Asset Management System

as defined by the
Uptime Elements Framework
Session #1 Session #2

Jan. 29th Monday Jan. 29th Monday

8:30am – 9:15am 9:30am – 10:15am
Champions III Champions VII

from a Maximo Perspecti ve

J o h n Re eve , A u t h o r, C R L , C M M S C h a m p i o n
Speaker Background Grand Gulf
Nuclear Station

U.S Patent 7,421,372

Maintenance
Scheduling

 2nd consultant hired by the company that invented  13,000 LinkedIn followers
Maximo.  100 postings on industry best practices, numerous
 Spent the first 10 years as an international consultant trade magazine articles
in project management supporting cost/schedule  Frequent speaker at Reliability Web and Maximo
design. Aerospace and defense industries, as well as software venues
nuclear power, depended on this software.  Book: Failure Modes to Failure Codes
 U.S. Patent in maintenance scheduling – called the  Able to comfortably discuss advanced processes for
“order of fire” for resource leveling both asset reliability and work force productivity.
 In the following 20 years, specialized in asset  Significant overseas assignments include Australian
management design. Defence Industry (Sydney), Australian Submarine
 Certified Reliability Leader Corporation (Adelaide), Pohang Steel (South Korea),
100 Guangdong Nuclear Power (China) and Power
Posts Generation Company of Trinidad.
 Aided in 1st RCM for Maximo Industry Best Practices
course, taught as PSDI consultant
 RELIABILITY LEADERs
Asset Reliability
CMMS PRACTITIONERS
Journey MX S/W CONSULTANTs

COST/SCHED. ANALYSTs
Asset Management is what you extract
from the Asset Management System
Advanced processes provide
the largest potential
MAXIMO return on investment

CMMS

The software may be world class but you still need someone to
state the vision, and then, develop supporting processes.
 How to get Certified
Read these or, attend a 1
books week course

Five main
Passport set verticals
 What makes up an
Asset Management System?
What value do the How do these
Uptime Elements elements relate
provide? to Maximo?

Most organizations would benefit from a

Long Range Plan
 Reliability Engineering
Asset Management
for Maintenance

Reliability Asset
Criticality Strategy Condition Vibration fluid executive operational strategy and corporate strategic asset
analysis development information analysis analysis sponsorship excellence plans responsibility management plan

Reliability Root cause Ultrasound Infrared motor risk asset asset lifecycle
testing Thermal human capital competency management knowledge management
engineering analysis testing
imaging management based learning

Capital Reliability Alignment & Non

Centered Destructive Machinery reliability decision performance continuous
Project balancing lubrication integrity
management design testing journey making indicators improvement
 Asset Management Although each journey is unique, the
Asset Management Roadmap creates a
Assumption: Roadmap comprehensive long range plan based
on organizational priorities and
o CMMS is installed. availabilities.
o Organization requests assistance in Asset Management processes
o Requests Long Range Plan showing improvement initiatives
The Long Range Plan also supports
Capture Failure
sustainment activities, such as:
Mode on WO  Benchmarking activities
Establish Define Perform  Attending Maximo World
Core Critical GAP
Create Team Procedures Analysis Configure
 Obtaining CRL staff accreditation
Strategic Identify Create System Define
 Error Checks and Proactive Audits
Plan 04 Best 06 AS-IS 08 Create Failure
Identify Practices TO-BE Action Create
02Stakeholders Plan 10 Create Analytic Implement
Long Range
07 Reliability Chronic
Define 05 Team 12 Load Failure
Perform Optimize Plan
End-Game 03 09 Analysis Criticality Planning
Missing Analysis Scheduling 20
01 11 Foundation Impl.
14 Conduct Mobile
Data Blended 16 Perform 18 Solution
Training RCM/PMO
13 Analysis
19
15 17

You can install software,

but you cannot install reliability.
Work Execution Management PM, PS and MRO are
is one of five verticals within the singled out due to
Asset Management System their significance and
framework, provided by complexity within
Uptime Elements. Work Execution.
Defects will never stop. They are forever
being introduced and perpetuated. ODR and DE are
typically new topics
Defect Tracking
within the CMMS
community.

