The goal of preventative or predictive maintenance is to reduce the probability of failure, or mitigate the consequences of failure of an asset or group of assets, or both. By understanding the risk of an asset’s downtime against production, safety, the environment, and a company’s reputation, maintenance professionals can develop an optimized plan to maintain their equipment.
Fluid Life has the tools and the expertise to assist a customer who is on the journey to optimized maintenance. With the desire for improved reliability and availability, customers can partner with Fluid Life’s Reliability Team to benchmark their current maintenance practices against industry leaders and develop a plan to close the gap. From full Reliability Centered Maintenance to Root Cause Analysis, Fluid Life will help you achieve best in class performance. Together, we will have an impact on your business, and will demonstrate measured success through key performance indicators.
Available Tools and Resources
Quality maintenance planning decreases equipment downtime, increases schedule compliance and wrench time, and increases production. Planned work is 10 times safer than unplanned work, and costs on average 3-9 times less than unplanned breakdown maintenance.
Planning Services is a well-organized methodology for deploying maintenance resources efficiently and for capably executing maintenance tasks such as Preventive or Conditioned Based Maintenance.
With Fluid Life, you will gain an entire team of maintenance planning experts and benefit from our experience on multiple sites to share and encourage planning best practices. We provide administration support by ensuring completed work orders are scanned and uploaded into your CMMS complete with notes and associated details. We strive for continuous improvement with precision maintenance auditing to ensure craft compliance to job plans and closed work order review to ensure all pertinent information is being captured and recorded.
Maintenance planning services are performed via:
- Definition and prioritization of the right work
- Development of the work structure and steps to complete tasks
- Recognition of the necessary tools, materials, and the skill sets
- Assurance of on-schedule accessibility of materials and assets
- Confirmation of completed work particulars through documentation in CMMS
Fluid Life’s Planning Services includes the following elements:
- Fleet Health Assessment
- Building and Reviewing Job Plans/Templates
- Processing Work Requests
- Condition Based Monitoring
- Preparing PM Packages
- Scanning, Entering & Closing Completed Work Orders
- Planning Majors (i.e. mid-lifes, rebuilds, change-outs)
- Planned Component Replacement Tracking and Budgeting
- Availability Tracking and Reporting
- Troubleshooting / Root Cause Analysis Participation
- Managing OEM and vendor relations for assigned fleet
- Analyze current practices and identify opportunities for improvement and/or ‘best practices’
Choose from a menu of services that we can provide anything from simple maintenance administration services to full scale equipment maintenance planning.
Preventative Maintenance Optimization or PMO is a process that challenges your maintenance activities against an asset or group of assets. By matching restoration tasks to specific failure modes for equipment, PM tasks are reconsidered based on how they have failed or are anticipated to fail. This predictive approach ensures maintenance departments aren’t spending resources doing maintenance too frequently, or not frequently enough.
The PMO process weighs the customer’s risk tolerance with recommendation from the OEM, the asset’s PM history, the asset’s failure history, and the performance required of the asset. An optimized PM plan is delivered based on this analysis that ensures the right maintenance tasks are performed at the right interval to ensure availability of the asset while minimizing the maintenance effort to achieve the required level of performance.
This exercise is similar to a Reliability Centered Maintenance evaluation, but on a much simpler scale. A reliability engineer can facilitate PMO with the assistance of personnel responsible for maintaining the asset.
If your equipment is not running as desired or is failing unexpectedly, then the assumptions that created the PM schedule need to be revisited to prevent future failures. This process will help you achieve that.
- Determine equipment candidates for PMO process
- Gather all current and past PM plans to maintain equipment, including feedback and as found conditions if available
- Observe PM task execution if possible
- List all spare parts required for current PM tasks
- Review the efficiency of current maintenance practices around the PM tasks
- Review the efficacy of PM tasks against each failure mode for the studied equipment
- Consider order of execution to allow for the greatest efficiency of execution of PM plan for an asset or group of assets
- Provide recommendations for an optimized PM task grouping and order of execution
- Optimized PM plan for maintaining studied equipment
- Upload new plan into CMMS
- Recommended maintenance procedure changes (spare parts, tooling, and work logistics)
Reliability Centered Maintenance (RCM), while resource intensive, is the most advanced method for developing an asset maintenance strategy. Using the risk tolerance level of the customer, default actions and proactive tasks (such as preventative maintenance, inspections, condition monitoring techniques and frequencies etc.) can be fully optimized to increase production availability and mitigate risk. Whether for a single asset, group of assets or an entire facility, Fluid Life has a right sized service to meet our customer’s needs. Fluid Life Reliability Specialists will setup custom equipment templates, gather all necessary data and deliver optimized preventative maintenance tasks and spare parts for reviewed assets in full collaboration with the customer.
