I-CARE services portfolio by I-care

SERVICES PORTFOLIO

Improve your maintenance thanks to I-care: Make sure that you comply with international standards (FDA, ISO, WANO etc.) Reduce non-scheduled shut-downs/Optimise scheduled shut-downs Decrease your environmental and safety risks Reduce your maintenance costs

Excellence in reliability Support Stock optimisation Energy Efficiency TPM & improvement in OEE Reliability engineering Long-term operation Excellent lubrication CMMS/EAM Training

I-care works every day in partnership with all types of industries: Process: pharmaceutical, chemical, petrochemical and food Energy: nuclear, cogeneration, wind power Extraction: cement and quarrying OEM: machine manufacturers ... What are the guarantees of success with I-care? European Leader with a presence in 7 countries, more than 60 engineers and 70 partners guaranteeing you local implementation of global maintenance. Sharing of experience and references with more than 100 satisfied customers Technical excellence gained over more than 10 years of industrial success Measurement and taking account of your returns on investment In short, I-care means proven industrial results!

I-care Headquarters Equipment in service Corrective actions Commissioning Expert Reports Support Training Products

Rue R. Descartes 18 7000 Mons - Belgium T. +32 (0)65 45 72 14 BE@icareweb.com

PART 1: CONDITION MONITORING 1. EQUIPMENT IN SERVICE...........................................................................................6 Periodic vibration measurements...............................................................................................7 Thermographic Controls - Qualitative measurements..............................................8 Leak Detection...........................................................................................................................................9 Remote analysis - Route Measurement...............................................................................10 Remote analysis â&#x20AC;&#x201C; Online measurement..............................................................................11 Oil Analysis......................................................................................................................................................12

2. CORRECTIVE ACTIONS...............................................................................................14 Balancing ........................................................................................................................................................15 Laser Alignment .......................................................................................................................................16

3. COMMISSIONING.......................................................................................................18 Before start-up...........................................................................................................................................19 During start-up...........................................................................................................................................20 Checks on systems under vacuum or under pressure...........................................21

4. EXPERT REPORTS......................................................................................................22 Identifying the root causes of failure ....................................................................................23

5. PRODUCTS ...................................................................................................................24 6. TRAINING .......................................................................................................................25

PART 2: RELIABILITY 1. RELIABILITY EXCELLENCE .....................................................................................28 Reliability Excellence...............................................................................................................................29 Reliability audit...........................................................................................................................................30 Project Management for reliability............................................................................................31 Creation/optimisation of maintenance plan.....................................................................32 Criticality analysis.....................................................................................................................................33 Integrating predictive maintenance...........................................................................................34 Planning and workload.........................................................................................................................35

2. SUPPORT.........................................................................................................................36 Planner, scheduler ...................................................................................................................................37

3. INVENTORY OPTIMISATION..................................................................................38 Inventory audit ..........................................................................................................................................39 Inventory definition and optimisation ...................................................................................40

4. ENERGY EFFICIENCY ................................................................................................42 Energy audit & mapping.....................................................................................................................43 Studying improvements ....................................................................................................................44

5. TPM AND IMPROVING OEE .................................................................................46 OEE.......................................................................................................................................................................47

6. RELIABILITY ENGINEERING ....................................................................................48 ROMSI ..............................................................................................................................................................49 FMECA...............................................................................................................................................................50

7. LONG TERM OPERATION........................................................................................52 Long term operation..............................................................................................................................53

8. LUBRICATION EXCELLENCE...................................................................................54 Lubrication audit.......................................................................................................................................55 Setting up a lubrication plan..........................................................................................................56

9. CMMS/EAM ................................................................................................................58 CMMS Audit.................................................................................................................................................59

10. TRAINING........................................................................................................................60

APPROACHES Whatever the technology, or the type of project chosen, our entire team of engineers is here for you.

