Cinco passos para implementar um programa de manutenção preventiva eficaz
CategoriesAsset Management

Five steps to implement an efficient preventive maintenance program

What are the main objectives when implementing a preventive maintenance program? In general, it is finding ways of maximizing equipment’ shelf life, assuring their availability and reliability, preventing downtime, at the same time that keeps the maintenance costs under control. However, between the general concept and the implementation of the program, there is a big distance. Know what are the main steps to count on a preventive maintenance program that keeps the asset condition as close as possible to the original.

1 – Assess the condition of all your assets

In first place, it is necessary to know the asset and its criticality, assessing its actual condition, the effort to which it is submitted and the history, to set the probable time when the failure will happen. Of course, it is not possible to establish an exact date when an equipment will fail, but analyzing its performance you can reduce this probability previously programing the maintenance.

The survey of the real condition of the asset must identify and record:

  • Number of failures, number of small stops, work accidents rate, downtime cost
  • Equipment’s performance
  • Setting the failures level – progressive reduction of failures
  • Setting maintenance goals

2 – Start the elaboration of a preventive maintenance program

This plan will assure the continuous quality of all the services, preventing failures and improving the production cycle, analyzing the consequences of a failure, such as detecting this failure and with which antecedence this failure can be detected.

All the preventive maintenance program operations must meet 3 requirements – applicability, efficiency and profitability. An operation is applicable if it can be implemented, it is efficient if it reduces the failures index and it is profitable if it improves the production.

The maintenance periodicity must initially follow the manufacturer’s instructions, but adverse environmental conditions of use may interfere with the schedule.

The maintenance actions are divided in two types.

One is based on time, that foresees replacing or restoring, in previously established intervals, pieces and components presenting more chance of failure according to their time of use. Once the time limit was reached, these conditions are executed apart from the status of the part at the date of the replacement. However, the actions based on time will only be efficient when there is a relation between the age of the component or piece and its failure probability.

Another way of assessing the need of maintenance actions is the one based on the condition, which takes in to account the periodical inspections results. The analysis of the history of these inspections allows to detect failures and anomalies signs in pieces and compounds from all the machines and equipment. The objective is monitoring the possible failures and act before they happen.

3 – Document all the actions

All the actions of the preventive maintenance program must be documented so that they are easily understood, using more drawings and schemes instead of text. Make it very clear how and why the inspection must be performed.

Besides the step by step of the maintenance actions, the document must contain the following information:

  • Services to be performed
  • Date when the services will be performed
  • People in charge of the services execution (name, position, function and contact)
  • Risks involved in the tasks
  • Necessary resources for the services execution (spare parts, tools, materials)
  • How much time will be spent in each service?
  • Cost of each service, cost per unit and total cost
  • Necessary machines, devices and tools

4 – Program services in an automatic and optimized way

Integrate all the assets data (operation, failures, maintenances already performed) in a solution for the planning and programming optimization of maintenance services. The system must simultaneously analyze the production needs, the maintenance priorities, the planning guidelines and the use restrictions. From this information, the system provides a series of suggestions to optimize the programming and the execution of the services, contributing to reach the excellence in productivity, operational efficiency and safety.

5 – Register all the actions

Reports must be elaborated after each step of the preventive maintenance program and the information entered in the automatized planning system. These reports serve to analyze mistakes and successes, register replaced spare parts, expenses with spare parts, lubricants etc., and the average runtime of tasks execution.

Atech offers, through OKTO platform, a set of solutions turned to the asset management area able to understand companies from different sectors with dynamic tools, able to operate in a global level. One of these resources is the Solution for Maintenance Planning and Programming, providing an updated resources system, as well as the execution management of the most critical activities. Know more on Atech’s solutions for Asset Management and know how we can help you to manage assets in an efficient and reliable way.

ISO 55000: Como implementar a gestão de ativos na sua empresa
CategoriesAsset Management

ISO 55000: how to implement the asset management in your company

Launched in 2014, ISO 55000 series was considered a landmark in the history of asset management, setting a global standard that enables consistent and sustainable asset management over time, reducing costs with maintenance, downtime and increasing the operational effectiveness.

