Sessions
Barrick’s Maintenance Journey
Robert Cronin, Barrick Gold Corp., Canada
Implementing a new reliability approach to maintenance in a large global organization requires a vision and long-term plan that considers structure, culture and where the function can add the most value. In late 2008, Barrick undertook a major overhaul of its maintenance function across its 25 mine sites, developing a long-term program that extends to 2014. Learn about the challenge, the process and the milestones achieved to date, including engagement of technical staff at sites; development of policy, systems and standards; communication; and a systematic review process that supports local maintenance leaders and staff.
About Robert Cronin:
Robert Cronin is responsible for establishing systems and processes to improve asset management across Barrick’s global operations. He has been instrumental in developing and launching the company’s current long-term maintenance improvement initiative that extends to 2014. He is a Mechanical Engineer with more than 15 years of maintenance and operations experience in mining and minerals processing. He has specialist expertise in business improvement strategies, including lean manufacturing and Six-Sigma. Before joining Barrick in 2008, Robert worked for Rio Tinto (iron ore and aluminum smelting), Ernst & Young (asset management consulting) and BHP (nickel smelting).
Cable Splice Features
Paul Barringer, Barringer & Associates, Inc., United States
Cable splice failures were occurring in a major European chemical plant at the rate of approximately one per year. Each surprise failure costs US$500,000. The failure mode was judged to be a chance failure mode in keeping with electrical experiences, but analysis of the age-to-failure data showed a wear-out failure mode. Corrective action, in response to the real failure mode, has resulted in zero failures since 1994 until 2010. For expensive failures, this emphasizes why analytical tools must be used to solve important financial problems rather than use rules of thumb.
About Paul Barringer:
Paul Barringer is a reliability, manufacturing, and engineering consultant. His worldwide consulting practice involves, reliability consulting and training with a variety of discrete and continuous process manufacturing companies and service industries. The author of several training courses, he has more than 50 years of engineering and manufacturing experience in design, production, quality, maintenance and reliability of technical products. Barringer is a licensed Professional Engineer, the holder of six U.S. patents and a contributor to The New Weibull Handbook, a reliability text published by Dr. Robert B. Abernethy.
Can We Trust Tacit Knowledge in Making Asset Management Decisions?
Ali Zuashkiani, PhD, Director of Educational Programs, Center for Maintenance Optimization and Reliability Engineering, University of Toronto
Optimized asset management decisions can create substantial savings. These decisions include finding an asset’s optimum retirement age, calculating optimum inspection frequencies and knowing when to buy spare parts. The accuracy of these decisions depends on having historical data in appropriate formats, which usually do not exist. Tenured experts often have valuable experience, but how dependable is this tacit knowledge? How can it be documented and retained as companies lose aging employees? The powerful technique known as knowledge elicitation is one way. This session will explain the role of tacit knowledge in asset management decisions and how it is extracted and formulated through knowledge elicitation.
About Ali Zuashkiani:
Dr Zuashkiani has many years of practical experience combined with a strong scientific background in optimizing asset management decisions. In his role as Director of Educational Programs at the Centre for Maintenance Optimization and Reliability Engineering (C-MORE) at the University of Toronto, he has been involved in several Life Cycle Costing management projects for utility and gas distribution companies in North America and assignments on how to assess asset management practices in plants in the Persian Gulf. The author of Expert Knowledge Based Reliability Models, Ali is a frequent global speaker on asset management and has been Chair of the International Physical Asset Management Conference for the last six years.
Enhancing Asset Condition Monitoring and Tracking Capabilities by Leveraging Radio Frequency Identification (RFID) with Sensor Technologies
Dr. Albert Tsang, The Hong Kong Polytechnic University, Hong Kong
Radio frequency identification (RFID) is an emerging technology with huge potentials for business automation and effective asset management. Owing to its unique and automatic identification capability, RFID technology is gaining acceptance in industries, particularly those in manufacturing, logistics, security, and healthcare. In recent years, there is an emerging trend of research studies that leverage RFID with a variety of sensors (such as temperature, pressure, and motion) to collect rich data in support of timely decision making and situation analysis, essential inputs to evidence-based asset management. This presentation will introduce the basic components of an RFID system, and discuss the challenges of RFID technology in asset condition monitoring and tracking.