We take on full responsibility for all actions

Do it for you

We are self-sufficient in all our techniques and methods We communicate regularly on actions and results We work in compliance with quality standards and in complete safety

We are a day-to-day partner within your teams We adapt day-to-day to your environment We apply our or your methods with you We transfer techniques methods to you naturally

Do it with you

and

We guide and advise you in the application of methods and techniques

Drive you to do it

We train you to implement them in the most appropriate manner We help you at all operational and strategic levels We support you on an ad hoc or continuous basis

PART 1

Eq ui pm en Co t in rre se ct rv iv ice e Co a ct m io m ns iss io Ex ni pe ng rt Re Su po pp rt s or t Tr ai ni ng Pr od uc ts

CONDITION MONITORING 1. Design 2. Commissioning 3. Routine 4. Ageing Vibration Analysis Thermographic controls Leak detection Steam trap operation analysis Remote analysis/On-line Oil Analysis Electrical measurements Combustion engine measurements Balancing Laser alignment Checks on systems under vacuum or under pressure Fault diagnosis Search for root causes of failure Modal Analysis/ODS

Main Category

Condition Monitoring

EQUIPMENT IN SERVICE

PERIODIC VIBRATION MEASUREMENTS THERMOGRAPHIC CONTROLS - QUALITATIVE MEASUREMENTS LEAK DETECTION REMOTE ANALYSIS - ROUTE MEASUREMENT REMOTE ANALYSIS - ONLINE MEASUREMENT OIL ANALYSIS

Periodic vibration measurements CONTEXT Detection of failures before they occur Avoids unscheduled shutdowns Ensures equipment reliability Identification of a problem and location on the equipment Priority definition for each default

OUR METHOD Use of expert equipment with customised configuration optimised for each facility Continuous professional training of our engineers Use of PeakVueâ&#x201E;˘ patented technology enabling detection of a fault 6 months before a failure occurs Periodic on-site measurements at least quarterly

DELIVERABLES A detailed report is submitted to the client with identification of each instance of vibration on the equipment A summary table is provided showing in order of priority each fault detected on an item of equipment together with the action to be taken in each case

Thermographic controls Qualitative measurements

CONTEXT Identify all instances of heat released within a process Leak detection in a steam circuit Damage to a bearing Electrical fault Operation of a steam trap

OUR METHOD Measurements of the heat emitted by any item of equipment using a thermographic camera Identification and location of occurrences Comparison of the equipment components to assess the seriousness

DELIVERABLES A detailed report with infrared and visible images of the occurrences is submitted with a description of the default, its location and level of importance A summary table of the faults is also provided showing the order of priority and the action to be taken in each case

Leak detection CONTEXT Detection of gas leaks Quantification of the volume leaking Determination of the annual financial loss

OUR METHOD Survey of the leak-tightness of circuits under pressure in service using ultrasound detection Survey of the leak-tightness of a system under vacuum using an ultrasound generator and detection system

DELIVERABLES A detailed report is submitted to the client in order to ensure correct operating conditions or, if applicable, to suggest improvements in order to maximise the service life of the equipment Identification on a data sheet of the sensitive points in the circuit Financial study in order to quantify the financial loss associated with the leaks

Remote analysis - Route measurement CONTEXT Provide an analysis with a high level of expertise and optimum responsiveness Help you when a peak load on your team occurs in the field Provide analysis support Systematic analysis

OUR METHOD Use of analysis software linked to your monitoring system (any brand) Remote spectrum analysis Precise fault diagnosis Priority definition for each faults depending on seriousness Use of a portal accessible to all and simple, efficient read-out of indicators and conclusions

DELIVERABLES Diagnosis within 24 hours Supply of effective, simplified indicators Summary table of the main faults and action to be taken in each case Supply of a detailed diagnosis illustrated with the main graphs for each item of equipment

Remote analysis â&#x20AC;&#x201C; Online measurement CONTEXT Ensure the monitoring of your critical equipment at any moment Provide an analysis with a high level of expertise and optimum reactivity Provide remote support to your maintenance teams

OUR METHOD Use of analysis software linked to your monitoring system (any brand) Supply, installation, configuration and implementation of a customised online solution Remote spectrum analysis Precise fault diagnosis Use of a portal accessible to all at any time Use of trends to provide simplified monitoring in the control room

