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Taking control of maintenance-crew productivity

(in lingua inglese)

- Benchmark: Enables accurate benchmarking of suppliers efficiency for each covered discipline against Industry Norms
- Cost savings: Identification of further efficiency gains and motivate and enable suppliers to improve their productivity, achieve economies of scale
- Cost transparency: Enable to scrutinise suppliers costs structure to understand estimates, identify further savings, review productivity, and validate profit margin (cost vs. price)
- Cost accuracy: improve the quality of cost estimates, enable more accurate pricing, decouple profit from cost, and improve CAPEX and OPEX forecasting

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Atti di convegni o presentazioni contenenti case history
Conferenza Nazionale dell’Industria sull’ambiente e le bonifiche settembre 2015 Conferenza Nazionale dell’Industria sull’ambiente e le bonifiche

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Estratto del testo
Taking control of maintenance-crew productivity Closing the gap between ''Should take' and ''Does take' Alessandro Aresu (ARCADIS Italia) Convegno sul tema: Conferenza Nazionale dell''Industria sull''ambiente e le bonifiche. Direttiva IED e semplificazioni rete carburanti Ferrara, 23 Settembre 2015 Our experience shows that: '' Maintenance is the largest fixed cost (non-volume related) in a refinery or chemical plant and the third largest overall cost behind raw materials and energy '' Typically Refineries spend around '35M - '65M Per annum '' Every euro of reduced maintenance spending goes to the bottom line '' Every hour of increased uptime increases capacity without capital investment '' World-class performers have their maintenance costs below 1.4% of Plant Replacement Value (PRV) and their mechanical availability is above 96.7% 2 Understanding the impact of maintenance costs on refinery operational costs Our experience shows that: '' The amount of time crew spends on direct work (wrench time) is a small portion of the overall maintenance work order cycle time. Hence, improvements in wrench time (efficiency) alone will not yield significant improvements in maintenance crew productivity '' Through the analysis of a large number of observations of the tasks on schedule, we prioritize the areas within the overall maintenance work order cycle time that require improvement '' Based on prioritized improvements the average maintenance work order cycle time is reduced resulting in an improvement to the maintenance crew productivity 3 A holistic approach to identify Productivity improvements 1. Manage demand (1 '' 2) through a systematic process to prioritize maintenance work orders with a disciplined planning process 2. Manage delivery (2 '' 4) through process streamlining and standardization, spare parts and equipment readiness, and
personnel availability (2 '' 3). Through continuous improvement drive efficiency ( 3 '' 4) 3. Monitor performance (4 '' 5) through key performance indicators (KPIs) Cy c le ti m e o r B ac k log Resource utilization Impact of variability and resource utilization on maintenance High variability Low variability 1 2 3 4 5 Re du c e v a ria bility Improve utilization Identifying opportunities to improve maintenance responsiveness and reduce backlog under three categories 5 Comparative benchmark Industry Industry Average Worst Case 18% EC Harris Target 65% 0 10 20 30 40 50 60 70 - 10 20 30 40 50 60 70 Asia USA Europe Site A Site B Site C Site D Site E Per ce n tage Per ce n tage Location 6 Issues Driving Productivity 7 Do you know what inhibits your productivity ' OpEx optimization delivers tangible and quantified benefits throughout the life cycle of the asset Cost Quantum Efficiency Rate = X X Reduced quantum decreases the number of jobs, labour hours and inventory consumption Increased efficiency reduces the labour hours and re-work required to complete the quantum of work Improved Commercial Management reduces the overall cost of maintenance work delivery 6- 8%'' 5- 7%'' 8- 10%'' Cos t Red uc ti on O pp ortuni ty Quantum Reduction Efficiency Increase Rate Reduction Up to 20%
Reduction
'Can be a Site or Desktop study of the current position
'Report indicates areas for cost saving and improvements
'Delivers an estimated saving / Benefits case ''As Is' '' ''To Be' Review 'Wrench time provides a detailed measure of the sites productivity levels '' getting the crew to the activity 'Report indicates potential improvement initiatives Productivity Improvement 'Work Activity Norms (WAN''s) measure the efficiency of the crew at the work face 'Embedded Contract Factor (CF) provides a Continuous Improvement Plan (CiP) Efficiency Improvement (WAN''s) 'Various contracting solution tailored to work with the various tools to provide incentivised solutions to meet the
Client and Project needs Contracting Solution 'Integrate a transactional tool to manage the data Transactional IT Platform Apply a suite of industry-tested integrated solutions to deliver the value Realise the Benefit Understand the Issues Evaluate the potential Apply the improvements Incentivised Contract Solution 'Benchmark: Enables accurate benchmarking of suppliers efficiency for each covered discipline against Industry Norms 'Cost savings: Identification of further efficiency gains and motivate and enable suppliers to improve their productivity, achieve economies of scale 'Cost transparency: Enable to scrutinise suppliers costs structure to understand estimates, identify further savings, review productivity, and validate profit margin (cost vs. price) 'Cost accuracy: improve the quality of cost estimates, enable more accurate pricing, decouple profit from cost, and improve CAPEX and OPEX forecasting 'Risk management : Reduces risks of unforeseen ''surprises' associated with inaccuracies in cost for CAPEX and OPEX by better managing effort and cost estimate The outcomes Grazie dell''attenzione ARCADIS ITALIA alessandro.aresu@arcadis.com Tel: 02 488 41 600 '' 393 9099016 www.arcadis.com 11


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