From Chaos to Clockwork. The Drive to Peak. Route 6 Focus

Paul Boughton

You are invited to join Roald Rodseth on the Drive to achieve Peak performance

Having  just  successfully  completed  Route  5  of  the  journey to  Peak,  the  traveller  is suddenly confronted by a new dilemma. Before him is a confusing array of routes to take to complete Route 6. This is one of the most common and perplexing issues facing a maintenance  practitioner.

Modern  plant is made up of a multitude  of  machines  and pieces of equipment that are clamouring for attention. Added to this are a host of voices also calling for attention. The environment is complex and the demands many. There are operational, technical, financial and environmental demands to mention but a few of  these. What to leave and what  to  attend to becomes the overriding need to resolve. Not to drown in the sea of detail is now the name of the game and a workable, practical model of the sea of detail will help resolve the dilemma. This is where Impact Driven Asset Management comes into play and this philosophy will lead the journey into prioritisation and the creation of an asset management programme.

Machine recognition

The first step to resolving the dilemma is to take a good look at the machines and equipment. Stop and draw a Machine Map of them. Begin by drawing a square on a sheet of paper. This square represents the entire plant. Continue by breaking the plant up into its component parts until each item is identified to a level that is useful from an asset management analysis point of view. Using paper is  tedious  –  rather use the DRIVE asset management software application.

Not only is this process tedious, but making sense of what lies before one is daunting. So try the following.  Start by identifying all the  machines that are directly involved in processing the raw materials.

Collectively this  group is  called  the 'Forming  process'. The chances are that the most critical machines lie on this chain of  machines. Next  identify 'Linked systems'.  These are systems that bring material or energy or data into the Forming process or out of it. Complete the Map by identifying the remaining systems. DRIVE will guide and document the process with ease.

Machine impact

The next step is to assign a machine impact value to each item on the Machine Map.This  is  done  by  considering  the  impact of a catastrophic failure  of  the  machine in question on the loss of throughput of the production facility and the cost of repair of the machine. This is known as the Machine Impact value. Now rank the machines in terms of this impact value and this is the Machine Impact Hierarchy.

The next Route

So now the route through the sea of detail is clear. The answer is to start working on the highest impact items and to work systematic down the rankings. Following this approach will ensure that efforts are focused where it matters most and avoids the pull to issues that are not that important at that stage.

Yet another step closer to clockwork! 

You are now ready to move to the next Route.

Roald Rodseth is Managing Director, Radiant Operations International (Pty) Ltd in conjunction with DesSoft

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