IMEC 2008

Workshops

Workshop 1: Value Driven Maintenance® Business Experience

The 'real life' maintenance game
Facilitated By: Guy Delahay, Mainnovation

Being responsible for maintenance or asset management performance is not the easiest job. Whether your equipment is old and worn out or brand new and state of the art, you will face technical challenges on a daily basis. Empowering your people, improving your work processes and leveraging your (IT) tools sounds good, but how to do it in the best way? How do the results achieved so far compare to other companies in our type of industry? Should we focus on more uptime or reduce costs? Which are the ‘buttons’ to press on and what results will they have? Which best practices and three-letter buzzwords are best to start with? If you are puzzling with the answers and really want to get grip on your maintenance performance, there is a good reason to participate in the Value Driven Maintenance® (VDM) Business Experience workshop.

Focused Maintenance Strategy
During this workshop, you and your team members will be invited to play the most inspiring maintenance game on today’s market. You will learn how to derive a focused strategy, deal with the demands of your CEO, how to read and analyze KPI benchmarking reports, which variables you can change over time and what effect they have on the KPI score. You will find out that you actually can monitor your strategy with a limited set of KPI’s, closely linked to each other and with a measurable impact on added value created for your business. So you will also experience the difference between value and non-value adding activities, best practices and decision making. Isn’t that what Lean Maintenance should be all about?

Like Real Life
This dedicated maintenance game has been played at maintenance events all over the world so there is a record performance to beat. It is dynamic like real life. Strategy and decisions of all the teams are entered in a simulation tool, so your competitors will affect your situation. The team that creates the most economic value after a number of playing rounds wins the prestigious VDM award.

Learning by doing
Needless to say it is fun to play! And we all know, learning by doing is more effective than just listening to a presentation. Actually the game is also perfectly suitable for in-company events to gain understanding why a way of working must be improved, or to change the way Production or Financial Management thinks about maintenance.

Building a coherent structure
To be able to play a simulation like this, there must be a strong (planning and control) methodology behind it. But that’s the case in real life maintenance improvement too. Or like Bengt Svensson, Maintenance Manager Volvo Cars Sweden, puts it: “Basically, VDM is to maintenance what Windows is to the computer, an operating system. The concept is built on a coherent structure that effectively interconnects a number of different working practices, processes and technologies. The basic idea is that maintenance must add value”.

VDM is not only about calculating the value potential of your maintenance situation to convince your Board. It also delivers the full toolset to implement the changes that will deliver the added value and monitor your improvements from year to year along the journey to world-class maintenance. If you finally want to get a grip on your maintenance performance, join us at IMEC 2008.

Workshop 2: Life Cycle Costing Decisions

Facilitated by: Dr. Ali Zuashkiani

In this workshop use of evidence-based decisions will be illustrated to:

Find the optimal time to retire a capital asset based on its life cycle costs
Forecast future operation, maintenance, and capital costs for a fleet of assets

Concepts of Life Cycle Costing (LCC) and its complement Life Cycle Profit (LCP) will be introduced. Then, cases where the objective is to minimize the average cost, maximize total discounted benefit, or where the equipments’ utilization is variable, will be considered. Problems of the following kinds will be addressed in this workshop:

Establishing the economic life of equipment that is utilized steadily each year
Establishing the economic life of an equipment that has a planned varying utilization, such as using new equipments for base load operations and using older equipments to meet peak demands
Deciding whether or not to replace present equipment with a technologically improved equipment, and if so, when
Deciding on the best action: repair (rebuild) versus replace
?Deciding how to track an individual piece of equipment and deciding when it should be replaced
Determining future operation and maintenance costs of a fleet of assets with different ages
Predicting the number of future required asset replacements

The applications of the models discussed in this workshop will be presented through some real-world case studies. At the end, software packages called AGE/CON for mobile equipment replacement decisions and PERDEC for fixed capital equipment decisions will be introduced, and the way to use them to solve real life problems will be demonstrated. Furthermore, another software package that can be used to predict future operation and maintenance costs will be displayed.

Workshop 3: PAS 55 — A Specification for Asset Management

Facilitated by: James Reyes-Picknell, Conscious Asset Management, and Bob Rose, ATCO

Are you getting the most from your physical assets?
Are they being managed cost effectively?
Does your maintenance group cooperate with engineering on new projects?
Can your customers always rely on top quality products produced on time?
Can you meet market demand?
Do you have trouble getting new plant and equipment commissioned?
Does it take months to get your new plant and facilities running smoothly?
Do you have all the parts, tools, test equipment, skills and documentation needed to start, run and repair your systems?
Do you take advantage of new projects to inject performance enhancements throughout your business?
Do your physical assets contribute to your public image in a positive way?
Do your financial managers and executives truly appreciate the value you add?