Lets start
here.

Reliability LeaderTM, Uptime® ElementsTM, Reliability Framework and Asset Management SystemTM and Reliability LeadershipTM are the trademark(s) or registered trademark(s) of
NetexpressUSA Inc. d/b/a Reliabilityweb.com and its affiliates in the USA and in several other countries.
Reliability is Everyone’s Job -- including Operations
Goal #1: Build a proactive maintenance program which involves failure mode identification by O&M staff; precision
maintenance training for technicians; and RCM training for senior staff. Lastly, get Reliability Engineer involved.
Goal #2: Operations personnel should be used in 10-40% of all PM duties. This would free-up maintenance to
increase PdM activities, and gain a partner in asset reliability.
Operator Driven Reliability has operators performing minor & recurring maintenance tasks. Operators need to
accept ownership of asset reliability. They can (1) identify and report failure modes sooner, and, (2) perform basic
servicing by replacing filters, and performing lubrication. They could also have basic PdM tools with them on rounds.
ODR Basic Tasks – qualifying criteria
1. No more than one basic skill is involved, such as mechanical or electrical; but no special tool requirements
2. Only minor adjustments or lubrication activities
3. Troubleshooting “if then … then this”, e.g. electrical resets or clearing a jam
4. Defect elimination or improvement activities are encouraged
5. No significant disassembly
6. Before starting ODR program, there should be some type of “buy-off” to verify proper operator knowledge.
Senior maintenance staff should conduct walkdown to discuss possible failure modes.
7. Every operator who is assigned an ODR task should have access to the single point lesson (SPL).
Best-in-Class Tips:
 Some organizations have Defect Elimination teams who work together to make improvements.
 In some organizations, the maintenance staff is offered advance training in Condition Based Technologies.
Some Organizations focus heavily on Cost Management
How do you optimize Reliable companies will have a competitive advantage due to best-
in-class practices. This allows them to maintain a positive margin
costs to improve even in a depressed market place. Maximo Advanced Processes
reliability?
Maximo WBS 1.0
CMMS
OPERATOR DRIVEN RELIABILITY
Select CMMS based on I M P L E M E N T --- U T I L I Z E --- O P T I M I Z E
1. Ability to configure DEFECT ELIMINATION
2. User community size PLAN & SCHEDULE
3. Industry-product ratings RCM ANALYSIS
4. Number of available add-ons DAILY
PLAN PM OPTIMIZATION
Design CMMS to manage by exception BACKLOG
5. Identify failure analytic and M A NAGEMENT RCM SCREEN INSIDE CMMS
other key reports WEEKLY
2. Reverse engineer SCHEDULE
input reqmts. EMER/URGENT – PLANNED CORRECTIVE – PM/PdM - MINOR
CRITICALITY ANALYSIS
RACI SAFETY-HAZARD REVIEW cron ROOT CAUSE ANALYSIS
1.3 ORGANIZATION WORK PRIORITIZATION + CATEGORIZATION CHRONIC FAILURE ANALYSIS
RELIABILITY TEAM
STRATEGIC TACTICAL 1.2 BUSINESS PROCESS
Vision-mission ANALYTICAL REPORT DESIGN
WO Initiation Dept Goals ASSET CONDITION
1.1 F O U N DAT I O N DATA Business Rules
Flow charts WORK ORDER FEEDBACK
CMMS SOPs FAIILURE MODE ON WO
FAILURE ASSET PM LABOR KPIs + metrics MAINT.DOWNTIME CAPTURE
CODES INVENTORY M STO SCHEDULING
JOBPLAN CRAFT CALENDAR auto RO
ITEM replenish PROJECT COST TRACKING
LOCATION rop, eoq, RISK BASED
COMPANIES lead-time, safety PRIORITIZATION MATRIX
 Strategic Asset Management Policies

