Title: FORUM: Design for Maintainability CII Construction Project Improvement Conference September 11-13, 2005 Austin, Texas
1FORUMDesign for MaintainabilityCII
Construction Project Improvement
ConferenceSeptember 11-13, 2005Austin, Texas
George Conner Richard Danks Robert Post
2Presentation Agenda
- Making the Case Concept Overview
- NASA Implementation
- D for M Implementation Model
- Chevron Texaco Implementation
- Benefits of D for M
- Rohm Haas Implementation
3Design for MaintainabilityMaking the Case
Concept Overview
Richard A. Danks Deputy Chief, Facilities
Division NASA Glenn Research Center Cleveland, OH
4The Case for Design for Maintainability
5Life 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
6Landscape of Interrelationships
Chevron Pre-Operations Impact to Asset
Performance
7CII Research Project
- D for M research project 1997 - 1999
- CII Guidebook - 1999
- CII Education module - 2002
8Research Results
- Defined levels of implementation
- Common approaches to implementation
- Common attributes of success
- Model implementation process
9Maintainability Principles
- Reduce or eliminate wrench time
- Optimize Safety, Accessibility, Ergonomics
- Reduce Complexity or Task Difficulty
- Optimize Standardization, Interchangeability, and
Modularization
10Process 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
11D for M Process Highlights
- Early implementation Greatest impact
- Suite of tools to expedite implementation
- Continuous improvement carries
- over to future projects
12NASA 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
13NASA 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
14ImplementingDesign for Maintainability
George Conner Staff Reliability Engineer Chevron
Corporation Houston, Texas
15Approaches to Implementation
- Standard design practice
- Contract specification
- Cross functional participation
- Pilot program
- Integration into existing programs
- Formal maintainability program
- Comprehensive tracking
16Model Process
Source CII Implementation Resource 142-2 Page 16
17Model 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
18Implementing D for M
- Assemble cross-functional proj team
-
- Formal maintainability reviews
- Design to project maint. strategy
- Consider maintenance staff skills and
- training requirements
19Implementation Resources
- Implementation guidebook
- 22 Maintainability Practices
- 16 Implementation tools
- Implementation suggestions
- Establish a champion
- Pilot program if a new start
20Chevrons 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.
21Chevrons 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
22Implementation 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
23Design for MaintainabilityBenefits
Robert Post Technical Fellow Project
Engineer Rohm and Haas Company Bristol, PA
24Project Benefits
- Smoother project startup
- Less project rework
- Less costly maintenance
- Lower life cycle costs
- Metrics Continuous Improvement
- Supports CII Best Practices
25Long Term Benefits
- Eliminate the need for maintenance
- Increased task efficiency
- Reduced accidents
- Decreased downtime
- Access ergonomics
- Standardization/modularization
- Task simplification
26Experience 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
27Experience 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
28Experience 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?
29Benefits Summary
- The know-how exists!
-
- Domestic Must get commitment of
- management and engineers
- Overseas Much steeper learning curve
30Want 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