Maintenance Technology August 2017 - 12

PLANT PROFILE

Above. The Y-12 site houses many facility types, including some areas with gloveboxes.
Right. In the early days, as it is today, maintaining building and process support systems
was just as important as the process itself. In this photo, two men work on converter
motors in Beta 3 while two others observe.

that have to be done here. So it's not just a
single process."

Pursuing world-class reliability
With a commitment to reliability and
with corporate support, Y-12 commissioned the Univ. of Tennessee's Reliability
and Maintainability Center (UTRMC)
to perform benchmark assessments.
The next step was building pillars for
the foundation of an overall reliability
program. This included plans for an
improved culture, PM optimization,
training and education, full utilization
of technology and software, increased
ratio of proactive to reactive maintenance, continuous-improvement plans,
scheduling improvements, and employee
retention.
The UTRMC provided a subjectmatter-expert (SME) analysis of the
current state of the Integrated Work
Control (IWC) and Maintenance
Execution processes. The evaluation
consisted of site visits and evaluations of
the essential elements including:
■ synchronization of production, engineering, and maintenance reliability
improvement efforts
■ targeted opportunities for
improvement
■ plant employee training opportunities
■ methodology for transitioning plant
personnel from tactical (reactive)
maintenance
■ methodologies to a strategic posture
■ development of a reliability-based
plant culture.
"We talk a lot about the ratios between

12 |

MAINTENANCE TECHNOLOGY

how many corrective maintenance jobs
to do and how many things we do that
are proactive," Boudreaux said. "When
you look at Y-12, you can't just look at
that globally. You have to look at the
individual component. If you would
take a step back, we are a very reactive
maintenance organization. So what we
have done over the past few years is try
to turn that from a very reactive program
into a proactive program. A lot of things
we are seeing are all these unplanned
failures. And honestly, maintenance has
become very, very good at firefighting.
But it is very, very expensive to do that."
The pursuit for world-class reliability
has been a slow but fruitful process.
"The way that our program was set
up, we feel like we have turned the big
battleship," Boudreaux said. "It's a big
ship and requires a slow move to get it
to turn that corner. One way to be more
cost effective is to decrease the amount of
corrective work that we do. How do we
do that? We reinvest in the plant. We get
new equipment, and we maintain it the
way we are supposed to, but we also look
at the equipment that we have and ask
what we can do to increase the reliability
of those assets. We know that doing
preventive maintenance is safer, but we
can also save costs this way."
One huge early success has been
optimization of the PM program.
"We have increased the interaction of
our crafts with the development of our
packages," Boudreaux explained. "By
going through our PM Optimization
(PMO) process, we now have more thor-

ough documentation and better estimates
of the time and resources required for
each PM. We can now identify the costs
and the benefits."
The next step is communication.
"It hasn't been a difficult sale because
very few people would drive a car for
two years and never change the oil,"
Boudreaux explained. "A robust PM
program just makes good sense. And
we now have documentation that clearly
lays out the tenants of reliability. We now
have a road map that explains what we
have done and what we should be doing
over the next few years. Part of the plan
is to ensure this plan is communicated to
everyone in the plant."
Communication helps to provide
influence within the organization.
"Paul's [Durko] responsibility is to
influence the maintenance craft, for
example," Boudreaux said. "He works
with the maintenance manager and
his maintenance-execution team. He is
arranging for additional training to help
improve skills and capacity. With great
communication and influence, we can
produce a better-quality product for our
customer. The road map shows how
everything fits together for the future."
One of Y-12's core missions-
maintaining the safety, security, and
effectiveness of the U.S. nuclear weapons
stockpile-translates into the overall
reliability mission.
"If you want to think of similarities,
AUGUST 2017



Table of Contents for the Digital Edition of Maintenance Technology August 2017

Editorial
Uptime
On The Floor
Reliable Security, Reliable Operations
Highly Charged Reliability
Drowning in Data? Look to the 'Stars'
Reliable Pumping Supplement
SAP: Tips and Tricks
Steam-Trap Inspections
Saving Tribal Knowledge
Seats for Butterfly Valves
IIoT
ISO 55000
Understand Lube ID Systems
Tomato Processor Boosts Steam Output, Cuts Emissions
Products
Ad Index
Showcase
Final Thought
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - Cover1
Maintenance Technology August 2017 - Cover2
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - 2
Maintenance Technology August 2017 - 3
Maintenance Technology August 2017 - Editorial
Maintenance Technology August 2017 - 5
Maintenance Technology August 2017 - Uptime
Maintenance Technology August 2017 - 7
Maintenance Technology August 2017 - On The Floor
Maintenance Technology August 2017 - 9
Maintenance Technology August 2017 - Reliable Security, Reliable Operations
Maintenance Technology August 2017 - 11
Maintenance Technology August 2017 - 12
Maintenance Technology August 2017 - 13
Maintenance Technology August 2017 - 14
Maintenance Technology August 2017 - 15
Maintenance Technology August 2017 - Highly Charged Reliability
Maintenance Technology August 2017 - 17
Maintenance Technology August 2017 - 18
Maintenance Technology August 2017 - Drowning in Data? Look to the 'Stars'
Maintenance Technology August 2017 - 20
Maintenance Technology August 2017 - 21
Maintenance Technology August 2017 - 22
Maintenance Technology August 2017 - Reliable Pumping Supplement
Maintenance Technology August 2017 - 24
Maintenance Technology August 2017 - 25
Maintenance Technology August 2017 - 26
Maintenance Technology August 2017 - 27
Maintenance Technology August 2017 - 28
Maintenance Technology August 2017 - 29
Maintenance Technology August 2017 - 30
Maintenance Technology August 2017 - SAP: Tips and Tricks
Maintenance Technology August 2017 - Steam-Trap Inspections
Maintenance Technology August 2017 - Saving Tribal Knowledge
Maintenance Technology August 2017 - Seats for Butterfly Valves
Maintenance Technology August 2017 - IIoT
Maintenance Technology August 2017 - ISO 55000
Maintenance Technology August 2017 - Understand Lube ID Systems
Maintenance Technology August 2017 - 38
Maintenance Technology August 2017 - 39
Maintenance Technology August 2017 - Tomato Processor Boosts Steam Output, Cuts Emissions
Maintenance Technology August 2017 - 41
Maintenance Technology August 2017 - 42
Maintenance Technology August 2017 - Products
Maintenance Technology August 2017 - 44
Maintenance Technology August 2017 - 45
Maintenance Technology August 2017 - Ad Index
Maintenance Technology August 2017 - Showcase
Maintenance Technology August 2017 - Final Thought
Maintenance Technology August 2017 - Cover3
Maintenance Technology August 2017 - Cover4
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