Equipment Reliability Model Returns 8% Maintenance Cost Reduction
PCMS Engineering were appointed by Sellafield Limited to work alongside its central engineering team to implement the INPO AP 913 Equipment Reliability Model activities across the site; including training, coaching, facilitation related to Condition Monitoring activities, Maintenance Reviews and System Health.
The ChallengeAs an integral component of the maintenance re-engineering programme to ensure integration, co-ordination and delivery of standard equipment reliability practices across the site, the implementation teams had to tackle the following:
- Poor asset performance and condition results from inadequately planned/predictive maintenance and lack of focus and understanding of system reliability.
- Site maintenance schedules not making use of technology to ensure effective and efficient delivery.
- The technical basis of maintenance was poorly understood and not recorded – no basis to justify maintenance or control changes to regime.
- The site maintenance schedule contained many tasks that provided no benefit to asset performance and condition, therefore wasting site maintenance resources and funding.
Sufficient Site Equipment Reliability subject matter resource didn’t exist and had not been made available with the relevant knowledge and experience to effectively support the implementation of the accelerated IWM program arrangements. Without the necessary external resources and expertise to support the initiative the implementation, milestones would be significantly delayed beyond the executive agreed NDA implementation programme.
The SolutionDue to the scale and diversity of this initiative, the designed approach was to develop a central (ER) coaching team consisting of Sellafield and PCMS engineers. This team would provide governance and on-site mentoring, training and facilitation of the revised Equipment Reliability procedures.
- Technical Basis of Maintenance Reviews (TBoMs) established and used as the basis for change to maintenance regimes. The output of a TBoM review is an optimised maintenance regime and longer term leads to improved equipment reliability.
- Site Condition Monitoring (CBM) strategy to be developed, approved and implemented across 23 facilities.
- Maintenance review training to be delivered to over 150 engineers.
- Site Asset Condition and Ageing Policy and guidance to be implemented.
- Risk Based Inspection Reviews – Method of determining and adjusting examination and inspection periodicities by assessment of risk on lifting equipment and pressure systems, which are subject to specific pieces of statutory legislation.
- Roll out TBoM/Asset Condition training to 200+ system engineers.
- Advanced Maintenance Equipment and Technology Selection, Deployment and Training.
The ResultsThe site have reported the following operational benefits of introducing Equipment Reliability procedures:
- Improved nuclear and industrial safety through reduced and less intrusive maintenance activity.
- Improved performance and condition of assets.
- Reduced non-added value maintenance.
- 20% reduction in the ratio of planned to unplanned maintenance tasks.
- Increased reliability leading to increased availability.
- Reduced Condition Monitoring contract costs (make instead of buy).
- Improved Stakeholder relationship.
- Maintenance cost reduction target of 8% over a 5 year period.
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