Asset Healthcare Triangle
Stage 1: Planned Maintenance
Planned work is found to be three times more efficient than unplanned work. To assist organizations in implementing planned maintenance systems, we work closely with teams to design and document a new work management process, incorporate any changes to a maintenance management system, and assure, through training and coaching, that work is properly planned, scheduled and executed. We make changes in the preventive maintenance process, to assure that PM's are providing the desired results. Finally, we enhance the work management process by clearly identifying roles and responsibilities, setting expectations and coaching to meet performance objectives.
Stage 2: Proactive Maintenance
This stage builds upon the success of daily maintenance. Using RCM techniques, we completely redesign the preventive and predictive maintenance systems. By employing condition monitoring and predictive techniques, we begin to reduce failure events. Failure prediction is accomplished by using equipment history to identify time-based failures. Through a consistent program of failure analysis, failure modes are eliminated or mitigated.
Stage 3: Organizational Maintenance
Exploring the resources outside of maintenance and engineering to improve reliability plays a central role in Stage 3. In most cases operators can play a far greater role in managing equipment health than they do. By Stage 3 there is enough control of the work and the equipment that decentralizing some of the maintenance staff is valuable. Teams of operators and craftsmen increase the effectiveness of all the area work, and the operators learn to accept and perform some of the work that was performed by the craftsman. The craftsman gains a better understanding of the equipment operating requirements and characteristics, and we work to assure that each craftsman can perform more than one type of skill to maximize the utility of each hour worked.
Stage 4: Engineered Reliability
Our intention in Engineered Reliability is to proactively eliminate both failure modes and the need to maintain against failure modes. If in earlier stages we engaged in preventive maintenance, we are now looking at maintenance prevention. By Stage 4, we have systematically become more effective in our repair efforts. We are now minimizing the impact of equipment failures, and we are using all of our resources to identify equipment problems and maintain equipment condition. We are now able to tackle and effectively execute more complex equipment tasks.
Stage 5: Operational Excellence
Our experience shows that operational excellence is highly dependent on equipment reliability. In this stage, we develop a comprehensive approach to Asset Management. SAMI's approach, which we call Total Equipment Asset Management (TEAM)TM, integrates the cycle of annual business planning with the equipment condition necessary for each unit to meet the requirements of the business plan. We evaluate equipment criticality of all systems, identify the current condition of all components, develop operating specifications for all systems and components, and develop a zero-based maintenance strategy for each component in the plant.
SAMI Pyramid Quick-Links
Asset Healthcare Triangle Asset Healthcare Triangle & Maturity Matrix (pdf)
Production Management Triangle Production Management Triangle & Maturity Matrix (pdf)
Logistics Management Triangle Logistics Management Triangle & Maturity Matrix (pdf)
Capacity Development Triangle Capacity Development Triangle & Maturity Matrix (pdf)
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