FORUM: Design for Maintainability CII Construction Project Improvement Conference September 11-13, 2005 Austin, Texas

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FORUMDesign for MaintainabilityCII
Construction Project Improvement
ConferenceSeptember 11-13, 2005Austin, Texas
George Conner Richard Danks Robert Post
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Presentation Agenda

• Making the Case Concept Overview
• NASA Implementation
• D for M Implementation Model
• Chevron Texaco Implementation
• Benefits of D for M
• Rohm Haas Implementation

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Design for MaintainabilityMaking the Case
Concept Overview
Richard A. Danks Deputy Chief, Facilities
Division NASA Glenn Research Center Cleveland, OH
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The Case for Design for Maintainability

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Life Cycle Cost 30 Year Period
The Case for Design for Maintainability
Operation Maintenance 60 - 85
Land Acquisition, Planning, Renewal,
Revitalization, Disposal 5-35
Design Construction 5-10
Source Stewardship of Federal Facilities, 1998
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Landscape of Interrelationships
Chevron Pre-Operations Impact to Asset
Performance
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CII Research Project

• D for M research project 1997 - 1999
• CII Guidebook - 1999
• CII Education module - 2002

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Research Results

• Defined levels of implementation
• Common approaches to implementation
• Common attributes of success
• Model implementation process

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Maintainability Principles

• Reduce or eliminate wrench time
• Optimize Safety, Accessibility, Ergonomics
• Reduce Complexity or Task Difficulty
• Optimize Standardization, Interchangeability, and
  Modularization

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Process Characteristics

• Integrates downstream knowledge early in
• design process
• Model process provides implementation
• structure
• Long-term perspective
• Reduces life cycle costs
• Short term perspective
• Integration into existing processes
• Alignment
• Start up

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D for M Process Highlights

• Early implementation Greatest impact
• Suite of tools to expedite implementation
• Continuous improvement carries
• over to future projects

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NASA Implementation

• Engineering Construction Innovation Committee
• D for M selected as best practice for
  implementation
• Development of week-long course
• Presented at Field Centers
• D for M material presented in Sustainability
  course
• Centers implementing sustainable projects

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NASA Implementation

• Interdependent concepts
• D for M integrated with
• Sustainable (Green) design
• Commissioning
• Safety security
• Supports other NASA programs
• Reliability-centered Maintenance
• Reliability based equipment acceptance

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ImplementingDesign for Maintainability
George Conner Staff Reliability Engineer Chevron
Corporation Houston, Texas
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Approaches to Implementation

• Standard design practice
• Contract specification
• Cross functional participation
• Pilot program
• Integration into existing programs
• Formal maintainability program
• Comprehensive tracking

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Model Process
Source CII Implementation Resource 142-2 Page 16
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Model Process Elements

• Milestones
• Milestones are achieved through
• maintainability practices
• Practices
• Maintainability practices are
• implemented using tools
• Tools
• Tools basically document process
• steps in a checklist format

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Implementing D for M

• Assemble cross-functional proj team
• Formal maintainability reviews
• Design to project maint. strategy
• Consider maintenance staff skills and
• training requirements

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Implementation Resources

• Implementation guidebook
• 22 Maintainability Practices
• 16 Implementation tools
• Implementation suggestions
• Establish a champion
• Pilot program if a new start

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Chevrons Application

• Post Startup Performance unacceptable
• Developed Operations Assurance Process
• Team approach to selecting, developing, assessing
  and executing specific pre-operations activities,
  throughout the course of a project, that impact
  asset performance.
• Project development and execution is based on a
  structured phase gate approach
• Identify, Select, Develop, Execute, Operate
• Maintainability is part of the Operations
  Assurance (OA) process.

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Chevrons ApplicationOA Foundational Philosophies
Human Factors Assmt Maintenance
Strategy Mobilization Delays Resources
Competency Shift/Spares Constraints Mechanical
Handling Plan
BID Specifications Qualified Vendors Standardizati
on Reliability Modeling RCM Performance Indicators
Production / Utilization Operations
Strategy Resources Competency Operational
Flexibility Work Environment
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Implementation Summary

• CII has developed a robust D for M process.
• Milestones Practices Tools
• Early commitment / implementation is critical
• The implementation can be customized based on
  current state and ultimate goals.
• For Chevron, D for M is not a standalone effort
• Specific D for M applications adapted for the OA
  process generally reference
• Milestone 4 Plan Maintainability Implementation
• Milestone 5 Implement Maintainability Process

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Design for MaintainabilityBenefits
Robert Post Technical Fellow Project
Engineer Rohm and Haas Company Bristol, PA
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Project Benefits

• Smoother project startup
• Less project rework
• Less costly maintenance
• Lower life cycle costs
• Metrics Continuous Improvement
• Supports CII Best Practices

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Long Term Benefits

• Eliminate the need for maintenance
• Increased task efficiency
• Reduced accidents
• Decreased downtime
• Access ergonomics
• Standardization/modularization
• Task simplification

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Experience at Rohm Haas

• Domestic US Projects
• Reliability Design
• Functional focus
• Looks at reliability issues first
• Minimize failures and maintenance
• Identify/Resolve maintainability issues
• Mostly done prior to execution

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Experience at Rohm Haas

• Domestic US Projects but.
• Superior FEL definition yields faster/cheaper
• execution
• Everyone knows this, but
• Getting Front End schedule time resources
• Actual results vary
• US work is limited these days anyway

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Experience at Rohm Haas

• Overseas Projects difficulties
• Engineering Processes Vary
• Owner processes
• Contractor processes
• OM processes
• Cultural Viewpoint / Values differences
• Language
• Safety
• Quality
• What does Yes REALLY mean?

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Benefits Summary

• The know-how exists!
• Domestic Must get commitment of
• management and engineers
• Overseas Much steeper learning curve

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Want to Know More?

• CII Publication
• Design for Maintainability
• Improving Project
• Return on Investment

• CII Research Reports
• A Model Process
• for Maintainability Implementation
• State-of-Practice in
• Maintainability Seven Case Studies