DELIVERABLES Periodic measurements conducted on request Monitoring of trends Diagnosis of the fault when an alert level or alarm is triggered Diagnosis within 24 hours Supply of effective, simplified indicators Summary table of the main faults and action to be taken in respect of each machine Supply of a detailed diagnosis illustrated with the main graphs for each item of equipment

Oil Analysis CONTEXT Identification of anomalies appearing inside machines (wear and damage) Detection of contamination in the lubricant Definition of the chemical condition of your lubricant Plan the maintenance interventionwork as soon as possible

OUR METHOD Analysis and monitoring of the chemical properties of the lubricant (viscosity, dielectric, water, additives, type of oil, ...) Analysis and monitoring of the wear particles (number, size and type of wear particles) Analysis and monitoring of the external contaminants

DELIVERABLES Supply of a report with a table summarising the actions depending on the priorities Summary table of the main faults and action to be taken for each machine Supply of a detailed diagnosis illustrated with the main graphs for each item of equipment

NOTES

Condition Monitoring

CORRECTIVE ACTIONS

BALANCING LASER ALIGNMENT

Balancing CONTEXT Reduce the vibrations due to a problem of imbalance on the equipment Increase the lifetime of the equipment Reduce in the electricity consumption

OUR METHOD Preliminary vibration measurement on the equipment Balancing of the machine using weights screwed on, welded on, etc. (depending on the features of the equipment) Acceptance measurement in order to verify the balancing

DELIVERABLES A detailed report is submitted to the client in order to ensure a reduction of the vibrations Service provided on site without moving the equipment

Laser alignment CONTEXT Reduce the vibrations and internal forces created by misalignment Prevent premature wear on the bearings and all mechanical components in the equipment Reduce energy consumption

OUR METHOD Prior vibration measurement on the equipment if possible High precision laser alignment of the equipment, whatever the configuration of the machine Elimination of angular and parallel misalignment using shims

DELIVERABLES A detailed report is submitted to the client in order to ensure elimination of the misalignment Energy savings and improved service life of the equipment

NOTES

Condition Monitoring

COMMISSIONING

BEFORE START-UP DURING START-UP CHECKS ON SYSTEMS UNDER VACUUM OR UNDER PRESSURE

Before start-up CONTEXT Ensure that the start-up conditions are correct and that the equipment will therefore work properly Check the equipment and register the guarantee of the equipment with the supplier or manufacturer

OUR METHOD Check the alignment of the moving parts Check the levelness and overall geometry of the equipment Check the balancing of the machine

During start-up CONTEXT Ensure that the start-up conditions are correct and that the equipment will therefore work properly Check the equipment and register the guarantee of the equipment with the supplier or manufacturer

OUR METHOD Vibration Analysis performed at start-up in order to ensure there is no prior fault Temporary continuous monitoring in order to ensure that the run-in curves are properly followed Thermographic monitoring to ensure that the equipment temperature rises correctly Check that the mechanical tolerances are complied with in operation

Checks on systems under vacuum or under pressure CONTEXT Ensure that the start-up conditions are correct and that the equipment will therefore work properly Check the equipment and register the guarantee of the equipment with the supplier or manufacturer Check the leak-tightness of the equipment

Condition Monitoring

EXPERT REPORTS

IDENTIFYING THE PRIMARY CAUSES OF FAILURE

Identifying the root causes of failure CONTEXT Identify the root cause of a fault causing a shut-down of the equipment Propose technical solutions in order to prevent new occurence of this fault

OUR METHOD Use of advanced mechanical diagnosis methods Visual analysis of the components Analysis of the occurrence and recurrence of the failures in the past Discussion with the various parties involved (users of the equipment, manufacturer, ...) Study of the loads and various parameters applied to the equipment

DELIVERABLES A detailed report is submitted to the client with identification of each fault and determination of the primary causes of this fault Clear and effective advice on preventing recurrence of the fault is provided in the report

Condition Monitoring

PRODUCTS

As l-care is above all a service company, we think it is important to give you the necessary tools to be able to optimise the use of the different predictive maintenance tools. For this reason, l-care is linked to the major manufacturers of equipment in these various fields in order to offer you the best, customised solution for each situation. Our company has a department dedicated to the supply of equipment and identification of the best technical solution depending on the specifics of each company and acting independently of the supplier. For further information, please consult our dedicated brochure, which is also available on our website. We also have a web platform dedicated to the supply of equipment where you will find all the information you require: www.conditionmonitoringtools.com. If you have a specific question or require a quotation, please contact us on +32 (0)65.45.72.14 or at the following email address: product@icareweb.com.

