1. Downtime Reduction Ideas for a Symposium Presentation and Training

2. Message
Hi Readers
I am putting together slides for a Conference presentation and also for training on Downtime reduction, I am currently working in Angola.
Here are some example slides but I am looking for real examples.
These are only sample slides and is not intended to be a complete presentation

3. Seeking
Any photos of bad maintainability issues, labelling, access, design, lifting
Any photos showing improvements
Any examples where a specific repair took far longer than they should and what were the causes and any good corrective actions
Any examples of a Maintainability Study of a specific repair (see RCA approach)
A list of repair times or downtimes and the causes (see Statistical approach)

4. Definitions
Maintainability Review – a formal review of a plant or system or equipment may be as part of a new project or of an existing project. Review may identify candidates for a Maintainability Study
Maintainability Study (RCA approach) – a formal review of a maintenance job with a view to reduce the total time required, best when done as a team
Maintainability Study (Statistical approach) Uses a combination of statistics and RCA approaches

5. Maintainability Study (e.g. Team based approach)

6. Job Elements Locate Fault Handover & Access Test & Hand-over Dismantle
Assemble
Repair

7. Maintainability Study (RCA Approach)
Specify a target for the repair
Start a sequence of event chart with what you know
Equipment Failure
Downtime 12hours
Normal Operation
Activity 1
Determine Job Activities
Activity

8. Maintainability Study (RCA Approach)
Complete all the job steps by gathering info, interviewing people (waiting time can be put as a job step)
Estimate the time required for each job step

9. Sequence of Event Chart
Gather facts about each step (don’t look for corrective actions at this stage – collect all data first)
Remember we want a no blame culture
Identify factors that prevented the job step been done quicker

10. Sequence of Event Chart
List causal factors
Brainstorm for good corrective actions
etc

11. Maintainability Study (Statistical Approach)

12. Comments
This is just one example of a statistical approach

13. Improving Availability
Assume Plant Manager wants 3% extra Availability
Increase MTBF
Reduce MTTR
Improve both
Lets assume we feel Downtime provides the easiest path to improve Availability
Knowing the MTBF and the Plant Manager’s target availability, we can calculate a new target MTTR using Avail = mtbf / (mtbf + mttr)

14. Maintainability Study (Statistical Data Set)
Assume availability needs to be increased and MTTR is considered to offer the best opportunity
Determine current MTTR (actual)
Determine new MTTR (the target)
Plot the new line on the probability plot
Read of the target for each past repair
Read of the target for the new repair time
Conduct Maintainability Study

15. Past Performance Mean & Median Repair Time

16. Past Performance and Target Performance
Target line set to achieve a greater reduction for larger repair times and smaller reduction for shorter repair times
Job A took 356hrs now, target now 215 hrs
Job B took etc etc
For simplicity not all repair times shown

17. Statistical Analysis – More Detailed Analysis Required
Some times more work is required
Here Probability plot indicates multiple populations, i.e. 3

18. RAM Study with Improved Downtime/Repair Times
We can see effect on throughput, costs, availability from downtime improvements