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.