Tag Archives: asset reliability

Taking on Root Cause Analysis with Preventive Maintenance Software

Preventive Maintenance Software Analysis

Whenever an organization has a major failure of any sort, the top priority is to recover from the immediate damage or problems. From there, the next step is to keep it from ever happening again. Root cause analysis is a vital corrective step, allowing you to identify where losses are taking place and how they can be mitigated to improve equipment reliability and performance.

Root cause analysis is a maintenance troubleshooting method that helps organizations identify and control the systemic causes of a maintenance problem. When you experience a problem, you have to start by asking why the problem occurred. You repeat this process until you uncover the underlying cause. Toyota made the “5 Whys” method of root cause analysis famous. This method involves asking, “Why did this happen?” repeatedly until the cause is determined. Then you can come up with a long-term corrective action that will fix the underlying issue.

It’s important to go beyond the lowest level root cause because you could experience similar breakdowns again in the future. A string of failures usually leads to the problem, so it’s necessary to find a solution at each level of a root cause analysis.

Data is the Key

In order to conduct an effective root cause analysis, data is vital. Indeed, the more data that is available from an unbiased source, the better the chances of identifying the appropriate root cause of any failure. Unfortunately, finding an unbiased source of data can be problematic, as all people are by definition biased from their experiences and perspective.

In the context of asset failure, this is where preventive maintenance software becomes invaluable. All the relevant data for a given asset or class of assets is an ad hoc report away. If it has been utilized properly, the preventive maintenance software will contain a complete history of the asset, as well as detail the maintenance that should have been completed on the asset, according to both industry standards and/or manufacturer suggestions. The information contained in a CMMS system can be leveraged to carry out a root cause analysis. The solution that results can then form part of the equipment knowledge base.

Providing a Platform for Informed Decision Making

The end goal of any root cause analysis is to identify the changes that need to be made. These changes generally flow into one or more of the following categories: people, processes, and technology.

  • People: It is possible that the appropriate processes were established to prevent this type of failure, and that the technology was correctly identifying steps to prevent the failure, but that one or more individuals did not follow through on the correct actions.
  • Processes: Conversely, the data provided from the preventive maintenance software could point out a flaw in the processes associated with preventive maintenance. For example, the software could exclude the maintenance profiles for certain asset classes, or maintenance technicians may be instructed to only follow the maintenance processes identified by the software instead of also applying their expertise.
  • Technology: While any CMMS software is only as good as the data entered into it, it is also possible that the preventive maintenance software was not functioning properly. Perhaps integration across the various systems was incorrectly applied, or your organization has simply outgrown the software.

The effectiveness of root cause analysis largely depends on the amount of time spent preparing for it by carrying out a thorough investigation, collecting sufficient evidence, identifying the correct team members, and properly planning a root cause analysis meeting with the right people involved. It is of utmost importance to gather and analyze all relevant data in order to determine which of these factors played a part in the failure.

Perform Root Cause Analysis with the Help of Preventive Maintenance Software

If you are looking to implement maintenance software in your organization, DPSI can help. We have been in the industry for nearly 30 years and have over 50,000 satisfied users in 50 countries.

Asset Criticality and Risk Ranking – Recorded Webinar

Wouldn’t it be useful to know precisely how much time and resource should be applied to each of your assets?  With Asset Criticality, organizations are able to rate assets to determine how critical each piece of equipment is to areas such as safety, product quality, customer issues, environmental issues, and production.

During this 40 minute recorded session, guest speaker Terry Harris from Reliable Process Solutions LLC provides an overview of Asset Criticality and Risk Ranking and discusses how to:

  1. Derive the criticality rating for each piece of equipment
  2. Understand which equipment is important and critical to the process
  3. Assign resources and time based on equipment criticality value

The Enterprise Energy Asset Management Benefits

Data gathered by companies from its energy systems will be used to analyze energy efficiency to help decision makers take action on improving its energy facilities and procedures. With the Climate Registry pressuring companies to reduce energy use, carbon emissions will be reduced to eventually help reduce global warming potential (GWP).