Condition Monitoring

TRAINING

In order to provide you with the tools and weapons necessary to confront the different problems associated with predictive maintenance and the optimisation of reliability, I-care has developed its own technical training programme. These training courses focus on different topics associated with such problems, with the aim of enabling you to become independent in one or more fields. For this reason, the training courses are delivered by l-care employees specialising in each field and working in it on a daily basis. Thanks to this approach the tools and advice provided are not simply theoretical, but also close to the reality on the ground in every type of industry. The courses are also suitable for any audience at all levels in the company. We can also provide you with a certificate of the completion of the course and an exam allowing you to be ISO certified in the case of some courses. Finally we can offer the course on your site, at your premises or at our premises if necessary. For further information please consult our training course brochure which contains details of all courses. Please also visit our dedicated website: www.reliabilityschool..eu or email us at training@icareweb.com.

NOTES

RELIABILITY

Re lia b Su ilit pp y E xc o el St rt le oc nc k e op En tim er isa gy tio TP Eff n ic M ie nc a y Re nd im lia pr b Lo ility ove m ng e en -t ng t in e in r Ex ee m O ce r op in EE lle g er nt at CM lu io b n M ric S/ at TR io EA n AI M NI NG

PART 2

1. Design 2. Commissioning 3. Routine 4. Ageing Project Management for reliability Reliability audit Creation/optimisation of maintenance plan Criticality analysis Integrating predictive maintenance Planning and workload Process operator, Scheduler Stock Audit Stock definition and optimisation Energy audit & mapping Study of energy improvements OEE SMED FOMSI FMECA Long-term operation Lubrication audit Lubrication plan CMMS audit Short-term

Medium-term

Long-term

Adaptable

Main Category

Reliability

RELIABILITY EXCELLENCE

RELIABILITY EXCELLENCE RELIABILITY AUDIT PROJECT MANAGEMENT FOR RELIABILITY CREATION/OPTIMISATION OF MAINTENANCE PLAN CRITICALITY ANALYSIS INTEGRATING PREDICTIVE MAINTENANCE PLANNING AND WORK LOAD

Reliability excellence CONTEXT Maintenance costs too high, not controlled Non-optimised maintenance strategy (too curative and/or too preventive) Very restrictive regulation (environment, GMP) Limited resources and a strongly anchored emergency culture Maintenance far from reality on the ground, few referenced parts Complex organisation (flow), multiple roles Reduction in technical knowledge of your facilities Difficulty in perpetuating the culture of continuous improvement

OUR METHOD

+ +

EVALUATION OF RELIABILITY CRITICALITY ANALYSIS BREAKDOWN RECURRENCE STUDY

+ + + +

FMECA OPTIMISED AND RATIONAL MAINTENANCE PLAN UP-TO-DATE PARTS LIST INTEGRATING PREDICTIVE

+ +

OPTIMISED SCHEDULING ACCORDING TO YOUR RESOURCES REDUCTION IN COSTS/ WORKLOAD

DELIVERABLES Criticality analysis

Identification of sources of waste/loss

Fault analysis

Dynamic vision of maintenance performance (KPI)

Definition/Revision of maintenance strategy Maintenance Plan that is consistent with the reality on the ground and high-performance Standardised maintenance procedures Rational integration of predictive maintenance Training/raising awareness of those involved

Planning of tasks and evaluation of the workload Analysis of costs and benefits of solutions put in place and potential investments

Reliability audit OBJECTIVES To establish the current reliability of the company Set goals that meet your reality Propose improvements that are easy to implement, with visible impact aimed at motivating staff to enter into a positive logic of change Target areas for improvements while remaining faithful to the context of the company