00
50
-5
O
IS
 Asset Category; Asset Criteria/Definition
 Replacement Cost; Asset Condition Tracking
 Expected Service Life; Average Age
 Levels of Service
 Maintenance Schedules
 Cost Tracking; Growth Plan; Capital Projects
 Disaster Planning; Risk Management
 Asset Management Plan by Category showing SLA

Reliability LeaderTM, Uptime® ElementsTM, Reliability Framework and Asset Management SystemTM and Reliability LeadershipTM are the trademark(s) or registered trademark(s) of
NetexpressUSA Inc. d/b/a Reliabilityweb.com and its affiliates in the USA and in several other countries.
Maximo WBS Design the CMMS
to manage by
exception
ASSET MGMT
1.0 SHAREHOLDERS 1.1 CMMS DATA 1.2 KNOWLEDGE 1.3 END-GAME
TY
S I B AT E
ILI

MISSION-VISION
ON R

FOUNDATION INDUSTRY DECISION LONG RANGE CONTINUOUS

SP PO

CORPORATE POLICY DATA BEST MAKING PLAN (LRP) IMPROVEMENT

RE COR

PRACTICES
ASSET MANAGEMENT STRATEGY ANALYTICAL
TRANSACTION REPORTS
DATA
ASSET MANAGEMENT PLANS
RISK ACTION
MGMT TRACKING
Continuous
KPIs provide
Improvement
This initiative is certainly valid but if The analytical
MANAGEMENT measures;
reports could very The LRP is a
left up to the day-to-day worker, OF CHANGE analytics provide
well impact the greatly
minimal benefit may occur. Therein insight. Too
several techniques are warranted such data capture under-utilized
tool for often the CMMS
as WO Feedback, asset condition requirements.
consolidating user assumes
capture, chronic failure analysis, RCA, Thus if the CMMS
improvement the product
defect elimination, auditing, SQL error team fails to
checks, benchmarking, RACI chart, initiatives o.o.b. will have
think ahead,
asset owners, story boards, posters, and adding the analytics
capabilities
and of course training. clarity. they need.
will be lost. -- Steven Covey
 Create a Culture of
Reliability, Responsibility, and Accountability
 Leadership for Reliability states that leadership comes from everyone.
Foundation for Reliability  Executive Sponsor should be the champion of asset management – at the
executive level. He sets the AIM where reliability is an imperative. The executive
sponsor communicates goals and helps initiates change, assigns accountability,
and explains benefits. He also reviews expectations, addresses resistance, and
reviews risks/roadblocks. Lastly, he explains why continuous improvement is
critical. Top management is also responsible for creating and resourcing the Long
Range Plan – containing improvement initiatives.
 Reliability Leader - defined: Reliability Leaders promote excellence; develop
innovative ideas in support of improve work force productivity and asset
integrity’ plus, they nurture the development of others through demonstration
and engagement. Reliability Team is coordination central for improvement ideas.
 Anyone can be a reliability leader – including P&M Technicians. To be a
reliability leader, you must be able to lead and exercise reliability leadership
effectively with no title, no position, and no authority. A reliability leader strives
to create a better future that might not otherwise exist.
 Reliability Culture is created through leadership. And optimized performance is
a principal result of this culture.

Reliability LeaderTM, Uptime® ElementsTM, Reliability Framework and Asset Management SystemTM and Reliability LeadershipTM are the trademark(s) or registered trademark(s) of
NetexpressUSA Inc. d/b/a Reliabilityweb.com and its affiliates in the USA and in several other countries.
Maximo WBS Someone at the executive
level should be the
Understand shareholder values
primary sponsor of
Document goals & objectives 1.0 EXECUTIVE SPONSOR asset management
Promote reliability culture strategy
Communicate vision
1.1 1.2
SENIOR MANAGERS AL STEERING TEAM
N
IC

