Glen Fields - Final Project Presentation

What Sets CSI Apart... GBA 573 Consultants Company Background Located in San Diego, CA 5 Engineering Consultants Established in 2002 Specialize in Facility Assessment, Strategy Development, and Project Management

How Projects Get Started

Overview Project is to: –Perform an assessment at Disneyland –Optimize Maintenance and Reliability Program –Develop Customized Computer Reliability Software Program –Install Wireless Sensors to Monitor Equipment –Document Findings and Present to Management

Deliverables Deliverables of the Project are: –Assessment and Benchmark prior to Project Implementation –Equipment and Technology Matrix –Microsoft Project Schedule –Recommended Training Matrix –Identification and Documentation of Park Goals for the Condition Monitoring Program –Consultation of Work Flow Diagram for Optimized Implementation of Condition Monitoring Program

Maintenance Optimization Work Process World Class People Skills Technologies Management & Work Culture

Work process Identify Issues That Affect Maintenance Work Process Capture “As Is” Work Process Develop “To Be” Work Process Diagram

Work Processes: The CMMS system is used to plan and schedule the work, track machine history, and to track cost and savings information. Some of the key goals are prioritization of WO’s, elimination of unnecessary PM’s, and program justification. A key role of the IT group is the identification of the criticality of plant machinery so the work can be prioritized. Resources and technologies are assigned to plant assets based on equipment or systems importance to the production cycle. Performance of critical equipment is tracked and reported. Condition Monitoring plays a key role in acceptance and certification of plant equipment. Formal processes have been established to insure PDM is used on new and reworked equipment, incoming oils are inspected for quality, IR is used before shutdowns, and root cause studies are performed on all critical equipment failures. Feedback loops are in place on all WO’s and regular meetings are scheduled to discuss critical issues. Quality and Reliability are a way of life not a periodic process.

Work Process Designed for Maintenance Optimization Work Closeout Work Execution PdM Equip. Condition Directed Feedback PAM Root Cause Analysis Identifies Equip. Condition Maintenance Optimization What RM Equipment Failures Scheduled PM Tasks Feedback

Technology Identify Which Rides at Disneyland are Critical Based on the Criticality of the Ride, Assign Monitoring Technology Integrate Information Into an Equipment and Technology Matrix Install Monitoring Sensors on Equipment

Condition Based Maintenance Program Elements Maintenance Planning & Scheduling Maintenance Histories & Records Data Operator Log Data Design & Historical Data Engineering Maintenance Operations ALERTING TRENDING ANALYSES COST BENEFIT RECOMMENDATIONS REPORTING PDM Program Periodic Diagnostic Data Diagnostic & Process Data Batch Testing & Inspection Data

Technology Recommended Condition Monitoring Technologies –Wireless Vibration Monitoring Sensors –Wireless Lubrication Monitoring Sensors –Infrared Thermography

Equipment and Technology Matrix

Work Culture and Management Continued Focus on Benchmarking Facility Establish Vision Identify Goals Establish Global Metrics (SMART) –Specific –Measurable –Achievable –Reasonable –Timely Upper Management Visability

Work Culture and Management Plant managers know the importance of program, understand the financial impact, invest in the people and technology, and communicate regularly with the maintenance department. A formalized plan for plant reliability has been established and the impacted Team members. Performance measures are established, tracked, and reported on a regular basis. All members of the Team are asset owners and the emphasis is on elimination of critical equipment failures. Regular meetings are scheduled with all departments to communicate findings, plan strategies, look at WO optimization,and to optimize resource utilization.. Work Teams are established to break down reporting barriers and equipment ownership is assigned at the crafts level to empower the resources.

People / Skills Establishing and Understanding Roles and Responsibilities Developing and Maintaining Sponsorship Event Reporting Condition Assessment Reporting ROI Calculations Correlation of Technical Data Financial Aspects of Program

Program Costs

Schedule Detailed Project Schedule Developed Project Estimated at 6 Weeks