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George Conner Richard Danks Robert Post

FORUM: Design for Maintainability CII Construction Project Improvement Conference September 11-13, 2005 Austin, Texas. George Conner Richard Danks Robert Post. Presentation Agenda. Making the Case & Concept Overview NASA Implementation D for M Implementation Model

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George Conner Richard Danks Robert Post

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  1. FORUM:Design for MaintainabilityCII Construction Project Improvement ConferenceSeptember 11-13, 2005Austin, Texas George Conner Richard Danks Robert Post

  2. 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

  3. Design for Maintainability:Making the Case& Concept Overview Richard A. Danks Deputy Chief, Facilities Division NASA Glenn Research Center Cleveland, OH

  4. The Case for Design for Maintainability

  5. The Case for Design for Maintainability Life Cycle Cost — 30 Year Period Operation & Maintenance 60% - 85% Land Acquisition, Planning, Renewal, Revitalization, & Disposal 5%-35% Design & Construction 5%-10% Source: Stewardship of Federal Facilities, 1998

  6. Reliability Sys Configuration Equip Performance Availability Uptime Prod Eff / Utilization Production Losses Equipment Criticality Productivity Maintainability Factors affecting ability to perform Maintenance Total MTTR $$$$ Operability Asset Economics (Differential NPV) Operational Flexibility Degraded Performance Improvements OPEX & CAPEX Landscape of Interrelationships Chevron Pre-Operations Impact to Asset Performance

  7. CII Research Project • D for M research project 1997 - 1999 • CII Guidebook - 1999 • CII Education module - 2002

  8. Research Results • Defined “levels” of implementation • Common approaches to implementation • Common attributes of success • Model implementation process

  9. Maintainability Principles • Reduce or eliminate wrench time • Optimize Safety, Accessibility, & Ergonomics • Reduce Complexity or Task Difficulty • Optimize Standardization, Interchangeability, and Modularization

  10. 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

  11. D for M Process Highlights • Early implementation =Greatest impact • Suite of tools to expedite implementation • Continuous improvement carries • over to future projects

  12. 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

  13. 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

  14. ImplementingDesign for Maintainability George Conner Staff Reliability Engineer Chevron Corporation Houston, Texas

  15. Approaches to Implementation • Standard design practice • Contract specification • Cross functional participation • Pilot program • Integration into existing programs • Formal maintainability program • Comprehensive tracking

  16. Model Process Source: CII Implementation Resource 142-2 Page 16

  17. 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

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

  19. Implementation guidebook 22 Maintainability Practices 16 Implementation tools Implementation suggestions Establish a champion Pilot program – if a new start Implementation Resources

  20. Chevron’s 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.

  21. Reliability Maintainability OA Operability Chevron’s ApplicationOA Foundational Philosophies Human Factors Assmt Maintenance Strategy Mobilization Delays Resources & Competency Shift/Spares Constraints Mechanical Handling Plan BID Specifications Qualified Vendors Standardization Reliability Modeling RCM Performance Indicators Production / Utilization Operations Strategy Resources & Competency Operational Flexibility Work Environment

  22. 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

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

  24. Project Benefits • Smoother project startup • Less project rework • Less costly maintenance • Lower life cycle costs • Metrics & Continuous Improvement • Supports CII Best Practices

  25. Long Term Benefits • Eliminate the need for maintenance • Increased task efficiency • Reduced accidents • Decreased downtime • Access & ergonomics • Standardization/modularization • Task simplification

  26. 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

  27. 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…

  28. Experience at Rohm & Haas • Overseas Projects: difficulties • Engineering Processes Vary • Owner processes • Contractor processes • O&M processes • Cultural Viewpoint / Values differences • Language • Safety • Quality • What does “Yes” REALLY mean?

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

  30. 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

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