IO
G

T
TE

PROJECT MANAGER A
E R CMMS CORE TEAM RELIABILITY TEAM
RA

P
O
ST

RELIABILITY CHAMPIONS
CMMS BUSINESS P&S RELIABILITY HSE MATLS
ASSET CARE SPECIALISTS ADMIN ANALYST MGR ENGR MGR MGR
Goal: Create a OPS MAINT
Culture of Reliability POWER USERS MGR MGR
1.4 1.3
HR MGR
S

TECHNICIANS
Strategic
IE

Tactical
DIFFERENCE MAKERS
R

alliance OPS SUPV OPS

A

MGR
N

Team between
IO

TOTAL PRODUCTIVE MAINTENANCE VP

Based departments
IS

MAINT SUPV MAINT

OPERATOR DEFECT PLANT that supports
V

Approach MGR
DRIVEN ELIMINATION SYSTEM shared goals
RELIABILITY TEAMS OWNERS TRAINING MGR
 Only 11% of all failures are age related
Condition Based Technologies are scheduled activities, non-intrusive, and provide early warning.

If that is true, why are we doing so many

overhauls, replacements and servicing?

Age Related Random

Reliability LeaderTM, Uptime® ElementsTM, Reliability Framework and Asset Management SystemTM and Reliability LeadershipTM are the trademark(s) or registered trademark(s) of
NetexpressUSA Inc. d/b/a Reliabilityweb.com and its affiliates in the USA and in several other countries.
 Maximo WBS Goals:
Asset Preservation
1.RCM Decision Tree selects tactic Managed Risks
2.Strategy must be viable 1.0 D e l i v e r y M o d e l Less Downtime
3.Certified staff for CBT Return on Capital
4.Precision skills The life of an asset is documented by transactional data, CBT, SCADA and staff observations.
MEET STAKEHOLDER EXPECTATIONS
1.1 1.2 PF Curve Position
ASSET Opinions from tribal knowledge Low 1.3 SUSTAINED EXCELLENCE
TYPE O&M Technician sensory & log readings Low Decisions to be made
AND Graded asset condition Mid  Replace asset 1.5 COST AVOIDANCE RPT
FUNCTION CMMS failure history Mid  Design change
Data historian; SCADA Mid  Repair asset 1.4
Vibration analysis High  Continue operating Repaired
Infrared thermography High but alter frequency before failure
Ultrasound High  Install on-line
Fluid analysis High monitoring
Motor testing High  No action; no defect Training and certification should be
Non Destructive Testing (NDT) High supported as incentives for technicians to
increase skillset, provide more effective
maintenance, and be better compensated.
Preservation Techniques
 Machinery lubrication // Jack Nicholas, Jr., Uptime, Jun-Jul 2017
WORK SCHEDULE ASSIGNED CRAFT
 Alignment & balancing
 PM restoration PRECISION MAINTENANCE SKILLS
 Visual testing/inspection RISK BASED PRIORITIZATION MATRIX CRITICALITY
 Cleaning ASSET CONDITION
WORK BACKLOG MANUFACTURER/MODEL
CONDITION BASED TECHNOLOGIES PURCHASE HISTORY
ASSET RECORD WARRANTY; AGE
(CBT) REPLACEMENT COST
ROUTINE & URGENT WORK DATABASE
and PREVENTIVE MAINTENANCE FUNCT. CHARACTERISTICS
 How can you guarantee Reliability?
You can’t
But we can improve the odds

Reliability LeaderTM, Uptime® ElementsTM, Reliability Framework and Asset Management SystemTM and Reliability LeadershipTM are the trademark(s) or registered trademark(s) of
NetexpressUSA Inc. d/b/a Reliabilityweb.com and its affiliates in the USA and in several other countries.
 Maximo WBS Goal: The organization must
continually improve
1.Perform investment planning processes, reduce costs,
2.Ensure reliability in design 1.0 IDENTIFY & MANAGE RISKS and cut waste to
3.Manage capital projects remain competitive.
4.Operate & maintain It’s not possible to design out all possible defects therefore the organization
must deploy methods to detect failure, find true cause and mitigate it’s effects. RCA
Trigger
Points
CBT = Condition Based Technologies
NORMAL PLANT OPERATION 1.6
Root

