has toward attaining optimum business results. These organizations have maintenance managers, supervisors, and technicians who are responsible for the preservation of their physical assets. Upon talking to and sharing experience with many maintenance colleagues in various countries, I've learned that most maintenance supervisors and managers don't have a formal maintenance educational background, yet they must make important decisions regarding assets affecting their business's bottom line. We learn about maintenance the hard way, learning from equipment failures and guessing how to avoid them by applying what has resulted well in the past and what the equipment manufacturer tells us. When organizations realize they must do something about maintenance to improve their business bottom line, they're exposed to a lot of information about many tools boasting to offering what they need to do better. This presentation will showcase the results of various case studies performed by our consulting firm at crude oil pumping, pharmaceutical, and water treatment organizations located in North and South America. Several methodologies ranging from Uptime (Strategies for Excellence in Maintenance Management) to RCM-R, ACA, RCA, and even PdM were used to tackle situations at the strategic, tactic, and operational levels.

This case study will show how we used an analysis of standard work management metrics and a systematic approach to identify opportunities to improve our plant. We'll provide specific examples of how we developed and implemented the approach and the results we achieved. We'll also describe the fundamental understanding and steps that could be taken to implement a similar approach at any plant, or for any particular metric. Topics will include cultural recognition of KPIs as an improvement tool, not a personnel measurement stick; understanding all the various causes and influences on any particular metric; analysis and categorization of deviations; identifying losses as acute one-offs vs. chronic systemic issues; behavioural vs. procedural issues; understanding change/improvement requirements, what can be directly controlled and what can be only influenced; determining corrective actions; and tracking the resulting improvements. Specific examples will be derived from our site's application of this methodology to schedule compliance, PM/PdM compliance, and emergency work metrics.  

Setting up or organizing a storeroom is a major undertaking, but it has the ability to dramatically impact the ability of the storeroom to deliver its function.   Sadly, many storerooms are not organized properly and are forced into specific accommodations.   But armed with some basic information, you will be able to setup a proper storeroom.

A Risk-Based Approach to Spares Management 

Ross Markowski was part of the final phases of construction of a gas plant that was experiencing a change of ownership. Ross used the Capstone Project and the myriad changes happening at his site as an opportunity to think through the possibilities of a new organizational design and leadership model to achieve site-wide engagement in proactive maintenance for the upcoming commissioning and operation of the plant. Ross’s presentation summarizes the pros and cons of the existing and proposed organizational structures and touches on some of the challenges of implementation.Whether you are in oil/gas, manufacturing, forestry or another industry, you will find the lessons learned through Ross Markowski’s Capstone Project applicable to most situations where changes are occurring, work still needs to planned and executed and people are your most important resource in getting the work done.

While a host of factors influence profitability, maximizing your plant’s production output potential is arguably one of the facility’s greatest opportunities. An Asset Management, Reliability and Maintenance Strategic Plan can guide continuous improvement that’s aligned with bottom-line performance expectations for managing assets and people. This presentation will provide a framework approach for establishing your strategic asset management & reliability plan and the associated business case. Delegates will gain a fundamental understanding of how to establish a baseline: "know where you are," define where you’re going, who needs to be involved, how to measure the program’s progress and results, and what elements are essential for success.

Uptime describes the combination of activities that deliver fewer breakdowns, improved productive capacity, lower costs, and better environmental performance. The bestselling second edition of Uptime has been used as a textbook on maintenance management in several postsecondary institutions and by many companies as the model framework for their maintenance management programs.Following in the tradition of its bestselling predecessors, Uptime: Strategies for Excellence in Maintenance Management, Third Edition explains how to deal with increasingly complex technologies, such as mobile and cloud computing, to support maintenance departments and set the stage for compliance with international standards for asset management.This updated edition reflects a far broader and deeper wealth of experience and knowledge. In addition, it restructures its previous model of excellence slightly to align what must be done more closely with how to do it.The book provides a strategy for developing and executing improvement plans that work well with the new values prevalent in today's workforce. It also explains how you can use seemingly competing improvement tools to complement and enhance each other.This edition also highlights action you can take to compensate for the gradual loss of skills in the current workforce as "baby boomers" retire. This is the Text Book for Module 1 of the MMP Program.    It is available through PEMAC, contact pd@pemac.org for information on ordering.