Besides ISO 55000, that presents the general concepts of asset management, two other standards – ISO 55001 e ISO 55002 – complete the series. The first one specifies the requirements to set, implement and maintain the asset management system of an organization, as long as the second one provides guidelines for the application of the system.

This set of standards will be the guidance for an efficient asset management, enabling the company to implement a systematic and coordinated process to manage in an optimized and sustainable way its assets, assets systems, performance, risks and life cycle.

The Asset Management System

The implementation of all elements of standard ISO 55000 follows a methodology and processes compounding the asset management system, providing an integrated structure establishing the critical connections among all the elements.

See the steps which are part of the implementation of an asset management system:

1 – Policy

It combines the publication of the asset management policy, statement that establishes the principles to be observed by the organization to align the management objectives with the business objectives.

2 – Objectives

The management objectives must be Specific, Measurable, Attainable, Realistic and Time-bound – the so called SMART objectives – assessing matters such as asset productivity; asset sustainability; compliance, life cycle and costs rationalization.

3 – Strategy

The strategy shows how the business objectives will be changed into asset management objectives, defining goals and deadlines that must be reached from the management activities.

4 – Documentation

All the assets management activities must be documented, including operational and maintenance plans, capital investment plans – revision, renovation, replacement and improvement – and resources. This document must be periodically revised to assure that all the objectives are aligned.

5 – Leadership

The Board of Directors must support and approve this asset management policy, setting its applicability and reach, deadline and responsibilities. This group must assign an employee to supervise the development, implementation, operation and continuous improvement of the asset management system, but the Board of Directors must keep being responsible by it.

6 – Planning

In this step, all the short and long-term risks and opportunities are assessed, and how the asset management is integrated to other business processes.

7 – Support

It identifies resources and people necessary to the operation, besides aiding on the commitment of all the collaborators and widening the communication and collaboration among different sectors of the company.

8 – Operation

It assesses the implementation, controls processes, monitors risks and supports the change management.

9 – Assessment

It identifies metrics to measure the financial performance of the asset management, performing audits.

10 – Improvement

It corrects the non-compliance and establishes continuous improvement practices.

Asset Management Benefits

The implementation of an asset management system based on ISO 55000 is a strategic decision to the company, balancing costs and risks and increasing the quality of the service and the operational cost. See some of the benefits that may be reached with the asset management implementation:

Improvement of the financial support: the improvement in the return of the investments and the costs reduction can be reached, preserving, at the same time, the value of the asset without sacrificing the short or long-term performance of the organizational objectives.

Best decisions of asset investment: it enables the organization to improve its decision making and efficiently balance the costs, risks, opportunities and performance

Management risk: reduction of financial losses, improving the mental health and the safety, goodwill and reputation, minimizing the environmental and social impacts, possibly resulting in reduced liabilities, such as insurance premiums, fines and penalties costs.

Services improvement and way out: assuring the assets performance can lead to services or products that consistently meet or surpass the clients’ and stakeholders’ expectations

Demonstration of social responsibility: improving the organization’s capacity for, as an example, reducing the emissions, preserving the resources and adapting to climate changes, allowing to demonstrate socially responsible business practices and ethical administration

To show the compliance: offering transparency in the compliance with the legal, statutory and regulatory requirements, as well as adhering to the standard asset management, policies and processes.

Better reputation: through the improvement of the customer’ and stakeholders’ satisfaction and increased reliance.

Improvement of the organizational sustainability: the efficient management of short and long-term effects, expenses and performance can improve the sustainability of the operations and the organization

Better efficiency and effectiveness: reviewing and improving processes, procedures and asset performance can improve the efficiency and effectiveness, as well as reaching the organizational objectives.

