1.1 Managing the Maintenance Concepts
To manage the maintenance concepts it must be clear to all involved how a maintenance concept arises. Therefore a roadmap must be created in which all steps are given that are necessary in the standardised route to creation of a maintenance concept. If all steps are transparent and easily accessible for everybody the progress can be measured.
Acceptance matrix
When a new installation is built or a maintenance plan evaluated, all regions work according to the same sequence.
We start by setting the boundaries of all assets in an acceptance matrix. In this matrix an indication of acceptance of all company values is given.
Company values are set by management and are specific to every plant. The acceptation matrix is shown in Chapter 3.1.
Risk matrix
When the boundaries are set in the acceptance matrix a team must be formed to name all risks of the different assets in the plant. When the risks are named for all different assets the parameters needed for a risk matrix are appointed. For Evides Industriewater these parameters are:
- Failure mode
- Failure cause
- Failure type
- Mean time to failure
- Distribution
- Deviation
- Maintenance strategy
- Effect of maintenance
- Time to maintain
- Maintenance frequency
- Maintenance costs
Fig. 5.2, Risk Matrix (Vee Nayaran, 2004)
After the risk matrix has been drawn up, a well thought out maintenance plan can be made according to the philosophy of the company. For this plan it is necessary to know the critical assets and the time needed to repair these assets, as spare parts may be needed.
Solution for prioritization
Because Evides Industriewater consists of over 30 different plants in 6 different regions in the Benelux which are all separately run, but are also all in the running for improvement, a way of prioritizing the need for improvement must be developed. Therefore we made a shortlist of conditions which influence this need.
Fig. 5.3, Plant priority plan (PAS 55-1, 2008)
Each two letter code stands for a specific water treatment plant.
Now that all plants are prioritized as to the need for improvement a well thought out plan must be made so that all plants are evaluated in the same standardized way.
Solution for steps to be taken
If standardization is wanted all the steps for arriving at a maintenance plan must be recorded.
These steps are divided into four different phases.
- Asset data
- Risk analysis
- Maintenance management system
- Evaluation
Each of these phases must be divided into actions to be made.
For each plant these actions are standardized and recorded in the technical information system Livelink.
Fig. 5.4, Roadmap for a maintenance plan (Neefjes, 2014)
For every water treatment plant a list is made with the steps that have to be taken to come to an up-to-date maintenance plan.
In the link row there is a link to the official document involved.
All these steps are divided into the four phases of the complete plan.
This plan is the Evides Industriewater RBM plan.
An example of the end result, the maintenance plan, is shown in Appendix VI.
The KPI “managing the maintenance concepts” is measured in percentages.