Asset management refers to the system used to monitor and maintain items of value to an entity or group. This doesn’t just stop at tangible assets such as plant and equipment; Human resources, intellectual property and goodwill are all considered assets and are as equally important to manage effectively to ensure a high utilisation, sub-sequentially resulting in the greatest return on investment and lowest total cost of ownership.
According to the International Organization for Standardization’s ISO 55000:2014 “effective control and governance of assets by organisations is essential to realise value through managing risk and opportunity, in order to achieve the desired balance of cost, risk and performance”.
Calsta’s Asset Management System deploys a systematic approach covering the entire asset lifecycle of designing, deploying, commissioning, operating, maintaining, upgrading, disposing and replacing. We use tested and proven techniques such as LEAN, Six Sigma, Theory of Constraints (TOC) and Reliability Centred Maintenance to ensure your assets exceed predetermined reliability targets, meet component life expectancy and yield maximum return upon disposal while complying with legal, statutory and legislative requirements.
Asset Management Strategy
The International Organization for Standardization’s ISO 55000:2014 quotes “The process of implementing an asset management system can require significant time, effort and expense; however, the organisation does not need to wait until the entire system is operational to begin accruing benefits, or quick wins, in areas such as risk reduction, opportunity identification or process improvement can be identified early in the implementation, and can be exploited to demonstrate returns and gain stronger stakeholder support”.
Calsta’s Asset Management professionals can rapidly implement a bespoke strategy for your organisation with the ability to realise instantaneous and ongoing value through increased asset reliability, reduction in early component failures resulting in a reduction of total cost of ownership, improvement in utilisation of assets resulting in lower capital requirements and reduced unsafe ineffective field repairs.
Our strategy involves determining failure rates and criticality to the operation to combine a blend of Proactive Maintenance, Predictive Maintenance, Preventative Maintenance and Reactive Maintenance. This blend ensure reliability is maintained without incurring unnecessary costs.
Fleet or Asset Intervention
When an individual asset, asset type or entire fleet are not performing to their required reliability targets, it can have drastic implications to an operations ability to effectively generate revenue. It is not difficult to recognise the poor performing assets. However, it can be challenging to generate an intervention plan to improve the asset or fleet reliability.
Calsta follows a systematic approach to intervention based on analysis of data from multiple sources to provide factual information on the cause and effect of poor performance. Only then can an improvement program can be developed and implemented to design out faults, defect elimination and increase mean time between failures (MTBF).
Preventative Maintenance Strategy
Preventative Maintenance is the act of replacing components and lubricants, carrying out systematic inspections, or correction of impeding failures before they develop into major defects, at predetermined intervals to reduce the likelihood of failure.
Having a Preventative Maintenance strategy that is too aggressive will incur unnecessary costs from excessive maintenance activities, as well as increasing the likelihood of component failure from contamination and introduced faults from these intrusive activities. If the Preventative Maintenance strategy is too lean, it is likely defects will develop to failure before corrective action is taken.
Calsta recognise the advantages and disadvantages of Preventative Maintenance and use these to create a balanced strategy allowing the right amount of maintenance to be undertaken without compromising cost or reliability.
To ensure assets maintain high levels of reliability, major component shutdowns must be completed at regular intervals. While an asset is out of its operational duties, it is the perfect time to complete any additional maintenance activities, inspections and upgrades to ensure upon shutdown completion an asset can perform better than before. However, in Calsta’s experience, this does not always occur. A combination of poor planning and a lack of parts and resource availability causes shutdowns to be completed prematurely without all planned activities being completed.
Calsta have formulated a series of simple tasks to optimise major component shutdowns.
- Carry out a full Asset Condition Inspection to create a defect list and product upgrade requirements.
- Compile parts list and seek price and availability from suppliers.
- Plan major component shutdowns using a dynamic Microsoft Project schedule allowing full visibility into the progress against planned milestones. Integrated with component and parts delivery times and resource allocations.
- Physically inspect parts and components on site to ensure all parts which should be there, are there before the commencement of the shutdown.
- Monitor and Control shutdown activities to reduce deviation from plan.
Condition Monitoring Strategy
Condition Monitoring is the process of monitoring a parameter of condition in equipment with the intention of identifying a change implying a developing failure. Various methods are available and not all are relevant for every equipment type and function.
When Condition Monitoring is used incorrectly, it is expensive and time consuming, often resulting in lost opportunities. Issues making Condition Monitoring ineffective range from 1. Test taking too long to be analysed; 2. Incorrect testing techniques used; 3. A false negative or false positive due to incorrect diagnosis after analysis; 4. A test conducted after failure to determine what went wrong, a form of reactive maintenance.