OUR METHOD Interview of the key players for reliability in your business Field Visits "How do I care?" questionnaire Flow Analysis

DELIVERABLES Summary report in the form of: star graph and axis scoring Presentation of results Complete Report including the definition of your goals and action plan

Project Management for reliability OBJECTIVES Assessment and definition of the framework of the project Constant knowledge of exact progress in terms of budget, time and quality Easy identification of progress and delay factors for the relevant actions Vision that is both global and specific for each task

OUR METHOD Standard on-line monitoring tool developed specifically for reliability improvement projects Simple and relevant KPI Action follow-up and report sheets, project logbook, time and coding sheets of hours worked

DELIVERABLES Structured, rapid and effective follow-up meetings for all levels of decision-making: start-up, weekly, monthly, closure Simple and clear meeting minutes

Creation/optimisation of maintenance plan OBJECTIVES To control all maintenance activities in their entirety or in one part of the plant in terms of keeping to schedule, skills and quality To best manage the work load and quality control of internal operations and contractors To ensure optimal machine availability rates To have an understanding of the means for obtaining good reliability and maintainability of my assets To control all spare parts and tools used for predictive and preventive maintenance To ensure consistency in preventive and predictive activities

OUR METHOD Functionnal analysis

Functionnal analysis

Strategic choice for MP

Walkthrough

MP Strategy adaptation

Sort regarding operation constraint

Input

Plant

Criticality analysis Customer standard library

Job Lists

Tasks Lists

CMMS/ tree structure

Optimisation

Technical analysis Methods/Tools

Existing documents (maintenance plan) Logbook of failures Manufacturer maintenance manual

Necessary Inputs Occurence- Recurrence analysis

Administrative and logistic constraints

Skills/Expertise

BOM

DELIVERABLES A complete list of preventive and predictive actions configured for each machine which warrants this (up to around forty parameters available) A database suitable for an introduction to the CMMS used A database suitable for calculating the workload, the creation of geo-round, etc. Standardised maintenance procedures Involvement of all key players in the industry with suitable communication (Time To Care !)

Criticality analysis OBJECTIVES What maintenance strategy should be applied to the assets and why? How can we get all those involved in the industry (safety, quality, production and maintenance) to adhere to the fundamental principles of maintenance operations? How do you define "the right maintenance" and avoid over- or under-maintenance? How can budgets/maintenance investment be justified technically?

OUR METHOD Scope (boundaries) deﬁnition

No Raw eqpt list

Establishment of the assets List/study level

Yes Deﬁned scope

PARAMETERS:

No Yes Assets List/ Study Level validation

Safety

Parameters/ scale deﬁnition

Environment

Yes Parameters/ scale validation

Quality

DELIVERABLES Mapping of all assets or families of assets through their intrinsic and/or operational criticality Well thought-through and objective study providing the argumentsneeded to support maintenance and investment strategies Proposal for definition thresholds of different maintenance strategies Controlling workload in light of increased risks in relation to threshold slippage

Criticality mapping of the plant/line/Building

Matrix Creation/Filling

Production

Results Review/formatting (Graph)

Maintenance

Results presentation

Business

Integrating predictive maintenance OBJECTIVES What set of assets is eligible for the integration of predictive maintenance? How can the best monitoring techniques/methods be selected? What about technical feasibility? How much will it cost? How much is this likely to yield? Is it profitable? How can the impact of short- and long-term integration of these new measures be measured? What are the flows necessary for using the data and the sustainability of the project?

OUR METHOD Criticality Analysis

Criticality Analysis

No Raw eqpt list

Yes Existence of a criticality analysis?

Establishment of the equipment list?

