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Issue No. 28 - August 2009 |
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Since establishing this website last May of 2007, I have made many efforts to improve this site and provide some useful insights about our common link which is all about improving our equipment reliability and the way we do maintenance.
Finally should you be interested to contribute to our articles section or share any feedback, I encourage you to email me Click here to email me. If for any reason you wish to unsubscribe from our newsletter, kindly send my a blank email with unsubscribe as the heading and we shall remove you from our mailing lists. Once again welcome to our August 2009 edition of our Monthly Reliability Newsletter for this year 2009 and I hope that you enjoy reading and sharing with your people.
My Warm Regards,
Website : www.rsareliaiblity.com Inspired by Change . . . |
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By Rolly Angeles
Our previous July 2009 Newsletter covers the first part of a series of 2 parts and discuss the 7 basic questions on RCM. This second part will unveil if an eight question is required in the RCM process.
First let me start on how I started my involvement with RCM. 10 years ago, in September 1999, me and two of my colleagues at work attended a three day Public RCM Class in my country. After the training, I spend a great amount of time studying and researching this topic. My interest in RCM was overwhelming and finally, I develop my own training materials on RCM. I created three prototype teams two from operations and one team from the Facilities/Utilities section to undergo the RCM analysis. The team was carefully selected with an incumbent operator from each team . Each team also comprise a maintenance manager in order to support this initiative. Finally on December 1999, I completed my materials and delivered a three day RCM Class for these three teams and the people that attended the training were convinced beyond a reasonable doubt that their current way of doing Preventive Maintenance was not solving their day to day maintenance problems and that RCM should be implemented. An RCM roadmap was develop in order for the teams to go through the RCM process step by step and the analysis began. They provided me a schedule of their meeting twice a week in which most cases I facilitated the meeting. Each meeting lasted from 2 and sometimes up to 4 hours. We follow the RCM process very carefully and finally completed the RCM Analysis. Each of the 3 teams had submitted to me the RCM Analysis Report which includes the RCM Information Worksheet and RCM Decision Worksheet. The report also contains a comparison regarding how much failure mode their current Preventive Maintenance tasks were addressing compared with their derived RCM Analysis Report.
My first RCM Class, myself at extreme right, December 15 to 17, 1999
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Finally, I am more than happy to announce the debut of my book on World Class Maintenance. This is not only a book about the technical jargon of reliability and maintenance, it is a book that makes every single maintenance feel proud that they belong to the maintenance function. If you have been living through the day to day pressures of doing maintenance then this is your story.
Currently this book is available only through my website and is on a Print on Demand Basis. If you are interested to have a copy of this book, kindly send me an email and we shall provide you with the details. For more info about this book, you may visit this link: http://www.rsareliability.com/wcmbook.htm
Foreword message of this book was written by my good friend C. Robert Nelms or Bob as we call him. Bob is the founder and President of Failsafe Network. I’m glad to say that he is also one of the subscribers on this newsletter. You can click on this short video I prepared to know more about him.
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RELIABILITY & MAINTENANCE CONSULTANCY FIRM
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Where the learning just never stops . . .
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RSA
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For our complete archive of previous reliability newsletter |
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Our newsletter will be sent out ones a month and provide you with quality issues and resources on our most common link which is all about reliability and maintenance, as well as regular updates about our site. I would like to personally invite you to regularly visit our website and check out updates on our articles and training courses. |
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Some say that changing culture should start from the top; others say it’s a bottom-up approach. There is no easy and conclusive answer to this but all I can say is that change is something that must start from within us. I think nobody says it better than the late “King of Pop”, Michael Jackson himself, that change must come from the man in the mirror.
I'm starting with the man in the mirror, I'm asking him to change his ways. And no message could have been any clearer, if you want to make the world a better place, take a look at yourself and then make that change, Michael Jackson
Extract from WCM Book page 47
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OPERATION OVERVIEW: Substation operates with out interruption. It is a stand alone equipment that operates without human intervention. Substation is equipped with monitoring instrument and protective devices that shuts off the unit and transfers power source to the generator automatically in case of circuit faults and power failure. Operator intervention being introduce intentionally during scheduled power transfer and preventive maintenance activities only. Raw power is obtained from MERALCO (Manila Electric Company), the power distributor of NPC ( National Power Corporation). An AVR (Auto Voltage Regulator) transformer with a variable ratio was used to maintain the line transmission voltage at 34.5 kilovolt (kV) , 3 phase , 60 hz . This voltage is being transmitted through a 3 phase high tension wires, # 4/0, bared, referred to as the transmission line. A Meralco power fuse (type S and C SM -300 E rating at 300 amp) is installed before plant load or primary side of the substation. It is used to disconnect any portion of a primary circuit in case of overload and broad range of primary side electrical faults. The fuses are the most weak spot in the circuit that is made up of a fusible metal having low melting characteristic which will melt at a rated temperature. Should there be an overload, the fuse melts as temperature increases from overload current, thus disconnecting the supplied power.
Rate of Breakdowns Occurrences on their 10 Substations before and after RCM Analysis
Quote from their Facilities Manager, “ The dramatic reduction in our breakdowns of our sub-stations have something to do with their RCM Analysis perform by this team and we commend them for their efforts. Later on, I found out that their Manager assigned them to do RCM Analysis in their AHU, Cooling towers and other equipment in their Facilities section.
