Euromaintenance 4.0 Antwerp 2018

On 24-27 September 2018 Euromaintenance 4.0 was organised by BEMAS Belgium.

Our share was a presentation about continuous improvement of Cost, Availability, Reliability and Effectiveness (C.A.R.E.) of production processes.

On this page we share with you some parts of the presentation.

  1. The efficiency of production sites is mostly influenced by failure behaviour.
  2. Failure behaviour is created by assets + procedures + people. Only maintaining assets is too traditional.
  3. Care about C.A.R.E. (Cost + Availability + Reliability + Effectiveness).
  4. Maintenance plans must cover the ACTUAL failure behaviour of assets.
  5. Actual failure behaviour is described in Object and Process FMEA’s / FMECA’s.
  6. Effectiveness of maintenance plans is measured with the key-performance indicator MPE (Maintenance Program Effectiveness).
  7. Dynamic pareto’s help focussing reliability departments.

Any production process is managed by a combination of people + procedures and processes (including assets). This means the efficiency and the failure behaviour is also influenced by people + procedures + processes (including assets).

Doing maintenance is influencing failure behaviour. Operating assets is also influencing failure behaviour. Maintenance plans should be developed using the ACTUAL failure behaviour. A maintenance plan based on old and not accurate failure behaviour will never be effective.

This ACTUAL failure behaviour is described in Object FME(C)A’s and/or Process FME(C)A’s. These FME(C)A’s are used to develop the maintenance concept. This is a concept and its not ready yet. The maintenance concept is a  theoretical list of maintenance tasks for each failure mode in the FME(C)A. This maintenance concept must be nested into a maintenance plan which is used to update the maintenance program in the CMMS.

Failure behaviour is influenced by many factors like:

  • type and quality of raw materials
  • knowledge of procedures
  • knowledge of the production process
  • junior / senior knowledge of how to deal with failure behaviour
  • assets
  • interaction between assets
  • weather, humidity, temperature
  • quality end product
  • large / small batches
  • packaging
  • rework

Maintenance Plans are never finished

Almost all production processes are being modified, which influences the failure behaviour continuously. Changing factors in the list above, means that dynamic production processes have dynamic failure behaviour. This means the FME(C)A’s should continuously be updated too. This means also the maintenance concept/plan/program must be maintained too.

These FME(C)A’s are important for continuous improvement. The letters FM (Failure Mode) is the most important part of the FME(C)A. The difference between describing failures or failure modes is like doing reliability management or wasting it. Many industrial FME(C)A’s are based on failures instead of failure modes. This will almost always result in low quality maintenance plans, because they do not cover the right actual failure behaviour.  That will result in higher costs, unplanned downtime, quality and lead time issues. Reliability Management always starts with getting the communication on the right level. Not understanding the terminology will result in bad FME(C)A’s and bad maintenance programs. The best Reliability Management implementation starts with training in the terminology, methodologies and how continuous improvement can be executed. We offer Level 1 and a Level 2 trainings to be able to do thing right from the start.

The Object FME(C)A is the fast and less thorough approach and should only be used on low critical systems.

The Process FMEA is a thorough, well defined, high quality FMEA which should be used together with the high quality maintenance decision strategy to develop the high quality maintenance concept/plan/program. The Process FMEA is used for high critical systems. It costs more time, but the quality is much higher and payback times are much better then using Object FME(C)A’s.

We advise using 2 or 3 different methodologies to develop maintenance concepts. Never use one approach.

  • Reliability-centred Maintenance for high critical systems
  • Object Driven Maintenance for medium critical systems
  • Quick Maintenance for low critical systems.

Many organisations combine QM with ODM, which is fine as long as the FME(C)A’s are continuously optimised using PDCA (Plan-Do-Check-Act) circles.

Taking care of continuous improvement is taking care of people who work in identical ways. Working in Excel  result in many mistakes, because the controls are not build in Excel. Using Reliability Software like DORA is a must. 

Any production site can start in Excel, but in time they do need a standardised approach to be able to accelerate the continuous improvements of C.A.R.E.

We thank BEMAS for organising this great Maintenance Conference.

Please contact us for more information.