Atech, with decades of strategic and operational knowledge, developed a unique platform of Asset Management and Logistics – the set of solutions OKTO – that serves companies from many sectors. The Solution for the Strategic Asset Management Powered by Orion and API, developed in partnership with Compass, is part of OKTO, and it acts as a powerful consolidation and analysis tool, changing data into information to base the strategic decisions related to the asset management and aligned with ISO 55000 guidelines.

CategoriesAsset Management

Reliability: Understand why this is the new trend in the maintenance and production areas

The need of reliability in the facilities is not new, but the increase of issues related to the environment and safety are generating new needs to the industry. In this scenario, each time more companies are going beyond the statistics to improve their practices and their maintenance strategies, and the investment in reliability has been highlighted.

In Brazil, the industrial community has specially shown a strong interest in improving their maintenance strategies. This is visible by the fast growth of Abramam, a maintenance leader organization in Brazil, focused in helping to educate their members. Currently, it is among the most valuable maintenance corporations, including SMRP, in North America, and MESA, in Australia.

However, towards the reliability advances, the Brazilian organizations face a series of mistakes with regard to this concept and everything related to it. See next how this trend has created new perspectives with regard to asset management:

Reliability is Not Only About Eliminating Shutdowns

The best way of defining the reliability concept is how the probability of an asset or system failure in a given time under certain operation conditions. However, in many organizations this is wrongfully used, especially when we approach the failure concept.

Many people believe that failures are shutdowns only, i.e., when the equipment stop working. Accordingly, the organizations work with a series of mathematic formulas to establish the probability of an asset shutdown, not considering a series of other inefficiencies also considered as failures, such as slowness and safety issues, for instance.

An asset management with high reliability level considers as failures any problem affecting the equipment inefficiency, generating resources losses such as time and money, and contributing for possible damages to the company’s reputation. This includes, for example, a failure in an equipment that makes it unsafe to the environment and to the company’s employees.

Besides, when investing in reliability, there is a significant change in the way of approaching the reasons for the shutdown, which may happen for many reasons. A failure is not always caused by, for example, lack of periodical maintenance, such as lubrication, for example. Human failures, such as errors in the assembly, for example, are also causes that the managers must take into account and solve.

In other words, when adopting reliability practices in the maintenance strategies, the organizations can foresee not only the most “predictable” failures, caused by the use, but also specify items that fail due to improper facilities or other accidental damages, for example. This widens much more the industry capacity of acting with more safe and efficiency.

Mathematical Statistics Are Not Enough

Before this scenario, we see that a calculation that take into account only the use of equipment is not enough for guaranteeing more robust, efficient and safe maintenance strategies,

One of the most common mistakes related to the predictive analysis for programming the maintenance is that it is enough having the time average between the failures and occurrences. It is important to remember that this number is an average based on the failure concept associated to shutdowns and not to other problems that also interfere with the production efficiency. Besides, there is a big difference between probability and reality – because a failure is probable, it does not mean it will really happen.

The Asset Conditions is More Important than its Time of Use

For this reason, successful companies are engaged to incorporate maintenance strategies involving smart and modern monitoring systems, able to integrate data from different sources for assertively determining failures, not depending on estimations based on the time of use, and counting on real data of the asset condition.

These organizations have gone beyond the statistics, revising internal practices and developing strategic plans to establish a corporative view related to the reliability and to the good asset management.

Among the most successful tools for this there is the adoption of the reliability as a global concept instead of a practice to reduce the costs or downtime and an extensive use of performance metrics, as the use of the Replacement Asset Value – RAV – to reduce the maintenance costs.

Atech offers, through OKTO platform, a series of solutions for Asset Management integrating technology and decades of strategic and operational knowledge. Capable of operating globally, OKTO turns asset management more efficient and reliable, reducing the processes cycles and making easier the monitoring of the asset condition minute by minute.

Among these solutions there is Atech’s Asset Condition Monitoring, allowing the decision making during the production and maintenance, and the elimination of unnecessary preventive maintenances, reducing costs and speeding up the identification of problems that can affect the safety and efficiency. Know here OKTO’ solutions for the Asset Management area.

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