Chemical Engineering May 2016 - 62
Percent by Hours - All equipment Families
emergency Work by equipment Family
their culture drives planning, scheduling
and permanently solving problems
rather than just repairing them,
they drive their cost to a low level.
it is true that cost and mechanical
reliability are related, but if cost is used
as the driver, the long-term reliability
of the assets will suffer and maintenance
costs will go up (Figure 7).
top performers are not the organiQ1
Q2
Q3
Q4
Emergency
Non-emergency Predictive and
Preventive
Maintenance
Figure 5. This graph of percent of maintenance
spend by work order type shows that, while
non-emergency work percentage is relatively flat
throughout the industry, top performers (Q1) do a
lower percentage of emergency work and a higher
percentage of predictive and preventative work
are present in the industry when it
comes to production downtime; now
let us look at the trends regarding
maintenance costs of top performers.
Maintenance costs
it is easy to see how planned work
and many fewer hours of total work
allow top performers to reach optiQ1
Q2
Rotating
Q3
Fixed
I&E
Figure
6. This graph of percent of emergency work
by equipment family for all quartiles shows that top
performers (Q1) have a lower percentage of work in
all equipment categories than other performers
mum cost performance. it is important
to use the phrase " optimum
cost performance, " because cost
is the result and not the driver. top
performers, as stated above, do not
minimize the quantity of work based
on cost, and they do not overspend
to get some incremental perceived
improvement in mechanical availability.
they spend the exact amount
necessary to achieve the desired
level of mechanical availability. since
Q4
zations with the lowest maintenance
spending; the lowest-spending organizations
are Ram ei performers that
may have reached Q2 but are typically
found in Q3 or Q4 because their costfocus-only
mentality has negatively
impacted their mechanical availability.
Figure 8 shows that the area with
the greatest difference in spending
for top performers compared to other
performers is routine maintenance.
this is of course expected, as indicated
in the discussion above. top
performers work many fewer hours
than other performers, and as a result,
also spend much less on materials.
since their routine maintenance
work is typically planned and not
emergency work, one would expect
Circle 40 on p. 94 or go to adlinks.chemengonline.com/61495-40
ChemiCal engineering www.Chemengonline.Com may 2016
61
Percent of maintenance spend
Percent of work done
http://adlinks.chemengonline.com/61495-40
http://www.Chemengonline.Com
Chemical Engineering May 2016
Table of Contents for the Digital Edition of Chemical Engineering May 2016
Contents
Chemical Engineering May 2016 - Cover1
Chemical Engineering May 2016 - Cover2
Chemical Engineering May 2016 - Contents
Chemical Engineering May 2016 - 2
Chemical Engineering May 2016 - 3
Chemical Engineering May 2016 - 4
Chemical Engineering May 2016 - 5
Chemical Engineering May 2016 - 6
Chemical Engineering May 2016 - 7
Chemical Engineering May 2016 - 8
Chemical Engineering May 2016 - 9
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Chemical Engineering May 2016 - 11
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Chemical Engineering May 2016 - 15
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Chemical Engineering May 2016 - 97
Chemical Engineering May 2016 - Cover3
Chemical Engineering May 2016 - Cover4
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