Asset Management and Dynamic Work Plan- Part II
A change however minor should not be considered as trivial. Assets are capital intensive and require special attention and paramount focus to maintain them in good operating condition. A modification to an Asset needs to be properly reviewed and evaluated from technical and safety perspective. Proper care needs to be taken to ensure that the intended change meets the guidelines and design standards and does not pose any challenge to Health and Environment.
Organizations have established protocols and have been following guidelines to validate changes. In the previous blog Rejeesh had briefed about the modification that was planned to overcome the frequent oil leakage problem in Gear box. In this scenario we saw that the supervisor analyzed the failures and identified root cause to come up with a recommendation to change the oil to a different specification and different type of oil seal. So, are we all set to implement the change then? One would say that the recommendation from an expert warrants the implementation, really?
The impact of change was not evaluated from its design and safety point of view. Here the recommendation required a change of design; something that could possibility impact other departments or functions if not properly evaluated and reviewed. The remedial actions proposed in this scenario classified as an Engineering Change and required a Management of Change (MOC) process. Such changes should not be implemented considering individual or a department recommendation though it may be an expert opinion. It needs careful evaluation and analysis. MOC help to adhere to this process. In MOC process a cross functional team is involved and the proposed change is subjected to justification and validation among different stakeholders and proposed solution is finalized and agreed upon with collaboration. The recommendation and action items of approved MOC will have a department or personnel accountable with a specified timeline for execution.
Here in our scenario, the work plan getting modified as an outcome of MOC recommendation would essentially include special instructions for the operating conditions, the resources which meet the length and breadth of operating conditions, be it the temperature(in our scenario), the materials being handled, operational hours etc. giving it a generic flavor. The plan is a one source stop for particular maintenance/failures related to an Asset; the question is how to make this generic plan more specific?
The selection of applicable work plan for an asset is dependent on its operating conditions; in our case it is the high temperature. These factors could be anything like extended operation duration, work mandating usage of special tools, particular skill set with additional qualifications etc. They definitely require special and different treatment, so should we go ahead and create a separate plan for each of them? But before that, imagine how difficult such maintenance planning would get!
With Robust CMMS packages around we surely deserve a simple program which could help the planner to filter out a specific plan/ resources from a more generic work plan based on operational parameters. While the generic plan covers the length and breadth of possible work details, it should also contain filter criteria for the resources as applicable. Such a plan essentially would allow planners to set an "if-else" condition and tag it to resources, be it the materials used for the service, a skill working on the plan or a tool required to perform the work. Based on the values (selection criteria) fed as per the work details, it would then filter out all the resources matching the values. As per our scenario, let's say there are two oil grades SAE 90 and SAE60 meant for loaders which operate in the slag pit and the scrap unit respectively, both existing as part of a work plan and having these resources tagged appropriately against their operating temperature or the units they operate under. When such a work plan gets applied to a Slag unit work order the SAE 90 oil grade gets selected by default and the SAE60 gets left out. This way we will be able to create a template; a structure supporting dynamism and scalability.
Asset management is going through a phase of continuous change; remember the revolution I spoke about? Therefore I would like to keep this chain live and invite more views, critical assessments etc., a Part III maybe...