Technical faisability study

Equipment technology matrix

Economical faisability study

PDM Integration

Optimazed & predictive maintenance plan

ROI simulation

DELIVERABLES Controlling costs related to set-up in order to support the approach on an economic basis (CBA/ROI) A method for determining the application framework for predictive maintenance techniques on a technical basis (criticality, recurrence/occurrence of faults, FMECA) A complete structure of predictive actions configured for each machine which warrants this (equipment/technology matrix + flow of predictive maintenance integrated into the existing maintenance plan) A database suitable for an introduction to the relevant CMMS Involvement of all those involved in the industry with suitable communication

Planning and work load OBJECTIVES To quantify and organise your preventative and corrective maintenance interventions, major shut-downs, ... Plan your monthly, quarterly, yearly, etc Coordinate your maintenances with regard to production and other constraints Smooth out your workload per person, team, area, etc

OUR METHOD Data validation Analysis Method deﬁnition Customer’s needs identiﬁcation

Transposition Scheduling optimization

Validation meeting Implementation

DELIVERABLES Carefully designed micro- and macro-schedules A discussion medium for agreement between maintenance and production A visual tool that is flexible according to changes in technical and human constraints

Schedule overhaul

Smoothed organisation of your work load

Reliability

SUPPORT

PLANNER, SCHEDULER

Planner, Scheduler OBJECTIVES Managing daily maintenance activities Planning and preparation for periodic shut-downs

OUR METHOD Integration into your team of process operators/schedulers and your methods Autonomous replacement of your or your process operator(s) Adapting to your needs with input from our expertise, our external view, our precision and sense of priorities Use and mastery of tools for monitoring projects and the main CMMS

DELIVERABLES Receipt and prioritisation of work requests Creation and modification of work requests in the CMMS Processing of requests in order of work with allocation and planning of the task Analysis of the team's workload and monitoring of KPIs Creation and modification of the maintenance plan in the CMMS Managing how interventions run in collaboration with production Managing tooling and PPE, reserving and preparing parts Proposal requests and encoding of articles in the CMMS Orders and follow-up of parts and equipment Managing sub-contracting Carrying out site meetings, including the safety aspect Drawing up work permits

Reliability

INVENTORY OPTIMISATION

INVENTORY MANAGEMENT INVENTORY DEFINITION AND OPTIMISATION

Inventory management OBJECTIVES Establish the current level of inventory management of your business Identify opportunities for improvement in the management of inventories over different periods of time depending on your expectations: Short-term

Medium-term

Long-term

Organisation of the

Adaptation or carrying out facilities'

spare parts database

maintenance plans

Standardisation of spare part

Producing equipment

names

spare parts lists

Training

Organisation of the store

Definition of stock levels based on Setting up procedures and KPIs

Definition of stock levels based

the actual use of the

on the current situation and on

equipment (criticality, predictive,

an historical basis

preventive and curative maintenance, etc.)

Set realistic improvement goals in relation to your needs and your resources

OUR METHOD Interview based on quick questionnaires of the key players in the management of inventory in your company Field visit to your facilities and your storage areas Detailed analysis of stock management set up on a representative sample of your facilities

DELIVERABLES Summary report in the form of star diagrams and axis scoring Presentation of results Complete Report including the definition of your goals Proposal for an action plan including "Quick Wins" and specific actions

Inventory definition and optimisation OBJECTIVES Highlighting storage costs

Rationalisation of the quantities put into stock

Reduction in storage costs

Reduction in the risk of stock shortages

Improving store ergonomics

Improvement in picking time

OUR METHOD

Inventory Optimization

eh ar W

Or gan

Management ase tab Da

Res up ply

nt me e ag an M

ization

DELIVERABLE Organisation of the store Staff awareness-raising Structuring the tailored to needs

store

Improvement in ergonomics for the staff Establishment of a system forcontinuous monitoring of articles

Management of the database

Managing restocking

Highlighting duplicates

Optimisation of the quantities in stock according to the action needs of the company (existing maintenance plans, lists of spare parts for facilities, criticality, etc.)