Calsta can recommend the correct Condition Monitoring techniques to implement, the frequency they should be undertaken and the process to ensure value adding information is generated. Our specialists can assess this data to develop a penetrating view of what’s happening inside your equipment to drive evidence based decision making.
Tyre Strategy and Optimisation
Tyre replacement can be one of the highest cost consumables on a mine site. By adopting a rigourous and proven strategy to tyre management, increases in tyre life can have a drastic effect on the project’s bottom line.
Asset Condition Inspections
An efficacious way to determine the effectiveness of an Asset Management Strategy and maintenance department is through a thorough inspection of physical assets.
When a Calsta Asset Condition Inspection is conducted, a HME specialist will complete a detailed visual inspection, a thermographic inspection, an analysis of oil sample results as well as any other condition monitoring techniques being used, component life comparison to the OEM specified lives and identification of any outstanding product updates from the manufacturer.
At the completion, clients receive a detailed report containing recommendations to increase asset reliability, graphic representation of identified defects and analysis data providing fact and data for informed decision making.
Operational Health Assessment
Calsta perform operational health assessments on client sites using our house developed systems, tools and procedures as instruments to drive improvement at many levels on both Greenfield and Brownfield sites. An operational health assessment can be used to determine the cause of a known constraint or as an improvement technique aimed at identifying and remedying unknown constraints.
Our team of technical experts in the field of professional maintenance and asset management use techniques such as job shadowing, formal and informal interviews and physical inspections to develop an understanding of any constraints and areas of success in the working environment providing recommendations to remedy constraints and increase areas of success.
Infrared Thermography (IRT) is a predictive maintenance tool which must be included in any world class maintenance regime. Often maintenance professionals discredit the use of IRT as no more than a fault finding technique. However, this is usually because the technician is not experienced or adequately trained in thermodynamics or is unfamiliar with the equipment being inspected.
Infrared Thermography has capabilities in any mechanical, hydraulic or electrical system with the ability to detect heat anomalies much earlier than other test methods allowing a plan to be developed and to remedy the fault before it becomes severe.
Calsta’s thermographers are ISO certified in Infrared Thermography with relevant equipment experience to complement. This, coupled with Calsta’s IRT process, ensure benefit is realised from the predictive maintenance tool by reducing downtime and unplanned maintenance.
The right equipment, in the right condition, completing the right task. Three elements to ensure assets are being utilised to their full ability.
Calsta’s team can assess the requirements for the task being undertaken to ensure the asset being used is capable, without redundant capacity, to provide the most cost effective work.
Reliability Centred Maintenance
Reliability Centred Maintenance (RCM) categorises the assets which are business critical and then works to optimise the Asset Management strategy utilising applicable and cost effective tactics focused on the business critical assets.
Failure modes and root cause of failure modes should be examined once an asset is categorised as critical. The effects of each failure are identified using techniques such as Failure Modes and Effects Analysis (FMEA), Hazard and Operability Studies (HAZOPS) and Fault Tree Analysis (FTA). Consequences to consider include safety, operations and the impact on other equipment in the system.
When implemented correctly RCM can drive costs down for over maintaining non-critical equipment resulting in instant cash savings, increase reliability of business critical equipment ensuring all systems are effective and efficient, increased safety by early identification and mitigation of failures and increased mine productivity.
Failure Modes and Effects Analysis (FMEA)
Failure Modes and Effects Analysis is a core task in reliability and quality engineering involving the qualitative review of as many components, assemblies and subsystems to identify as many failure modes as possible, their cause and the effect of each failure. Failure modes and Effects Criticality Analysis (FMECA) is built on the foundation of FMEA with the second phase of an analysis on the criticality of failure.
A properly implemented FMECA has many advantages such as improving the quality, reliability and safety of assets. Calsta’s specialists are able to develop, iterate or assess an FMECA register to ensure comprehensive detail is captured to prevent failures and reduce their severity.
Short and Long Term Planning
People don’t plan to fail, they simply fail to plan
Planning and scheduling is a core element to any maintenance function. Without adequate planning, equipment reliability fails rapidly causing mine production to follow. Any maintenance facility aiming for world class status must have a strong process driven planning department.
Calsta can provide a gap analysis for the state of your current planning department as well as a road map to strive for world class capabilities increasing machine reliability and mine production.