Facilities, companies, municipalities and organizations across North America, its’ states, provinces, territories and native sovereign nations, participate in a voluntary agreement. The Climate Registry works towards a common goal to identify, track and record greenhouse gas emissions. This is an ongoing effort to help in the reduction of global warming.

Emissions reporting is an important element included in the Climate Registry. The standardized procedure calls for companies to identify harmful emissions and to establish methods to manage them. Current and future greenhouse gas emissions can be managed, with the goal of reducing the company’s carbon footprint.

Within an electrical distribution grid, energy asset management covers all sources — distributed generation of energy, energy storage devices and renewable energy sources. As constant, real-time monitoring of indirect and direct sources is required, asset management software is indicated as these programs can best handle multiple sources and locations around the world.

In addition to tracking real-time energy use, greenhouse gas emissions from specific energy related assets can be tracked by efficient energy asset management. Included with this are HVAC systems, refrigeration, lighting, vehicle and transport, among many other types of equipment. Energy reduction efforts can be tracked in this way.

Protocols are provided by the Climate Registry to assist in energy asset management programs. These guidelines include an in-depth analysis of asset specific attributes linked to energy use. For a more accurate measure of harmful emission sources and energy sources, automated programs are highly recommended. The software programs can provide a greater oversight, and an hourly record of asset energy consumption.

Short and long-term objectives are defined through energy asset management with regards to energy consumption. Opportunistic areas are revealed and a plan of action can be put in place. Considering that energy is one of the top three largest operational expenses of any enterprise, any company’s goal would be to reduce energy risk and improve performance in its operations. Energy risk factors associated with design and operation can be identified as part of a comprehensive plan to manage all energy sources.

Elements which create practical opportunities for companies can be combined with any asset management program which can help monitor and save on energy use. Several things are achieved, including energy reduction, cost control and for all environmental health.

The Sustainability Resource Planning (SRP) platform delivers a broad range of enterprise solutions to over 40 global clients with a service network of over 7,500 consultants consisting of 65,000 application users. Verisae’s software manages, and monetizes energy costs and carbon emissions while providing a rapid ROI. Learn more at http://www.verisae.com/articles.

Author: Daniel Stouffer
Article Source: EzineArticles.com
Panasonic Lumix G2

Getting Lean with Better Performance Maintenance and Tracking

The best way to get fit and stay fit is to maintain an exercise regimen and eat less junk. The same is true for your plant and equipment. By implementing a planned maintenance program and identifying maintenance waste items, you can create an environment where lean maintenance and lean manufacturing coexist. In the long run, you could improve reliability, realize significant gains in process efficiencies, and reduce the costs of maintenance activities.

Read how one food and beverage manufacturer has done just that.

Have you implemented lean strategies to leverage the full value of your assets? What maintenance regimens do you have in place to address equipment and plant repairs? Are you implementing lean on the factory floor? We’d love to hear your thoughts and ideas. Please leave a comment to this post.

The Evolution of EAM: From a Preventive Maintenance to a Reliability Strategy

Guest post by Sylvelie Franke, Director Marketing, Strategic Solutions, Infor EAM

Asset management has been around for decades and is now considered a mature industry. But, that’s all changing with the evolution—transition, if you like—of the technology and the inclusion of energy, automation, and business intelligence (BI) to really have an impact on your operational, financial, and energy efficiency performance.

Infor’s John Murphy, director of Solutions Management, sat down with the editor from Manufacturing Business Technology in this interview to discuss the latest tools, technologies, and strategies that companies are implementing to get a holistic view of all of their assets and how they’re using this real-time information to manage their assets more efficiently.

“More and more of our customers are moving toward incorporating advanced reliability and risk management techniques,” said Murphy. “They are trying to make better use of real-time information, including energy usage, to help them understand the health and financial performance of equipment. Turning the wealth of real-time information into intelligence is not easy, but when done right provides companies with an accurate perspective on when the equipment performance is starting to degrade, so that they can respond at the right time.”

John also touches on asset management in the cloud, reliability, and mobile technology, and where maintenance management practices are heading in the future.

Read the entire article, “QA: The Latest Asset Management Strategies And Tools,” (Manufacturing Business Technology).