Plant Services - February 2008 - (Page 28)

ASSET MANAGER DMADV This version – define, measure, analyze, design and verify – applies to designing products or processes, or to an existing process that requires more than an incremental improvement. Define determines the design goals in light of customer demands and deliverables. Measure helps determine product, service and process characteristics, as defined by the internal or external customer. It uses actionable and quantifiable business specifications such as design failure mode effects analysis (DFMEA) as part of a reliability-centered maintenance program. It’s a risk assessment. Analyze is how you determine the design options that best meet customer needs while minimizing risk. Design brings out the optimal design alternative and provides design details. In some cases, simulation software provides an invaluable tool for fine-tuning designs. Verify is how you validate that the design delivers on quantifiable customer needs. Start with a pilot implementation. Use project-management and change-management techniques for increased stakeholder buy-in. Six Sigma and RCM Some assets don’t experience enough failures to warrant statistical analysis. Reliability-centered maintenance (RCM) provides an excellent substitute for traditional Six Sigma tools during the measure and analyze steps. RCM identifies what a system is supposed to do, how it might fail and the effect of a failure. Optimizing asset performance and reliability comes from understanding how to better manage the failure modes through more effective maintenance policies. These policies include some combination of failure-based, condition-based and use-based maintenance. Other key variables to consider are frequency and nature of inspections, and whether to perform a major or minor maintenance procedure at various degradation stages in the asset’s life. Six Sigma and CBM Condition-based maintenance (CBM) is an excellent tool for monitoring during the final step of both DMAIC and DMADV methodologies. CBM can trend data to ensure that a process remains in control, either through manual inspections or via online, real-time automation. For example, if vibration readings trend outside specification tolerances, taking action can avert a potentially catastrophic failure. RCM and root cause failure analysis (RCFA) can determine the appropriate frequency and nature of data collected. Role of the CMMS CBM, RCM and RCFA are sophisticated measurement and analysis tools available on the most advanced CMMS packages. However, even basic CMMS packages can be useful for collecting and analyzing Six Sigma data. For example, if the Six Sigma team wants to reduce scrap and rework, as well as improve process and machine capacity, the CMMS can track relevant metrics such as asset performance and reliability. In turn, problem, cause and action codes can be analyzed to determine maintenance-related factors affecting scrap levels, rework and process/machine capacity. The CMMS can then identify root causes for minimizing negative effects on asset performance and reliability, thereby meeting the goals of the Six Sigma project. Finally, the CMMS can be used to monitor the process during the control or verify steps of DMAIC or DMADV. (Editor’s note: The Plant Services CMMS/EAM Software Review, posted at www.PlantServices.com/cmms_review, provides a side-by-side comparison of more than a dozen popular software packages.) E-mail Contributing Editor David Berger, P.Eng., partner, Western Management Consultants, at david@wmc.on.ca. 28 www.PLANTSERVICES.com February 2008 http://www.PlantServices.com/cmms_review http://www.toppsproducts.com http://www.PLANTSERVICES.com

Table of Contents Feed for the Digital Edition of Plant Services - February 2008

Plant Services - February 2008 Contents From the Editor Letters The PS Files Up and Running Crisis Corner What Works Asset Manager: Why Six Sigma? Technology Toolbox: Ensuring a Calm Response Cover Story: Best Practices Awards Lubricants: A Slick Success Story Motors: Reliable Torque Compressors: Before You Call for Help Web Hunter: Exploiting Intellectual Capital In the Trenches Product Picks Classifieds Fast Facts Energy Expert: Energy, Climate and Food

Plant Services - February 2008

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