Setting up a robust process for article creation

Anticipating consumption by studying previous consumption

Updating the database of articles (cost, deadlines) Standardisation of labels for existing articles

Supplier rationalisation

Setting up procedures suitable for the operation of the store Establishing KPI

NOTES

Reliability

ENERGY EFFICIENCY

ENERGY AUDIT & MAPPING STUDY OF IMPROVEMENTS

Audit and energy mapping OBJECTIVES To highlight the efforts needed to achieve a sufficient level of energy efficiency To highlight the distribution of energy consumption by energy vector and by equipment

OUR METHOD Energy performance questionnaire Detailed listing of the different energy vectors Quantification of consumption by vector Comparison of energy systems in relation to a benchmark threshold Energy Audit How: • From customer info (invoices, old readings) • From readings on site or ad hoc measurements

O U R

Energy Mapping

S T U D I E

How: • Monitoring from meters • Analysis of consumption graphs

DELIVERABLES Compressed Air

Electricity

Heat

Steam

Cold

Vector

Equipment

Costs (€/ year)

Steam

Steam Generator

43,800

Compressed Air

Compressor

...

Electricity

Engine

....

Building lamps

560.64

Chiller

....

Cold

Study of improvements OBJECTIVES Select, quantify and implement energy improvements

OUR METHOD Pre-requisite: audit results Identification of Quick Wins and long-term gains Feasibility Study Estimate of cost savings Estimate of investments Calculation of the return on investment

DELIVERABLES Overview of Quick Wins and long-term gains identified Costed returns on investment Technical monitoring of project implementation

Improvement

Equipment

Economy

Investment

RSI

Replace engine

Compressor, engine

x €/year

X’ €

X’’ Months

Regulation

Compressor, regulation

Y €/year

Y’ €

Y" Month

Insulate pipes

Pipes

Z €/year

Z’ €

Z" Month

Repair leaks

Leaks

ZZ €/year

ZZ’ €

ZZ" Month

NOTES

Reliability

TPM & IMPROVEMENT IN OEE

OEE

OEE CONTEXT Production line displaying: Micro-shutdowns or recurrent faults Too much scrap or products of lesser quality Repair service calls that are too long Little maintenance or monitoring Changes in size/production that are too long Unsuitable maintenance planning

OUR METHOD Batch 1

Batch 2

Batch 4

Batch 3

Batch 5

Continuous Improvement

Initial Situation: Determination/ Evaluation

OUR CONTRIBUTION: Analysis of OEE Choosing and setting up methods & tools Drawing up and submitting appropriate deliverables

YOUR REALITY:

Modification of working methods

Your goals:

Process control

Availability Performance

Increase in output

Quality

Final situation: Revision/ Improvement

Batch 1

Batch Batch 2 3

Batch 4

Batch 5

Batch 6

DELIVERABLES SMED: Reduction in the time to change over FMECA: Analysis of failure modes, their effects and their criticality 5S: Safety marking, labelling, organisation Maintenance Strategy: Predictive, preventive, scheduling, metering, etc Inventory Management: parts available in sufficient quantity Study linked to reliability: Machine Improvements

Batch 7

Batch 8

Reliability

RELIABILITY ENGINEERING

ROMSI FMECA

ROMSI OBJECTIVES Obtaining operational equipment right from commissioning Optimising availability (optimising time for service interventions & minimising faults) Risk reduction Improvement of organisation (Inspection & maintenance) Start-up Period

Overall Equipment Output

Objective

Reliable

Operable Functionality

Overall Equipment Output

Number of faults

Maintainable

Reliability in design

Ergonomics/Accessibility

Sure

Control of risks Integration of safety systems

Installation

R O M S I

Robustness/Quality

Reduction in the period for ramp-up

Overall Equipment Output

Objective

Inspectable

Overall Equipment Output

Number of faults

Installation

Readability

OUR METHOD Research & Engineering department/maintenance communication channel Anticipating maintenance in the specifications Integration of RAMS concepts (Safety and Availability through Reliability and Maintainability) ROMSI Evaluation Grid

DELIVERABLES Identifying weak points and strengths of the equipment Recommendations for control of maintenance Techno-economic analysis by recommendation Prioritisation ROMSI Evaluation Matrix

FMECA OBJECTIVES

ali ty

itic Cr

Adapt existing preventive and predictive maintenance tasks depending on the criticality of the failure modes

