FEATURE TRAINING & SKILLS
MAKING THE MOST OF YOUR FACTORY ASSETS
Peter Jackson, senior consultant, MCP Consulting Group, tackles the challenges to implementing an effective asset management plan by outlining 10 factors which need to be taken into consideration, analysed and acted upon
L
eading manufacturing and service companies know that effective Asset
Management is a basic need for long term competitiveness. But even today, MCP has evidence that
fewer than 10% of company sites in the UK have mastered this skill and hence the ability to claim to have ‘leading-the- world’ status’. The overall UK profile of where sites are on the journey to becoming ‘world-class’ is shown in Figure 1 (below, right). So, where is your company in terms of
effective asset management? You should consider the following 10
point asset management challenge… 1. Are you following a long term plan to
apply asset management’s best practice ways of working? 2. Are you confident that each item of equipment (physical asset) has an appropriate, risk-based annual maintenance plan? 3. Are you using a planning process such
that technician or craftsman’s time is mostly planned one week in advance? 4. Are you sure you have the ‘right’ spares in stock? 5. Do you know that the total cost of
your maintenance is correct for the current approach to asset management? 6. Is it clear that operations and project leaders care about the processes for effective asset management? 7. Do operational roles include asset
management duties, tasks and objectives? 8. Do you apply specific asset
management KPIs that are compared to targets and are actively used to drive continuous improvement? 9. Are there partnering arrangements
with key outsourced providers or suppliers that allow for sharing risk and rewards? 10. Are you confident that the full scope
of effective asset management is understood by all employees? If your response is NO to even a few of these challenges, then an effective asset management programme will deliver benefits to your organisation. Here we address the 10 challenges above for a sustainable asset management (AM) journey:
26 NOVEMBER 2016 | PROCESS & CONTROL
1. Long Term Strategic Plan Improving AM has to be done in a
formal strategic manner. ISO 55000 clearly indicates the need for an AM system that describes the policy and strategy for life long care of installed assets. The AM Policy and Strategy documents need to be ‘owned’ by those involved 2. Maintenance Plans After determining how important an asset is the appropriate tools and techniques must be applied to mitigate the likelihood of its failure. The resulting annual maintenance schedules for each asset must be stored in the CMMS for reference in the maintenance planning process 3. Planning Work Weekly maintenance schedules are
essential and should not interfere with output. A maintenance planner is mandatory, with tasks managed as Works
Operator Asset Care (OAC) engages the user in the correct use of equipment and encourages them to undertake maintenance themselves
Orders and results recorded. Maintenance best practice is to plan in advance more than 80% of the available resource man- hours 4. Spare Parts Management Spare parts account for approximately a
third of annual maintenance spends. The subject is gaining greater attention under the title Maintenance, Repairs and Operating Materials (MROM) management. From developments of techniques in Supply Chain Management (SCM) their application for engineering spares management is entirely appropriate. Traditional storemen are being encouraged to be ‘Subject Matter Experts’ (SMEs) in the complex world of MROM management. 5. Cost of Maintenance Guidelines suggest what should be the annual cost of maintenance relative to the replacement-as-new value of all the assets in a given portfolio. Depending on the business sector, world-class providers are expecting the maintenance budget to be between 1 and 3% for a highly developed AM system. Are you meeting this target? 6. Functional Involvements AM cannot be delivered as an
engineering initiative alone. Managers, project engineers, HR and finance all need to recognise their involvement in the delivery of an effective AM system. 7. Operator Asset Care (OAC) - (see
Peter Jackson BSc (Hons) Mech Eng. MIAM
Figure 1: So, where is your company in terms of effective asset management?
image above, left) For highly reliable equipment performance it is essential that those who operate (use) the equipment do so in a sensitive manner. OAC engages the user in the correct use of equipment and encourages them to do whatever maintenance they can for themselves. 8. KPIs (Key Performance Indicators) Measuring the management of
workload and the effectiveness of the planning to ensure costs are in-line with budgets, and the equipment is performing at the design standards is a must. Visually showing the results as trends in a dash board format is current best practice. 9. Outsourcing Is appropriate where there is a business
benefit…but think before leaping into the arms of a provider hoping they understand the subject which is a mystery to you. If you cannot write a comprehensive user requirements specification (URS) for the outsourced subject you need to become knowledgeable before you outsource. 10. Understanding and Communication Regular communication of the progress
and results of the full application of AM across the business is necessary to ensure a culture where application of world-class processes become ‘business as usual’. MCP has supported clients from all over
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