All asset-intensive organisations seek answers to a few, fundamental questions: "What do I own, where is it, what condition is it in, what is its remaining useful life, and what is its remaining economic value?" Few organisations are able to provide accurate and satisfactory answers, with uneven data entry standards over many years production. A proactive, coordinated asset management programme can efficiently manage the life cycle of your assets, lengthen their effective life and reduce equipment failure and associated costs such as loss of production.
Our experienced asset management consultants help you to maximise your assets’ utilisation and useful life and reduce your plant operating costs. Our plant asset management professionals help reduce the risk of downtime, identify where outages and breakdowns are likely to occur, and put in place preventative plans, plan future maintenance activities, undertake predictive asset health monitoring and information, diagnose health issues and provide remediation support. But it all starts with accurate underlying data. Plant asset management programmes should work hand-in-glove with materials management, maintenance and the sourcing of supplies and replacements. Infoplus MDM undertake asset management projects both during migration to new ERPs and for ongoing system improvement projects.
The asset register details the organisation’s assets (ID number, make, model and description), location, condition, remaining useful life and economic value. Possibly it might include information such as warranty details, lease end date and disposal details. Infoplus MDM consultants arrange every asset in the register in hierarchical fashion, with clearly defined parent-child relationships. Building your high quality asset register data provides core inputs into your asset management system and maintenance schedules of maintainable units, down to the component level. This foundational data allows management of your assets from installation through operational life time and maintenance to disposal. Critically, it enables more sophisticated maintenance strategies. Implemented alongside material master data standardisation projects, it provides the answer to the questions "why am I holding this spare part?" and "which machine is this spare part for?"
Reliability Centered Maintenance (RCM) seeks to ensure the reliability of your plant’s equipment and processes through understanding equipment functions, functional failures, failure modes and failure effects. Our consultants develop effective RCM strategies on safety, operational and economic criteria, using failure data, system design redundancies, process and operating experiences. Employing commercial tools and a systematic, structured decision process, we develop specific maintenance strategies for every asset, including mitigating plans for each failure mode. Our experienced consultants employ a structured decision process to ensure RCM failure modes are specified at a detailed level, addressing the part, problem and specific causes of failure, generating a reliability strategy and mitigating tasks that enable you to optimise the operational reliability of your plant and assets.
Reliable equipment performance requires timely executed maintenance to proactively address causes of equipment failure. Risk management recognises that failures with high consequence normally occur infrequently, while failures with low consequences occur more frequently. As probability increases historical data becomes available for events that have occurred, however potential failures with high consequences often lack failure data. Infoplus Risk Based Maintenance (RBM) consultants employ the same functional descriptions of systems, sub-systems, functional failures and failure modes as used in RCM, but introduce an explicit risk calculation. Our RBM consultants quantify, for each asset, the probability of failure (PoF) and the consequences of failure (CoF) in order to map a criticality matrix (Lo-Lo, Lo-Hi, Hi-Lo, Hi-Hi) and generate your maintenance strategy, including acceptable and non-acceptable risks. This allows the development of an informed and appropriate maintenance mix for your plant, encompassing time-based maintenance and condition-based maintenance techniques.
Condition Monitoring (CM) determines the condition of machinery in operation by periodic monitoring and undertakes data analysis to highlight potential equipment problems. It is a predictive or condition-based technique of early fault detection, trending results against levels of acceptability, generally employing advanced technologies, enabling the repair of components prior to failure. A successful CM programme includes knowing when to monitor, what to listen for, how to interpret results and when to action. Infoplus CM consultants have expertise in the application of the various technologies to combine a number of condition monitoring tools, providing an effective monitoring package for your plant. CM helps not only to potentially predict failure and reduce the possibility of high consequence failures, but allows you to order parts in advance, schedule your manpower, and plan concurrent repairs.
Just like a cake recipe, a Bill of Materials (BoM) lists the ingredients and quantities of a finished product, only the costs of errors are much higher. Your BoM is a product recipe and contains a comprehensive, detailed list of parts, components, assemblies and sub-assembles, as well as detailed instructions for gathering and using the required materials. Our professional consultants will prepare your BoMs based on the spare parts recommended by the manufacturer or through part lists, and our master data Subject Matter Experts will catalogue items as stock or non-stock, for inclusion in your material master. This process creates a foundational building block that feeds into multiple areas of your business. Infoplus MDM consultants can generate BoMs either in a flat structure or multi-level, as per business requirement. Multilevel BoMs include maintenance assemblies as recommended in ISO 14224. Our consultants can, as required, create and link material BoMs against equipments or Functional Location. Maintenance BoMs can also be created against specific maintenance Task Lists, improving management of spares in advance of maintenance routines.
Initial spare parts requirements in Oil and Gas upstream projects are typically contained in a Spare Parts Interchangeability Record (SPIR). Information flows from the vendor or Original Equipment Manufacturer (OEM) to the Engineering Procurement Contractor (EPC) to the plant operator. The SPIR data should contain cross-references to equipment and sufficient information to allow procurement of the required spare parts. However, the quality of the information is famously poor and, much of the data is traditionally in excel format, varying between and within projects, and contains vast, unknown duplication and spares overstocking. Infoplus consultants review SPIR data submitted by vendors, undertaking full cataloguing of the spare parts, identifying duplicates, making spares recommendations and building your Bill of Materials. Our professionals take you from a jumble of inconsistent excel spreadsheets into providing a collaborative solution that captures, verifies and delivers you high quality spares data. Infoplus SPIR solutions generate foundational electronic data, ready for syndication across your ERP.