About Dr. Albert Tsang:
Albert H.C. Tsang is Principal Lecturer in the Department of Industrial and Systems Engineering at The Hong Kong Polytechnic University. With the University for 28 years, he specializes in quality, reliability, performance management and physical asset management. He obtained his PhD from the University of Toronto. Prior to joining the University, Dr. Tsang worked for nine years in manufacturing in industrial engineering, quality assurance, and project management. A founding member and former Chairman of Hong Kong Society for Quality (HKSQ), Dr. Tsang also holds four patents, is the author of WeibullSoft (a computer-aided self-learning package on Weibull analysis), and co-author of four books in the areas of physical asset management and industrial applications of RFID technology.
How Social Media is Changing Our Behaviour and Expectations in EAM Application
Anders Lif, IFS World Operations AB, Sweden
Social media have, in many ways, changed our behavior and the way we share information. With social media, word-of-mouth has increased in significance as people reach each other and share experience much more efficiently. Social media is changing our professional buying behavior in everything from spare parts to IT. It also affects how EAM solutions are designed and how we cooperate in the business environment. It is driving mobile client usage. With mobile Internet traffic doubling annually for the past five years -- faster than any other type of Internet traffic -- smart phone "apps" are continuously being developed and are increasing the effectiveness of the smart phone users. The world is changing – are you?
About Anders Lif:
Anders is IFS Global Director for Product & Industry Marketing. In this role he heads up IFS corporate functions such as product marketing, partners & alliances, IFS eChannels and IFS global industry directors. Starting with Siemens for eight years in automation and control systems, he joined IFS in 1998 and later assumed R&D responsibility for IFS EAM solutions. Anders guided several IFS industry teams before assuming his current position.
How to Maximize Thermal Imaging for Process Control
Jon Chynoweth, NEC-Avio, United States
The use of remote-placed thermal imagers for monitoring production lines is a cost-effective tool to increase production and product quality, reduce scrap and improve margins. While a straightforward case can be made for implementation of on-line thermal imaging, a total engineered system is needed to maximize effectiveness of this solution. When designing this solution, a key step is to determine and control the emissivity of the product and environment to maintain long-term, accurate temperature measurement. This presentation will discuss the parameters for designing the overall package necessary to meet these goals. It will also illustrate the effect of emissivity on temperature measurement and the measures necessary to compensate for this phenomenon.
About Jon Chynoweth:
Jon Chynoweth has been involved in the development and marketing of thermal imaging cameras and related software for 25 years. He has been instrumental in development of smaller, higher-resolution thermal cameras, as well as technology advances for safer inspections of high-voltage electrical panels, remote substation monitoring for utilities and critical vessel monitoring in the petrochemical industry. His development of imaging software for process control and utility applications led to a career with Raytheon as manager of sales and marketing for uncooled cameras. Jon later formed his own business, ultimately acquired, to develop thermal cameras and software. His current position is with NEC-Avio as Product Manager for North America.
Improving Equipment Reliability at Ontario Power Generation’s Nuclear Power Plants
Ken Sutton, OPG, Canada
Ontario Power Generation Nuclear produces about 50% of the electricity used in Ontario, from ten reactors located at the Pickering and Darlington plants. While personnel and nuclear safety is always the number one priority, equipment and system reliability is a cornerstone of the nuclear program. While each CANDU reactor is shutdown every two to three years for scheduled offline maintenance, a great deal of maintenance can be done online with the plant producing power. Planning for shutdown maintenance starts two years in advance of the actual outage. Online maintenance is done via a weekly schedule with planning starting 20 weeks in advance, using a rolling cycle. Maintenance efficiency and effectiveness are measured using a number of metrics which are reviewed continuously at all levels of the organization. A large predictive program constantly monitors key parameters on major components and safety-significant equipment.
About Ken Sutton:
Ken Sutton is a Professional Engineer and Project Management Professional with over 30 years experience in the electric utility industry at Ontario Power Generation (OPG). While he has worked in many areas, including Operations and Maintenance, his area of expertise is Work Control, the department/processes responsible for planning and scheduling Maintenance and operational activities at the power plants. Ken has led maintenance backlog reduction initiatives and numerous work scheduling improvements which have helped improve equipment reliability. He is OPG’s representative to C-MORE, and is currently Manager, Work Control at Pickering A Nuclear.
