Reliability Excellence (RE)

Transcription

1 Reliability Excellence (RE) Taking it to the next level Greg Ramon May 1, 2014

2 Asset Management History 1985 to 2003: Reactive Maintenance Reactive fix it when it breaks 2003 to 2012: Maintenance Excellence Proactive fix it before it breaks 2013 and beyond: Reliability Excellence Risk Based fix critical assets before they break

3 109 Pumps (2000 HP to 60,000 HP)

4 Electric Power Facilities

5 39 Check Structures, 35 Turnouts

6 6 Communication and Control Facilities

7 Reactive Maintenance 1985 to 2003 Start-up and operate the system Deliver Arizona s full Colorado River allocation Optimize the use and sale of electric power Reactive Maintenance fix it when it breaks

8 Improving Maintenance Practices Business Case for Change: Aging infrastructure (20 Years of service) Decreasing system reliability Increasing maintenance cost Poor safety record (30 recordable injuries some Years) Aging Workforce/knowledge transfer Assets control the organization

9 Maintenance Excellence Objective Reduce accidents and injuries Proactive process fix it before it breaks Organization gains control of the assets Increase Operational Availability (capacity) Manage the Maintenance Budget

10 Maintenance Excellence Implementation: Perform baseline audit Develop a 5 year Master Plan Evolve the workforce What s in it for me? Design workflow processes, roles, and responsibilities Reorganize to support the new processes Develop metrics to measure performance Perform follow-up assessments to gauge progress

11 Maintenance Excellence 2003 Reactive Organization Structure General Manager AGM Maintenance Maintenance Manager Maintenance Manager Maintenance Manager Maintenance Manager Supervisor Supervisor Supervisor Planner Planner Planner Team Lead Team Leader Team Leader Team Leader Team Leader Team Leader Team Leader Team Leader Team Leader Electrician Mechanic Maint. Wkr Electrician Mechanic Maint. Wkr 4 Electrician 6 Mechanic 4 Maint. Wkr 4 Electrician 3 Mechanic 2 Maint. Wkr Electrician Mechanic Maint. Wkr Electrician Mechanic Maint. Wkr 2 Electrician 2 Mechanic Maint. Wkr 3 Electrician 3 Mechanic 2 Maint. Wkr 4 Electrician 2 Mechanic Maint. Wkr

12 Maintenance Excellence General 2013 Proactive Organization Structure Manager AGM Maintenance Asset Owner West Manager Asset Owner South Manager Centralized Support Mgr. Maint. Control Manager Area Supv Area Supv Area Supv Area Suprv Heavy Overhaul Maint. Engineering 4 Electrician 6 Mechanic 2 Maint. Wkr 4 Electrician 3 Mechanic 2 Maint. Wkr 3 Electrician 3 Mechanic 1 Maint. Wkr 2 Electrician 3 Mechanic 2 Maint. Wkr Heavy Overhaul Heavy Overhaul HVAC Planning CMMS Support Fire Systems Electrical I&C Protective Coating

13 Maintenance Excellence Evaluating Performance First assessment completed March 2003 (baseline) Maintenance reorganized in 2004 and assessments since 2003 (2 external, 3 internal) Last assessment (external) in 2011 by CH2M Hill

14 2011 CH2M Hill Assessment Objective a. Benchmark CAP s maintenance program b. Perform an organizational review c. Validate CAP s internal assessment process Assessment Process a. Question based survey and employee interviews b. Risk assessment of each audit category c. Risk assessment of seven CAP facilities

15 Maintenance Excellence CH2M Hill Audit Category Scores 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

16 Maintenance Excellence Assessment History World Class Excellence 81% 82% Proactive 60% 65% Emerging 42% Reactive 2003 Life Cycle 2004 Internal 2007 Internal 2009 Internal 2011 CH2M HILL

17 2011 CH2M Hill Assessment Water Services Association of Australia Water utility assessment Water utilities from North America (13) Global water utilities (27)

18 CAP VS North America Water Utilities The United States Seattle Public Utilities Tacoma Water Tacoma Public Works Portland Water Bureau Portland BES Anchorage W/WW Philadelphia Water Dept Cincinnati MSD Toho Water Authority Los Angeles Water & Power Washington Washington Washington Oregon Oregon Alaska Pennsylvania Ohio Florida California Canada Region of York Ontario Region of Peel Ontario City of Toronto Ontario Water Services Association of Australia

19 CAP VS Global Water Utilities Australia Sydney Catchment Authority NSW Sydney Water NSW Hunter Water NSW Gold Coast Water Queensland SEQ Water Queensland Brisbane City Council Queensland Gladstone Area Water Queensland Central Highlands Water Victoria City West Water Victoria South East Water Victoria Melbourne Water Victoria Coliban Water Victoria Goulburn Valley Water Victoria Wannon Water Victoria Hobart Water Tasmania Water Corporation Western Australia SA Water South Australia New Zealand Manukau Water Metrowater North Shore City Council Christchurch City Council Dunedin City Council Watercare New Zealand Hong Kong Hong Kong Water Supplies Department The United Arab Emirates Abu Dhabi Distribution Company Abu Dhabi Sewerage Services Company Sultanate of Oman Oman Wastewater Services Company Water Services Association of Australia

20 Maintenance Excellence 2011 CH2M Hill Results CAP Score = 72% North America Group Global Water Utility Group Water Services Association of Australia

21 Reliability Excellence 2013 to 2016 Objectives: Optimize Maintenance Excellence (continuous improvement) Establish asset criticality relative to Safety and Operations Apply Reliability Centered Maintenance (CBM) process Implement Condition Based Monitoring technologies Risk based process fix or replace just before it breaks prevent failure of critical assets and allow some non-critical assets to run to fail

22 Reliability Excellence Continuous Improvement