Project Operation Readiness

Objective(s):

The goal here is to

• Clarify work order processes
• Establish SOPS (Standard Operation Procedures).
• Improve medium and long-term planning
• Build a collaborative relationship between engineering and production with the proper practical working tools.
• Identify and quantify the risks (financial, operational, safety, environment) from the use of those assets to deliver the business needs.
• Identify the needed controls, the plans and activities that are necessary and sufficient to mitigate those risks.
• Identify how the business develops the desired balance of cost, risk and performance, communicate those relationships.

Milestone(s):

• Basic building blocks created to manage the planned maintenance currently.
• Assessment of your plant assets and EAM.
• We will evaluate technical and non-technical aspects of your organisations asset management system.
• Creation of asset management framework-approved terms
  • Set principles for asset management within your organisation.
  • Create related models, strategies and standards for asset management within your organisation.

Method(s):

• FFP reliability will analyse your business needs and identify your objectives.
• Using a risk-based data-driven analytical, critical processes as per CAMA (Certified Asset Management Assessor) standards, we will develop an asset management action plan for your business.
• The use of ISO 31000 risk management tools and methodologies like FMECA, Hazard and operability study, human reliability analysis, LORA Six sigma, TPM, 5S, RAMS, Autonomous maintenance, RCM we guarantee better plant uptime and reduced costs.
• FFP reliability’s use of strategic road maps allows the achievement of reliability via a balance of cost, plant performance, risk and workforce as required by ISO 55000. This is done with the use of strategic planning tools
• Scheduling will be defined by the maintenance concept document which defines:
  • How operations, maintenance and spares support planning and execution and the integration.

In phase 1 the following reporting and tasks will be tailored to suit your business needs:

• EAM and Plant assessment/Audits/ ISO5500x
• Strategy, Policy and objective, Steering committees
• RACIs, Social systems, Skills Assessment on work force with training plans
• Health and safety compliance, KPIs, Goal alignment to AMS
• Asset performance analysis and improvement plans
• Business processes, Cost reports
• Asset register and criticality
• Work order identification, prioritisation, planning, scheduling, execution and review
• Material Management/Spare Parts Management
• Downtime Processes, Problem-solving entrenched
• EAM analysis and improvement
• Shutdowns /Outage

“We are what we repeatedly do. Excellence, then, is not an act, but a habit.” – Aristotle

Objective(s):

• Achieve AME/OE excellence

Method(s):

Holistic review of all the above phases implemented to audit how they are working in action.

Assessing the level of Inclusion across the disciplines/departments of control and automation, legal compliance, spares management, people development, engineering

Thus, allowing them to live the organisations vision, mission and uplift its values.

“By failing to prepare, you are preparing to fail.” ― Benjamin Franklin, Founding Father of the United States

Objective(s):

• Creation or adoption of proper tools to sustain the system is crucial and this creates a plant with engineering reliability.

Milestone(s):

• Proper tools to sustain the system are in place.

Method(s):

• RAM
• Equipment Standardization
• Life Cycle Analysis, Six Sigma, RCA, TOC, Affinity analysis, Barrier analysis
• Vendor Reliability Measures

Objective(s):

• Create understanding of your assets, costs and workforce and creating business processes/tools /business continuity plans to help empower the workforce to achieve better results
• Reduction in downtime and increased production
• Stores best practise program which includes a link to your site EAM (Enterprise Asset Management).

Milestone(s):

• Entrench EAM (Enterprise Asset Management)
• Adoption of reliability tools and processes

Method(s):

Use of our stores best practise program which includes link to your sites EAM (Enterprise Asset Management).

We entrench plant assets, value, operations and maintenance with the holistic, practical tools to enable better workforce productivity, resulting in increased reliability, reduced downtime and increased production.

This is also done by leveraging the following processes and tools:

• Preventative maintenance plans-RCM
• Asset Strategies and failure analysis
• Strategic planning tools of PESTEL analysis-birds eye view of environment while contemplating a project
• SWOT analysis
• Condition Monitoring -CBM best practise
• Lubrication best practises
• Autonomous/operator-based Maintenance – TPM, 5S, OEE
• Spare parts Optimisations- Bill of Materials, EOQ, best practises for your stores
• Craftsman skills development- RACI, Skills Matrix
• Equipment History analysis, – bathtub curve, reliability failure distribution, MTBF, MTTR, RBD
• Root Cause Problem elimination
• Maintenance Facilities
• Maintenance and Capital Budget Management
• Standard Work instructions/Business process on maintenance management and plant equipment and asset care

Have you ever asked:

• Is that performance report accurate?
• With C&A (Control and automation) being the heart and brain of most industrial sites, is C&A delivering reputable data?
• Do you have issues with Process control loops not keeping your products in spec?
• Analog inputs not making sense?
• Not enough alarms or too many false alarms?
• PLC network issues causing loss of productivity?
• Do you see the value of your EAM?
• Does the EAM reports link to your plant’s performance?

If not, we can assess and determine the areas of improvement needed to make the EAM a tool not a hurdle.

Objective(s):

• Improved user acceptance of performance data
• Making EAM a usable tool
• Stabilising and improving your assets, costs through workforce culture adjustments.

Milestone(s):

• Completion of EAM interfacing and integration
• Sustainable flow of reliable data
• Adoption of tools by workforce

Method(s):

• Together we can use the power of your SCADA, PLC and EAM system to track and inform you reliably, on key performance measures.
• we can assess and determine the areas of improvement needed to make the EAM a tool
• Introduce and/or optimise the following:
  • Craftsman skills flexibility, succession planning, training
  • Maintenance engineering and production operational integration
  • Benchmarking
  • Vendor/Contractor Management and reliability
  • Utilities optimisation
  • Early equipment management-projects onboarding of assets, processes.
  • Control and automation-process control optimisation
  • C & A standards.
  • Self-audits