A Journey Toward Evidence-Based Asset Management
Amin Elsherif, Suncor Energy
With widespread adoption of computerized data collecting systems, companies have become data rich but not always information rich. At the same time, decisions about company assets are becoming more important. Today, executives are uncomfortable leaving those decisions to intuition, and are looking for evidence-based reasoning. This has led to Evidence-Based Asset Management (EBAM), a powerful selection of tools that can create significant value in a short period of time and with little effort when compared to the value. This presentation will present Suncor’s journey toward EBAM and its resulting benefits and challenges.
About Amin Elsherif:
Amin Elsherif is a Professional Engineer, Mechanical Engineering with a M.Sc. in Computerized Reliability and Maintainability in Mechanical System Design. He is also a Maintenance Management Professional “MMP” with 20 years of experience in the Oil & Gas industries. Amin is the president of the Plant Engineering and Maintenance Association of Canada, Fort McMurray chapter. He started his career with Shell, then joined CALTEX (Chevron & Texaco), and currently working with SUNCOR Energy, Inc., as a Director of Reliability Engineering.
Maintenance Decision-Making Based on the VDM KPI Dashboard
Guy Delahay, Mainnovation, Inc.
Maintenance decisions can be made on different levels. It could be the best maintenance rule for an elementary failure mode, the best direction for a complete plant or even the best investment decision for a portfolio of assets/plants. In this presentation, we will focus on transforming data from your CMMS/EAM system into meaningful management information. To make better maintenance decisions you first need a good decision logic (which is delivered by the Value Driven Maintenance, VDM methodology) and secondly, a tool (the VDM KPI Dashboard) that provides you relevant maintenance intelligence instead of making judgments based on gut feeling only. The presentation will include case studies of companies that have incorporated a Plan/Do/Check/Act mindset and continuously improve their maintenance performance, based on real measurements and evidence.
About Guy Delahay:
Guy Delahay is an industrial engineer with over 25 years of experience in maintenance and asset management improvement. He has been involved in projects with Volvo Cars, Essent Energy, Johnson & Johnson, Simplot, ConAgra Foods, the Port of Rotterdam and many others. Guy worked for leading consultancy organizations before founding Mainnovation in 2000. Co-author of the book VDM: New Faith in Maintenance, Guy is also a former chairman of the Dutch Maintenance Association.
Modeling the Cost of Maintenance Across a Fleet of Complex Facilities
Bob Platfoot, Covaris, Australia
Operators of large asset fleets based across multiple facilities can struggle to determine the optimum budget for maintenance per facility. This problem becomes more complex when the maturity of work management and cost capture is low. The challenge is then to justify the correct level of funding essential to maintain the assets at a reasonable level of condition consistent with the operational tempos present at each facility. The modeling presented in this session is based on a practical case concerning 246 public hospitals, where not only was there uncertainty about the historical level of work, but the actual configuration of assets per hospital often had to be estimated as well. It presents a logical framework which can be applied to other large fleets and allow operators to test their data and their budget guidelines. This session will also cover some of the difficulties in handling large data sets, poor quality data and various tests necessary to allow the model to be built up to a convincing outcome.
About Bob Platfoot:
Bob Platfoot is a Principal of Covaris Pty Ltd, an engineering consulting and technology development company based in Sydney, Australia. The company provides services in reliability engineering, maintenance systems, risk management and asset management. Bob has worked across a broad mix of utilities, manufacturing, FM and mining, with recent work completed in mining, food, water and power utilities, health and airports. Prior to establishing Covaris, Bob was a faculty member at the University of NSW where his team developed innovative maintenance engineering techniques, resolving problems in PM optimization, maintenance contracting and design-induced problems.
New Standards for Reliability and Maintenance Performance in a Global Marketplace
Al Poling, HSB Solomon Associates, United States
Global competition has changed the manufacturing landscape forever. Reliability and maintenance are being leveraged worldwide as competitive advantages. But what does good reliability and maintenance look like? Decades-old benchmarks are no longer valid. The bar has been raised with best performers achieving mechanical availability approaching 100% with costs approaching 1.0% of replacement asset value (RAV). To confirm your competitive position, you must measure and compare your performance to others in your industry. In this session, current world-class performance thresholds will be shared and insights provided into the factors that influence world-class performance as well as those that do not.
About Al Poling:
Al is a project manager with Solomon Associates where he works with clients to identify performance-improvement opportunities through participation in The International Study of Plant Reliability and Maintenance Effectiveness. He started his technical career as a maintenance and reliability engineer and has held plant and corporate leadership roles in maintenance and reliability with several companies. Al is a Certified Maintenance and Reliability Professional (CMRP), and served as Technical Director for the Society for Maintenance and Reliability Professionals (SMRP) from 2008 to 2010. A regular presenter at Maintenance & Reliability conferences worldwide, Al has also published several white papers and articles on maintenance and related topics.
