Asset criticality and Maintenance Strategy Review (Kimberly Clarke)
about the project
The client installed a new $40 million tissue machine along with its associated stock preparation, converting and packaging lines. As part of the installation project the development and delivery of a full reliability focused maintenance plan was required. Further deliverables included training, coaching and mentoring of the on-site maintenance practitioners in the new systems, processes and procedures along with the monitoring of program performance in the operational phase and performing program adjustment as required.
• Reviewed design documents, drawing and manuals for the complete production line. This enabled the development of a Master Equipment List and associated Asset Functional Hierarchy including all mechanical, electrical, instrumentation and control equipment down to lowest maintainable item level.
• Provided a criticality review of the master equipment lists and ranking of the assets’ criticality considering equipment failure modes, failure causes and failure effects, commercial integrity, product integrity, safety integrity, environmental integrity and equipment integrity based on FMECA/RCM principals. Where an intolerable business risk was identified, mitigating tasks were determined through a reliability decision process that focused on predictive and preventative techniques first and foremost. These agreed tasks were then assigned action owners and frequencies to allow the ready integration into the sites new maintenance management systems.
• Configured the master data for upload into the new CMMS.
• Provided on-going training, coaching and mentoring of site staff in the application of the maintenance strategies.
We produced a fully documented and installed reliability-focused maintenance plan for a major capital installation, ready to apply at handover and commissioning stage of the OPEX phase of ownership. Furthermore, we provided training and material to the maintenance teams with best practice maintenance management systems, processes and procedures at their disposal.
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