PERFORM PRECISION
1.1 1.5 SIGNIFICANT Cause

O&M TECHNICIAN
CRITICALITY 1.2 RCM 10-15% EVENT

CMMS PM/CBT
Analysis

MAINTENANCE
ANALYSIS ANALYSIS Time-

LIBRARY
70-75% Usage Monthly
1.3 PMO Meeting
ANALYSIS based
Work 1.7
M
G G

Orders RECURRING Chronic

1.4 OEM 10-15%
O VIN
RA

RECOMMENDATIONS FAILURE Failure

Analysis
PR LI

CBT
Discovery
ROUTINE + URGENT REPAIR WORK WO COMPLETION UPDATES
Store RCM
Analysis
1.8
results inside WO
CMMS One-off WO failure mode comparison
Feedback
Pareto sort identifies worst offenders and drills down on failure mode to find true cause
 Present LRP to Stakeholders

Road
Upper Mgmt Conduct Review LRP Conduct User Surveys CRL Accreditation
Setup/Configure Fields: Activate CMMS Functionality: Perform RCM Cost Avoidance Report
• 5 Annual Maint Costs to Asset • Type-Ahead Analysis
• Functional Failure on WO • Prefix WO with “YY-”
• Out-of-Service on WO
• TypeWork field (with pic list)
• WO Feedback
• Capture Actions Performed
• Setup Capital Tool Tracking
• Meter-based PMs
Perform PMO
Analysis
Store RCM
Analysis
inside
CMMS
Map
Create Power Applications: Perform
Bus. Rule: Criticality Gather OEM Enhance Understanding
• Defect Tracking Recommendations
• RCM Analysis Screen CM Analysis Perform Asset the end-game
• WO Ranking Matrix Worktype Defect Reliability gives an
• HSE Accident/Incident Tracking for Repair Design- Elimination organization
• PM Basic & Commitment Repository Setup Reliability Build significant
Team Failure Chronic competitive
Analytic Failure advantage.
Analysis
Failed Component Capture Capture
Setup

Component Problem Failure Accurate Optimize

Cause Code Mode Failure Data Root Cause O&M Costs
Analysis with ROA
Asset Install Date, Warranty Allow Pareto Sort on Report:
Expiry, Replacement Cost • # Work Orders Organizations
Setup Asset Cond. Capture • Operational Downtime Improve that deploy
• Asset Condition Perform Precision Maint. Training Workforce the best
Autoscript for Oper. Downtime • Avg Annual Maint Cost / ERV Productivity reliability-
• Asset Age Design-Build Pass-Down Report based
Autoscript for Avg Ann Maint $$
Improve CMMS SOPs Provide maintenance
• Build Charter Ease-of-Use practices
• Build RACI Incident Reporting Promote for Core provide the
• Formalize WORM team Job Safety Create Backlog best
AutoScript Growth Report System use
• Create Business Rules availability at
Formalize • Build CMMS Definitions for Rough lower cost.
Core • Create Error Checks Estimate Improve Job Imp. Backlog
Team • Define Business Analyst Planning Management
• Maintain Punchlist AutoScript Punchout Setup SR Evaluate
• Solidify Vision/Mission for Backlog Make Oracle WO required Web Speed/
• Create Posters Ranking Spare Part Based Perfor- TRM John Reeve
• Setup Book Club Integration Integrate MX PR to Oracle mance Rev 1, 11/02/2017
Authors Breakfast – IMC 2017

Benchmarking: An Essential Strategy maximo Failure Modes to Failure Codes

for every CMMS Core Team
world
Aug. 2018 *** Short Course ***

John Reeve John.Reeve@TRMNET.COM