Optimizing Mining Hoist Maintenance Decisions Through Blending Oil Analysis and Hazard Modelling
Pedro Cancino, Dictuc Tribologia, Chile
This presentation discusses work completed at Chile’s Collahuasi mine to improve the existing oil-analysis program for its electric hoist systems. Oil-analysis results from its hoist systems were analyzed along with their failures and repairs over a six-year period. Using the proportional hazards model approach, key condition variables relating to failures were found from among 22 elements monitored. Those variables were incorporated into a decision model that provided an optimal recommendation on whether to continue operating a hoist system or remove it for overhaul on the basis of data obtained from an oil sample. The decision model, when triggered by incoming data, provided both a recommendation based on an optimal decision policy as well as an estimate of the unit’s remaining useful life.
About Pedro Cancino:
Pedro Cancino is Operations Manager of Dictuc, a subsidiary of the Pontificia Universidad Católica de Chile, an engineering consulting and technology company based in Antofagasta, Chile. He started his career in Copec and in 2006 started his own business TribologyLab. Two years later he entered into a joint venture with Dictuc, starting a Laboratory for CBM and giving advice to mining companies on PdM. As Operations Manager, he is responsible for positioning the services of asset-management consultancies, used-oils laboratory services and spot contract in the Chilean Mining Cluster.
Power Interruption Reliability Modeling and Optimization in Hydro One
Bo Ji, Hydro One, Canada
Delivering reliable electricity to Ontario customers is very important to Hydro One’s business. In power distribution reliability, maintaining a lower power interruption frequency and duration is not the only task; determining magnitude and trend are also important. Furthermore, having a sound model to predict time to next interruption and optimize maintenance work is key to lower operation and maintenance costs. Hydro One has made significant progress on this model, and this presentation outlines its framework based on Hydro One’s asset performance data and EXAKT tool. It also illustrates the modeling and optimization process, explains the statistic fitness testing for the model and shows the real-case verification of model soundness by back testing using historical data.
About Bo Ji:
Bo Ji has worked in Hydro One’s Business Performance Division since 2006, and is responsible for analyzing Hydro One’s distribution reliability and business performance. He has also played important roles in many collaborative research projects on reliability and maintenance at the company. Prior to 2006, Bo worked as a project manager at a leading consulting firm focused on designing and developing Air-China’s Operation Management System, and also worked for DaimlerChrysler Research and Development Center. Bo holds degrees in Computer Science and Mechanical Engineering.
Process Data: An Untapped Source of Potential CBM Information
David Williams, Teck Resources, Canada
Teck’s Trail Operations is exploring a new way to track the health of its equipment. Condition monitoring has been its mainstay for years, which has consisted of traditional condition monitoring tools. Trail now wants to take advantage of its myriad process-control data points. While key to running the day-to-day operation of the plants, this information can also be used to warn of upcoming equipment issues. This presentation will review Trail’s efforts to add this form of condition monitoring to its maintenance strategy.
About David Williams:
David Williams is the Reliability Leader for Teck Resources, a diversified mining and mineral development company headquartered in Vancouver, Canada. David began the reliability portion of his career in 2001 at Teck’s Lead and Zinc smelter in Trail, BC. While in Trail, he played a key role in the development of Trail’s Reliability Department. In his current role, he helps all Teck sites develop their Reliability programs.
Remaining Useful Life of Power Transformer: CMMS Requirements
Wendelin Schuhmann, Manitoba Hydro, Canada
The remaining useful life (RUL) of a power transformer study is done in collaboration with C-MORE to develop a model for predicting RUL of repairable systems using condition monitoring data, such as dissolved gas analysis (DGA). One objective is to confirm that major failures of the transformers can be predicted with confidence using data presently available. Another is to determine Computerized Maintenance Management System requirements that would allow for cost-effective, efficient use of such a model in practice. Current data-collection practice and possible solutions to overcome practical limitations are discussed, such as using Work Management Measures.
About Wendelin Schuhmann:
Wendelin Schuhmann, PE, graduated from the University of Manitoba as an electrical engineer and presently works for Manitoba Hydro as a reliability engineer. His responsibilities include development of performance measures and performance targets, and representing reliability engineering interests within the company’s enterprise asset management system.
