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Asset Information for FMEA-Based Maintenance Asset information for FMEA-based maintenance Jan Braaksma Published by: University of Groningen Groningen The Netherlands Printed by: Ipskamp Drukkers B.V. ISBN: 978-90-367-5806-2 (book) 978-90-367-5807-9 (e-book) © 2012, Jan Braaksma RIJKSUNIVERSITEIT GRONINGEN Asset information for FMEA-based maintenance Proefschrift ter verkrijging van het doctoraat in de Economie en Bedrijfskunde aan de Rijksuniversiteit Groningen op gezag van de Rector Magnificus, dr. E. Sterken, in het openbaar te verdedigen op donderdag 15 november 2012 om 12.45 uur door Anne Johannes Jan Braaksma geboren op 25 februari 1980 te Leeuwarden Promotores: Prof. dr. ir. J.C. Wortmann Prof. dr. ir. G.J.C. Gaalman Copromotor: Dr. ir. W. Klingenberg Beoordelingscommissie: Prof. dr. B. Iung Prof. dr. H. van Landeghem Prof. dr. R. Teunter ISBN: 978-90-367-5806-2 (book) 978-90-367-5807-9 (e-book) Contents 1 Introduction 1 1.1 Motivation of the study .......................................................................... 1 1.2 Feedback is essential for FMEA-based maintenance ........................... 4 1.3 Industrial setting .................................................................................... 5 1.4 Research aim .......................................................................................... 6 1.5 Research objectives ................................................................................ 7 1.6 Thesis outline ......................................................................................... 9 2 Failure Mode and Effects Analysis in asset maintenance: a multiple case study in the process industry 11 2.1 Introduction ......................................................................................... 12 2.2 Methodology ........................................................................................ 14 2.3 Postulates ............................................................................................. 16 2.4 Multiple case study ..............................................................................20 2.5 Summary, discussion and implications .............................................. 33 3 A quantitative method for Failure Mode and Effects Analysis 37 3.1 Introduction ......................................................................................... 38 3.2 Modeling the Probability of the Failure of Assets.............................. 40 3.3 Pumps in a European gas field and US nuclear power plants ........... 47 3.4 Discussion, summary and implications .............................................. 54 Appendix 3: Application quantitative modelling results within FMEA procedure ...................................................................................................... 58 4 Design of a Maintenance Feedback Analysis (MFA) method for continuous FMEA-based maintenance 60 4.1 Introduction ......................................................................................... 61 4.2 Literature .............................................................................................. 62 4.3 Methodology ........................................................................................ 66 4.4 Case study ............................................................................................. 68 4.5 Design principles for continuous FMEA-based improvement........... 78 4.6 Design of a maintenance feedback analysis (MFA) method .............. 82 4.7 Conclusion and discussion of the results ............................................ 87 Appendix 4: Failure Mode and Effects Analysis without and with MFA .. 88 5 A review of the use of asset information standards for collaboration in the process industry 89 5.1 Introduction and background ............................................................ 90 5.2 Methodology ........................................................................................ 92 5.3 Literature survey on asset information standards in the process Industry ................................................................................................ 94 5.4 Two Case studies (Stork GLT and Akzo Nobel Botlek) .................... 105 5.5 Adoption of asset information standards in other industries ........... 112 5.6 Summary, conclusions and research directions ............................... 118 Appendix 5: Illustration of asset information standards .......................... 122 6 Conclusion and discussion 125 6.1 Main findings ..................................................................................... 125 6.2 Directions for further research .......................................................... 128 6.3 Societal relevance ................................................................................ 131 Samenvatting (Summary in Dutch) 132 Dankwoord 136 Bibliography 138 Chapter 1 Introduction This chapter includes a motivation for the research presented in this thesis (1.1), a description of the industrial setting in which the research takes place (1.2), the research aim (1.3), the research objectives (1.4) and the outline of this thesis (1.5). 1.1 Motivation of the study Reliability, safety and sustainability of capital assets is of major importance to our society. Maintenance has an important role in assuring the integrity of assets and thereby in assuring the reliability, safety and sustainability of these capital assets (Moubray, 1992). The importance of Maintenance (MRO, Maintenance Repair and Overhaul) is also represented by a yearly turn-over of 18 billion euro and employment for around 300.000 people which is 4% of the working population in the Netherlands (NVDO, 2011). The total value of the Dutch capital assets is being estimated at 400 billion euros (Veenman and Besselink, 2010). Plant maintenance is therefore a major operational activity, the cost of which typically represents some 4% of the capital employed, in the process industry this can be 6% (Haarman and Delahay, 2005). Maintenance concepts Given the significance of maintenance for operational excellence as well as health, safety and environment, the importance of a good maintenance concept is paramount. A maintenance concept can be seen as the policy, or the approach that governs the amount of maintenance and type of maintenance actions to be performed on an asset. For example, the maintenance concept determines the choice between planned maintenance with fixed intervals or planned maintenance with variable intervals for an asset. Asset definition In the remainder of this thesis, the terms plant/ installation, equipment and products are grouped under the term ‘asset’. 1 For asset management we use the definition of Mitchell and Carlson (2001), cited in Schuman and Brent (2005), where asset management is defined as a strategic, integrated set of comprehensive processes to gain greatest lifetime effectiveness, utilisation and return from physical assets, whereby assets are defined as production and operating equipment and structures. The maintenance concept of an industrial asset is nowadays seen as an essential part of the design (phase) of the asset (Dongen, 2011), but can also be determined or improved in the operations and maintenance phase of an asset. The importance of a life-cycle approach to the design, management and continuous improvement of assets is well described (INCOSE, Dreverman, 2005, Schuman and Brent, 2005). Maintenance and asset information Only with effective maintenance the assets continue to do what the users want them to do (Moubray, 1992). An important aspect in determining the maintenance concept is the information that is available and how this asset information is used. Some authors mentioned a number of problems with the information management in a maintenance environment: 1. uncertainty of future information needs: it is unclear which data has to be registered or maintained for future asset management (Tsang et al., 2006, Veldman et al., 2010), 2. maintenance knowledge is insufficiently accessible: much of the information is embodied in persons (Moubray, 1992, Mobley and Smith, 2002, Bloom, 2006), 3. information cannot be used without additional knowledge: asset data is stored without sufficient context to be interpreted correctly and used effectively, (Pot, 2007, Tsang et al., 2006, Teoh and Case, 2005), 4. maintaining high quality asset data is complex and costly: the quality of asset information is difficult to establish, which is further complicated by often terabytes of data which need to be maintained (Garg and Deshmukh, 2006, Tsang et al., 2006), 5. heterogeneity of storage applications: data is stored in several non-integrated systems, e.g. Computerized Maintenance Management Systems (CMMS), process data and RCM data which complicates analysis which needs several data sources (Garg and Deshmukh, 2006, Smith and Hinchcliffe, 2004, Haarman and Delahay, 2005). 6. data hand-over problems: the breaking-point (caused by the hand-over) of asset data between maintenance and engineering (Dreverman, 2005) 7. lack of information standards: which complicates the exchange of asset data (Dreverman, 2005). 2 Reliability Centred Maintenance (RCM) Reliability Centred Maintenance (RCM) is currently seen by many authors as an important approach to design /develop a maintenance concept (Moubray, 1992, Mobley and Smith, 2002, Waeyenbergh and Pintelon, 2002, Stamatis, 2003, Bloom, 2006, Seyed-Hosseini et al., 2006). RCM also described in the SAE JA1011 standard starts with a zero-based review to determine the maintenance requirements of any physical
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