Dave Alexander – August 2010 Developing a Sustainable Maintenance Strategy A Living Program ACARP Roadway Development Operators Workshop September 2010

Slide 2 Dave Alexander – August 2010 Winston Ledet 1994 Du Pont Study

Slide 3 Dave Alexander – August 2010 The Vicious Cycle of Reactive Maintenance Backlog grows PM is missed Temporary Repairs More repeat work Resources taken by Breakdowns Head / Budget Reduction Standards Drop

Slide 4 Dave Alexander – August 2010 Holistic Approach The Right People The Right Time The Right Stuff Continually Improve

Slide 5 Dave Alexander – August 2010 Road Map Example

Slide 6 Dave Alexander – August 2010 A Fundamental Question As equipment gets older, is it more likely to fail?

Slide 7 Dave Alexander – August 2010 Founders of RCM - Nowlan & Heap found that failures could be grouped into 6 patterns Conditional Probability of Failure Age CC 5% A 4% B 2% F 68% D 7% E 14%

Slide 8 Dave Alexander – August 2010 Failure Mode Driven Strategy

Slide 9 Dave Alexander – August 2010 Optimising The Maintenance Plans PMO is a process which uses principles of Reliability Centred Maintenance (Failure Mode Analysis) to to rationalise existing maintenance strategies Using the structure of the RCM, fitters, electricians and engineers review all of the PM tasks that are currently utilised in the CMMS and also analysed the failure history Tasks not addressing a failure mode are removed Tasks are rewritten to be descriptive Specifications are provided Corrective Actions are written Illustrations are inserted

Slide 10 Dave Alexander – August 2010 Maintenance Tasks

Slide 11 Dave Alexander – August 2010 PMO Analysis

Slide 12 Dave Alexander – August 2010 Optimising The Maintenance Plans

Slide 13 Dave Alexander – August 2010 Group Task Libraries Shuttle Car - Frame - Wheel End - Hydraulics - Electrics - Cable Reel - Drive System

Slide 14 Dave Alexander – August 2010 Strategy Change Control

Slide 15 Dave Alexander – August 2010 Governance Schedule Compliance PM Effectiveness Routine Order Start Date

Slide 16 Dave Alexander – August 2010 Living System (DDA) Downtime Data Analytics Major DelayMinor DelayDetail DelayEquipment Level 2Equipment Level 3Equipment Level 4Failure Mode Continuous Miner01 - Air/Water02 - WaterFilter AssemblyElement Blockage Continuous Miner06 - Hydraulics05 - HosesWing ExtensionRetraction HoseJIC FittingCross Threaded Continuous Miner04 - Electrical System12 - Electrical SystemControl SolenoidCoilInsulationFractured

Slide 17 Dave Alexander – August 2010 Living System (DDA) Downtime Data Analytics Equipment Level 2Equipment Level 3Equipment Level 4Failure Mode Filter AssemblyElement Blockage Wing ExtensionRetraction HoseJIC FittingCross Threaded Control SolenoidCoilInsulationFractured Group Library

Slide 18 Dave Alexander – August 2010 Living System (RCA)

Slide 19 Dave Alexander – August 2010 Questions & Answers