- Assist the customer in classifying critical equipment if not already complete
- Identify equipment to undergo the study, often starting with the most critical assets
- Develop a plan to conduct the study by asset group
- Gather and review maintenance history on study equipment
- Gather all relevant drawings, vendor manuals, OEM specifications, site policies and procedures, bills of material, and maintenance tasks for the study equipment
- Create or review the company’s risk matrix and levels of risk tolerance
- Analyze the data and pre-complete as much of the study as possible
- Gather the right team of individuals and name a facilitator
- Train the group on the RCM process
- Conduct the initial studies and develop a plan for the living program
- Produce a report as outlined below
- Report on pre-study risk and mitigated risk
- RCM basis by asset, including failure modes and effects used to develop the tasks and spares to mitigate the risk of failure
- Optimized PM task lists for each asset or group of assets
- Optimized spare parts lists for each asset or group of assets
- Timing for conducting the living program reviews
- Gantt chart of implementation schedule
A site’s criticality analysis should be a living document. As new assets are commissioned and other assets age, the risk profile for the owner operator will change. Fluid Life partners with our clients to deliver an independent, third party prospective on the risk associated with an asset (or group of assets). Our Reliability Specialists assist customers in identifying the most critical assets to a site or process using a risk-based model that incorporates the potential impact on people, production, environment and reputation. Total risk, once assessed, is used to drive asset maintenance strategy.
This exercise will assist the customer in determining the right spare parts to stock in the right quantity. This can be accomplished on a single asset or a group of assets. Factors such as demand rate, carrying cost, and ordering cost can be used to calculate economic order quantities. The end result will be a reduction in parts that are overstocked, and elimination of dead stock items.
This exercise can have a significant impact on the bottom line while ensuring the right parts and tools are available when needed.
Failure Mode and Effects Analysis is a step-by-step approach for identifying the ways an asset or process can fail. The process utilizes a cross-functional team with knowledge about the process, asset or service. Once the team is assembled, the scope for the FMEA must be defined, the team must address the following questions for each asset or process under consideration:
- What are the functions of the asset (in line with the scope)
- How can each function fail to meet a required standard of performance?
- What scenarios can lead to those failures?
- What are the consequences of those failures?
- How serious are those consequences?
- How often will they occur?
- Can they be predicted?
- What is the associated risk with those failures?
Fluid Life will facilitate and contribute to the RCA process. Root Cause Analysis is an approach for identifying the underlying (“root”) cause(s) of an incident such as equipment failure after it has occurred. Usually employed when something goes wrong, it can also be used to identify what led to something going right so it may be duplicated in the future. Fluid Life’s Reliability Specialists are trained to employ different techniques to assist our customers in determining what the problem was and why it happened, determined by the loss potential of the incident.
Three service levels (Minor, Moderate & Severe) are available depending on the nature of the incident and the customers desired output. Fluid Life’s Reliability Sales Specialists work with customers to help determine which service level is right for them.
- Determine the loss potential – calibrate the RCA effort and process to the incident
- Consult the corporate risk matrix to validate the recommended effort
- Secure the scene (if appropriate) and gather initial data (pictures, statements, parts)
- Select the team of personnel to conduct the investigation
- Choose the right RCA tool to conduct the analysis
- Gather evidence (inspection results, maintenance histories, personnel interviews)
- Complete the study
- Compile the results and summarize the findings
- Present findings to relevant parties to prevent the incident from re-occurring
- Report of corrective actions with clear actions, owners, and due dates
- Failure timeline and RCA methodology output
- Summarized learnings in an incident report that can be shared (if appropriate) that describes the impact of the failure to production, people, environment, reputation, or other criteria that are relevant to the customer
1. Vibration Analysis Program Audit
Gain significant value by conducting an independent audit of your existing Vibration Analysis Program. Our audits are a cost-effective review of your program’s current operations to ensure that gaps are closed and value is maximized. The consequences of programs that are not optimized range from downtime to significant safety issues – bottom line, lost production and productivity. At Fluid Life, customers who take action based on our audits get their CBM programs back on track without any major downtime.
- Program improvement
- Gaps identification
- Data collection points consolidation
- Measurement route reviews
- Parametric measurements optimization
- Database enhancement
2. Vibration Analysis Program Setup
A comprehensive Vibration Analysis Program is not only designed for data collection and analysis, it is also meant to deliver on set maintenance objectives and provide an excellent return on investment (ROI). At Fluid Life, we have the expertise to set up an efficient program that is specifically tailored to meet your overall organizational goals and deliver real results with respect to ROI.
- Criticality Assessment
- Machinery Data gathering and Database Layout
- Database Design and Parametric Setup
- Steel ID Tagging of Data Collection Points for repeatability of data
- Hard-wiring of necessary and required machinery
- Route Setup, Communication and Testing
- Data Collection
- Data Analysis and Reporting
- Routine Data Collection, Analysis and Reporting Deployment
- KPI and Metrics Determination
- Training and Knowledge Transfer Orientation
3. Ad-Hoc Machinery Vibration Surveys & Analysis
Do you need a one-off machinery vibration survey and analysis of all the rotating equipment in your plant even without having a routine vibration analysis program in place? Or do you need to know the signature (not just overall readings) of your newly overhauled piece of critical machinery? Here at Fluid Life we have a flexible structure to accommodate your requirements and provide value to your overall objectives.
What it entails:
This service is designed for a one-off ad-hoc request to carry out a vibration survey and analysis on any machinery or group of machines that requires the attention of our professional engineers and specialists. We have helped customers to rightly reject overhauls from third party shops based on the supporting data. Other customers have benefited from our ad-hoc call-outs to be able to gain a quick insight into machinery repair prioritization for up-coming scheduled Turn-Around (TAR) Maintenance operations. Take advantage of our expertise and do not leave your machinery without a data capture event before and after an overhaul.
Contact us if interested in one of our vibration analysis services or speak directly to one of our sales representatives for more information.