Workshop Objectives:

To show how conventional thinking is too narrow in focus to produce sustainable business benefit
To show the importance of asset management interfaces that are often ignored today
To demonstrate the benefit of managing assets vs. managing maintenance, engineering and reliability
To show the importance of thinking “life cycle” in all areas of your business
To present the world’s first and only specification for the optimized management of physical assets: PAS 55-1
To present the implementation guidelines for applying PAS 55-1
To present the competency requirements for the management of physical assets and infrastructure
To demonstrate the importance of PAS 55-1 in regulated industries such as utilities of all sorts
To demonstrate the value of PAS 55-1 in non-regulated industries
To introduce the first step in certification – the Asset Management assessment
To present an approach for implementing PAS 55-1 in your current business environment

Facilitators:

Don’t miss this opportunity to learn about PAS 55 from this combination of visionaries: consultant plus private sector regulated industry insider. James Reyes-Picknell is the author of the popular text, ‘Uptime – Strategies for Excellence in Maintenance Management’, 2nd edition (2006), President of Conscious Group Inc., and a forward thinking proponent of PAS 55. Bob Rose is presently the Supervising Engineer for Transmission Asset Management at ATCO Electric in Alberta. Bob is an industry leader in his drive to adopt PAS 55 at ATCO’s privately-owned operations to deal with increasingly stringent regulatory and often competing business requirements.

Workshop Content:

This one-day workshop will include mapping your asset management mindset (an exercise), discussion of today’s prevailing concepts, and group exercises. We will also address:

Battling business units
Why take a new approach? Why now?
- Why does it matter in regulated industries?
- Why does it matter in non-regulated industries?
PAS 55-1 – Its history and an overview of its underlying principles and concepts
- The 6 areas and 21 elements needed to optimize Asset Management
Application of PAS 55-1 (how to implement it)
Competency requirements for managing such a program
Getting certified to PAS 55-1

Workshop 4: Half-Day Making the First Step Count in the Reliability "Stairway to Heaven"

Facilitated by: Steve Murray, ABB Reliability Systems North America

Most maintenance and reliability professionals have seen some form of the hierarchy of maintenance methodologies, from reactive maintenance to lifecycle management, and recognize the need to scale this ladder. Most would agree that the first step is not only the most important as it signals the beginning of a structured reliability approach, but also the one holding the biggest overall financial opportunity.

Many practitioners make the mistake of adopting solutions that promise to climb this hierarchy too quickly, altering or even omitting steps. However, for many companies, a wide-ranging, overly ambitious approach is not the best solution, as there may be budget, personnel, experience or other limitations. For these companies, a streamlined approach to take the first step is the most effective method.

A reliability management program that provides manufacturers all they need to make this important first step can be gained through a combination of focused assessments, business processes that drive productivity and cost reduction targets, and a hosted reliability system operated by skilled professionals on the manufacturer's behalf.

This presentation will demonstrate the successful application of such an approach including an overview of the business process, an understanding of the underlying technology, and actual examples of this approach in a number of process and manufacturing industries.

Workshop 5: Half-Day Process of 3 Dimensional PMOptimization

Facilitated by: Ed Stanek Jr., LAI Reliability Inc.

The demand for greater asset reliability and cost reduction have most of us turning to our PM Programs. The challenge is what to do once you get there.

The few methods available to us either have us reaching out to our craftspeople for notes and feedback, or focus mainly on added reliability requiring extensive exercises while missing the hidden efficiency in the process.

3 Dimensional PMOptimization is a process which first opens capacity and elevates effectiveness through 1. Initial Optimization, and continues to dial in the process through an ongoing analysis of 2. PM Task Pass/Fail Analysis and 3. Equipment Reliability Analysis requiring a fraction of the time and resources of other methods.

Reduce PM Labor Hrs by 40%
Reduce Scheduled Downtime by 35%
Improve PM Coverage by 50%

This process fuses common sense, reliability disciplines, and automation to take the PM program to new levels.

In this exercise-based workshop you will:

Learn the process of 3 Dimensional PMOptimization
Work through the 14 opportunities found within each PM
Actually use data collected in the PM to Manage PM’s at a task level
Learn to partner with existing efforts
Fill the CMMS gaps
Fuel the process with the gains obtained
Develop a strategy for a clear path forward

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