De te mo ction de

Ef f ec ts

Creation or improvement of a tailored maintenance plan

Fa i mo lure de

A N A L Y S I S O F F A U L T

OUR METHOD Functional breakdown of equipment Establishment of failure modes New equipment or existing equipment

Definition of the effects of failures Determination of fault detection modes

Appropriate maintenance plan and adjustment of preventive and predictive maintenance tasks

Definition of the criticality of failures

DELIVERABLES Better knowledge of failure modes, of their effect(s) and their criticality Tailored maintenance Improvement in maintenance time management Eradicating over-maintenance without incurring risks

NOTES

Reliability

LONG TERM OPERATION

Long term operation OBJECTIVES Short term Identification of wear mechanisms Optimisation of reliability Medium/Long term Extending the useful life of your facilities Increase in availability Optimising use (capacity factor)

OUR METHOD

•

Occurrence/Recurrence of faults

•

Change History

•

Statutory Inspections

Analysis of obsolescence

OUR METHOD

Analysis of aging

•

Technical records/Readings on site

•

Technology monitoring

•

Supplier contacts

Analysis of Capacity •

Current use

•

Potential for increase of use

•

OEE

DELIVERABLES Action plan: Changes to the equipment Update the maintenance plan Study of costs: ROI Definition of priorities according to business, quality, SSE and reliability criteria

Reliability

LUBRICATION EXCELLENCE

LUBRICATION AUDIT SETTING UP A LUBRICATION PLAN

Lubrication audit OBJECTIVES To establish the initial situation by measuring your ability with respect to good practice regarding the lubrication of machines To target areas for improvement while remaining faithful to the context of the company To set goals that meet your reality To propose improvements that are easy to implement, with visible impacts aimed at motivating staff to enter into a positive logic of change

OUR METHOD Field Visits Interview of the key players for reliability in your business "How do I care?" questionnaire in order to achieve a representative and reproducible assessment of your lubrication practices Flow Analysis

DELIVERABLES Report Measurement of the initial situation SWOT study Definition of objectives through areas for improvement List of actions Presentation of results Summary available in sheet form

CBA

Study of the costs and benefits of the implementation of the actions proposed in the report Definition of priorities

Action plan

Proposal for an action plan including "Quick Wins" and specific actions

Setting up a lubrication plan OBJECTIVES Increase the reliability and the lifetime of your machines Reduce costs by streamlining types of lubricants and their suppliers, and by controlling consumption Control the quality of food and non-food lubricants

OUR METHOD

PHASE 0

PHASE 1

Audit

Summary

PHASE 2

PHASE 3

PHASE 4

Setting up the plan

Storage of lubricants

Continuous Improvement and Training

DELIVERABLES Routes & schedules for Inspection

Oil Store •

• •

•

List of lubricants suitable for your needs Tailored to your consumption Equipped to cope with daily service interventions Designed to respect the environment including a lubricant recycling plan

• •

Inspection rounds Schedule of inspections/ lubrications

Procedures

•

Procedures for lubrication • Procedures for the management of the store (cleanliness, handling, etc.) and the oils • KPIs and continuous improvement process

Staff Training

• •

•

Lubrication procedures Procedures for the management of the store (cleanliness, handling, etc.) and the oils KPIs and continuous improvement process

NOTES

Reliability

CMMS/EAM

CMMS AUDIT

CMMS Audit OBJECTIVES Establish the initial situation by rebuilding your tools and maintenance management processes Identify the existing tools and processes which are computer-assisted Targeting areas for improvement to be followed in the creation of tools and processes and/ or in the implementation of the existing tools and processes in the system Know the extent of the possibilities of your CMMS tool and optimise its use Set realistic improvement goals in relation to your needs and your resources

OUR METHOD Inspection of your facilities Interview based on quick questionnaires of the key players in your technical department and specifically data, encoding and documentation managers Detailed analysis of your processes and the use made of them in your CMMS tool according to 13 major work areas

DELIVERABLES Summary report in the form of spider graphs and area grading in two views: existing processes and computer management Proposal for optimal use of your CMMS, regardless of its brand Presentation of results Complete report including the definition of your goals and action plan

Reliability

TRAINING

NOTES

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