Just recently, I conducted an in-house training on RCM. After the training ended they organized a short management presentation the following day in which their CEO, VP for Operations and all high ranking people in their organization were present. I delivered the RCM presentation for a couple of hours as well as answering questions that rise up from time to time from the management team. Finally when I ended the presentation, the CEO stand up and said “Just do it”. But up to this point in time, they have not started with their RCM Analysis even if their CEO had given the nod. Perhaps what he meant was Just do it after finishing priority no. 75 or just do it next year or just do it when you want to or if you have the time. Am I missing something here ?
Finally I am convince that with these experiences which I have shared with you, I hope you agree with me that there should be an eight question in the RCM process. And this must be answered even before doing any RCM Analysis in the first place and the eight question is “Are We Ready for the Change?” because if the plant or industry is not ready with the change then questions 1 to 7 in the RCM Analysis will be deemed useless in the first place and even if you hire the best RCM consultant in the planet. And so to wrap it up the Classical RCM 8 Questions are :
1. What are the functions and associated performance standards of the asset in its present operating context ? 2. In what ways does it fail to fulfill its functions ? 3. What causes each functional failures ? 4. What happens when each functional failure occurs ? 5. In what ways does each failure matter ? 6. What can be done to predict or prevent each failure ? 7. What should be done if a suitable proactive task cannot be found ? 8. Are we ready for the change ?
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My first RCM Class, myself at extreme right, December 15 to 17, 1999
I spend around 3 weeks checking each document averaging around 1 week per team to check how the process was done. I returned their documents with few corrections in which they immediately corrected. Finally, I gave the signal to them to carry out the implementation of the RCM Analysis. The two teams from operations were hesitant to change their PM Process simply because in order to change something you also need to revise the current specs they are using which were subject to approval from several people on the top. You see, everything we do in this plant are heavily documented and each have a corresponding specification number for PM. Finally the team told me to talk to their supervisor and so I went on and talk to their supervisor and discuss the implementation of the RCM Analysis. The supervisor shook his head and said that he cannot decide on this matter and instructed me to talk to their manager. This were the same managers who attended my RCM Class and so after talking to them, they said that they cannot decide on this matter and told me to talk to their Top Manager. And so I went on and talk to their Top Manager and told him that your team performed this analysis and have dramatically trimmed down all activities on maintenance done from 350 to 200 and this is some accomplishment they have made. The Top Manager told me that in order to comply with your RCM, he told me that this is what he is going to do. He will implement the RCM Analysis but the people still need to perform the current Preventive Maintenance activities in order to conform with the specs. My jaws dropped and told him that if we do them both simultaneously then it is like sweeping the floor to get rid of dirt and after cleaning it then we put dirt and trash on the floor once again. I told him that if you are going to implement RCM then you must drop whatever PM activities you are currently doing, since everything is already covered in the RCM Analysis. I left the room in dismayed. The same thing happened in the other team which is also from operations. Finally their leader approach me and told me that the added activities in their PM were a result of action items from meetings, Quality and Customer Audits throughout the time the machine was operating. In short the RCM Analysis of the two teams from operations were never implemented and I think the documents remain in their drawers.
The third team from Facilities and Utilities implemented the RCM Analysis and as the months passed they were all shocked with the results. After completing the RCM Analysis they implement it on their 10 substations. Their breakdowns from their substation were reduced dramatically just by implementing the RCM Process. A failure or breakdown on any of their 10 substation can paralyze more than a couple of hundred equipment in operations. |
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RCM Prototype Team from Facilities / Utilities Pilot RCM Equipment—Substation D & E |
RELIABILITY NEWSLETTER |
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RSA |
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Inspired by change |
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• Gallery: New pictures for 2011 added from the gallery portion. • Newsletter: Aug. 2011 Edition finally released to our subscribers. Email me if you want to subscribe to our Newsletter. • 2012 Training Schedule: If you are interested to attend in any of our public workshop and master class for 2012. Send us an email or register online. • WCM Book: If you’re interested in buying the book on World Class Maintenance, The 12 Disciplines. Send me an email to reserve. WCM Book is now available. Get your copy now. • In-house Training :Should your industry be interested for in-house trainings we are now accepting regular schedules for in-house training for both local and international countries on courses that we currently offered. Contact us |
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World Class Maintenance Management - The Twelve Disciplines Book is now available here. This is not only about the technical jargon on reliability and maintenance, it is a book that makes every single maintenance proud that they belong to the maintenance function. If you have been living through the day to day pressures of doing maintenance then this is your story. If you are interested in this book, send me an email. Click Here ! |
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Select the courses of your choice and it can be made available in CD . Click Here ! |
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We are very much flattered and humbled by your feedback and testimonies. Your messages are the main reason for allowing us to stay in this business. With all humility we say thank you and rest assure that we are continuously improving. Without your support in our training there won’t be us. Read More ! |
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• If your industry is interested to join and participate in any of our upcoming public training and workshop for this year 2012 you may send us an email or simply fill out the registration form provided on our schedule site. You may Click here to visit our schedule training for 2012 Schedule. |
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Our Reliability Newsletter will be provided once a month to our valued subscribers. It provides highlights as well as issues and lessons regarding our most common link which is all about improving the reliability of equipment. |
