Glen Fields Final Project Presentation What Sets CSI Apart Company Background Located in San Diego CA 5 Engineering Consultants Established in 2002 Specialize in Facility Assessment Strategy Development and Project Management GBA 573 Consultants How Projects Get Started Overview Project is to Perform an assessment at Disneyland Optimize Maintenance and Reliability Program Develop Customized Computer Reliability Software Program Install Wireless Sensors to Monitor Equipment Document Findings and Present to Management Deliverables Deliverables of the Project are Assessment and Benchmark prior to Project Implementation Equipment and Technology Matrix Microsoft Project Schedule Recommended Training Matrix Identification and Documentation of Park Goals for the Condition Monitoring Program Consultation of Work Flow Diagram for Optimized Implementation of Condition Monitoring Program Maintenance Optimization Work Process People Skills Technologies Work Execution Daily Running Maintenance 8 0 Work Execution Scheduled Qualification Work Close out 6 0 Inter Departmental Communication 5 0 4 0 Utilization World Class 7 0 Work Management Systems 3 0 2 0 Training Maint Diagnostics Technologies 1 0 0 0 Information Integration Tools Benchmarking Setting Goals Continuous Improvement Communication Mechanisms Accountability Global Metrics Organization Leadership Management Work Culture Work process Identify Issues That Affect Maintenance Work Process Capture As Is Work Process Develop To Be Work Process Diagram Work Processes The CMMS system is used to plan and schedule the work track machine history and to track cost and savings information Some of the key goals are prioritization of WO s elimination of unnecessary PM s and program justification A key role of the IT group is the identification of the criticality of plant machinery so the work can be prioritized Resources and technologies are assigned to plant assets based on equipment or systems importance to the production cycle Performance of critical equipment is tracked and reported Condition Monitoring plays a key role in acceptance and certification of plant equipment Formal processes have been established to insure PDM is used on new and reworked equipment incoming oils are inspected for quality IR is used before shutdowns and root cause studies are performed on all critical equipment failures Feedback loops are in place on all WO s and regular meetings are scheduled to discuss critical issues Quality and Reliability are a way of life not a periodic process Work Process Designed for Maintenance Optimization RM Equipment Failures Scheduled PM Tasks Maintenance Optimization PdM Equip Condition Directed Feedback PAM Root Cause Analysis Identifies Equip Condition What Work Execution Feedback Work Closeout Technology Identify Which Rides at Disneyland are Critical Based on the Criticality of the Ride Assign Monitoring Technology Integrate Information Into an Equipment and Technology Matrix Install Monitoring Sensors on Equipment Condition Based Maintenance Program Elements Periodic Diagnostic Data Diagnostic Process Data Maintenance Histories Records Data PDM Program ALERTING TRENDING ANALYSES COST BENEFIT RECOMMENDATIONS REPORTING Batch Testing Inspection Data Operator Log Data Design Historical Data Maintenance Planning Scheduling Engineering Maintenance Operations Technology Recommended Condition Monitoring Technologies Wireless Vibration Monitoring Sensors Wireless Lubrication Monitoring Sensors Infrared Thermography Equipment and Technology Matrix Circulating Water Pump 1A Circulating Water Pump 1B Circulating Water Pump Motor 1A Circulating Water Pump Motor 1B Hotwell Pump 1A Hotwell Pump 1B Hotwell Pump Motor 1A Hotwell Pump Motor 1B Pulverizer 1A Pulverizer 1B Pulverizer Motor 1A Pulverizer Motor 1B HP Boiler Feed Pump 1A HP Boiler Feed Pump 1B HP Boiler Feed Pump 1C HP Boiler Feed Pump 1A HP Boiler Feed Pump 1B HP Boiler Feed Pump 1C Forced Draft Fan 1A Forced Draft Fan 1B Forced Draft Fan Motor 1A Forced Draft Fan Motor 1B N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 N1 E N1 E N1 N1 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 N4 E12 N12 N12 E12 N12 N12 E E E E X X X X E2 E2 E2 E12 N12 N12 E12 N12 N12 X X X X X X X X X X X X X X X X X X E12 N12 N12 E12 N12 N12 E E E N12 N12 N12 N12 N12 N12 N12 N12 N12 X X X X X X X X X X X X X X N12 N12 N12 N12 X X X X X Equipment Owner DP AMPS X X X X E3 E3 E3 E3 Flow Temperature Pressure Disch Performance Broken Bar Detection Hi Pot Testing X X N3 N3 N2 N2 N2 N2 N2 N3 N3 N3 N3 N3 N3 N3 N3 N3 N3 Megger PI Mill Fineness Acoustic Leak Ultrasonics Water Chemistry Lube Oil Analysis Infrared Thermography On Line Vibration Component Description Vibration Periodic Process Data J Doe M Jones J Smith J Doe M Jones J Smith J Doe M Jones J Smith J Doe M Jones J Smith J Doe M Jones J Smith J Doe M Jones J Smith J Doe M Jones J Smith J Doe Work Culture and Management Continued Focus on Benchmarking Facility Establish Vision Identify Goals Establish Global Metrics SMART Specific Measurable Achievable Reasonable Timely Upper Management Visability Work Culture and Management Plant managers know the importance of program understand the financial impact invest in the people and technology and communicate regularly with the maintenance department A formalized plan for plant reliability has been established and the impacted Team members Performance measures are established tracked and reported on a regular basis All members of the Team are asset owners and the emphasis is on elimination of critical equipment failures Regular meetings are scheduled with all departments to communicate findings plan strategies look at WO optimization and to optimize resource utilization Work Teams are established to break down reporting barriers and equipment ownership is assigned at the crafts level to empower the resources People Skills Establishing and Understanding Roles and Responsibilities Developing and Maintaining Sponsorship Event Reporting Condition Assessment Reporting ROI Calculations Correlation of Technical Data Financial Aspects of Program Program Costs Product and Service Quantity Cost Per Device Cost Per Line Item Wireless Vibration 1000 Sensors and Transceivers Wireless Lubrication 500 Sensors and Transceivers Infrared 2 Thermography Equipment 100 100 000 50 25 000 Integrated Software Suite Labor Travel Report TOTAL COST 4 seats 25 000 100 000 NA NA 1 NA NA 15 000 60 000 5 0000 15 000 425 000