The Role of CBM Optimization for Both Industrial Equipment and Cancer Screening
Dr. Andrew K.S. Jardine and Dr. Sharareh Taghipour, University of Toronto, Canada
The presentation will introduce the extension of models used for condition monitoring of industrial equipment to cancer screening. This is a new research direction being undertaken by an interdisciplinary team of researchers familiar with equipment condition monitoring and physicians and scientists who specialize in cancer screening and cancer research.
About Andrew K.S. Jardine:
Dr. Jardine is Director of the Centre for Maintenance Optimization and Reliability Engineering (C-MORE) at the University of Toronto and Professor Emeritus in the Department of Mechanical & Industrial Engineering. Author of Maintenance, Replacement and Reliability, first published in 1973 and now in its 6th printing, he is also the co-editor or co-author of Maintenance Excellence: Optimizing Equipment Life Cycle Decisions (2001), Maintenance, Replacement & Reliability: Theory and Applications (2006) and Asset Management Excellence: Optimizing Equipment Life Cycle Decisions (2011). In addition to his university activities, Dr. Jardine has carried out innumerable consulting assignments in the general area of optimizing physical asset management decisions.
About Sharareh Taghipour:
Dr. Sharareh Taghipour is a postdoctoral fellow at the Centre for Maintenance Optimization and Reliability Engineering (C-MORE) at the University of Toronto. She obtained her PhD in Industrial Engineering from the University of Toronto, and received her BSc in Mathematics and Computer Science and her MASc in Industrial Engineering from Sharif University of Technology, Iran. Her research interests include reliability analysis, inspection and maintenance optimization models, analysis and modeling of censored data, and applications of maintenance optimization models in medical decisions. She has authored articles for several journals including IEEE Transactions on Reliability, Reliability Engineering & System Safety, Journal of Operational Research Society and others.
SMED: Immediate Improvement of Asset Utilization
Enrique Mora, MORA International Group, Inc., United States
SMED is one of the least-used lean strategies. Most manufacturers still lose large amounts of productive time and money by not implementing it because downtimes caused by setups and changeovers are constantly overlooked or underestimated. Most of these can be cut in half with a one-week Kaizen geared toward implementing the “single-minute-exchange-of-dies” approach. The resulting validated measurements and data can assure optimal asset utilization and optimized ROI. As it becomes entrenched in company culture, the benefits of SMED permeate to other processes, not just setups.
About Enrique Mora:
Enrique Mora brings more than 30 years experience analyzing, designing, and implementing improvement projects and transitions to world-class manufacturing systems. Enrique is a certified Lean Manufacturing, Maintenance and Reliability Consultant whose clients have included Ford Motor Co., Unilever, NASSCO, Herbalife, Sundance Jacuzzi, Baxter, FANALCA-Colombia, Monsanto, Wrigley s, Du-Pont-DAK Americas, Barrick Gold Peru and many others. In addition to implementing Total Productive Maintenance (TPM) and Total Process Reliability (TPR) in over 100 operations across nine countries, Enrique serves as a technical advisor for Leadership, Lean Manufacturing implementation and sustainability, workflow improvement, set-up time reduction, and other improvement efforts. During his career, Enrique has held the positions of maintenance engineer, plant engineering manager, and senior consultant. As a professional trainer, he has conducted over 100 bilingual (English-Spanish) public seminars and several hundred in-house seminars, as well as numerous training courses for senior executives, managers, supervisors, and hourly personnel in America, Mexico, Central and South America, and Africa.
Transitioning From a Reactive to Predictive Culture
Shamir Ladhani, Enmax Power Corp., Canada
Predictive maintenance involves responding to signals of potential failure of a particular piece of equipment. However, the traditional approach in utilities like ENMAX has been to rely solely on time-based maintenance. The challenges, in moving from a well-entrenched time-based maintenance approach to a predictive one are twofold. The first is to change the underlying business processes and practices supporting time-based maintenance. The second, and perhaps more challenging of the two, is to shift the hearts and minds of field, office and management staff who have employed time-based maintenance practices for decades. This session will outline strategies and techniques employed by ENMAX Power Corp. that have proved successful in transitioning toward a predictive-maintenance organization.
About Shamir Ladhani:
Shamir Ladhani is Director of Transmission Engineering Services at ENMAX Power Corp., a wholly owned subsidiary of the City of Calgary, headquartered in Alberta, Canada. He oversees substation engineering, equipment maintenance and transmission system planning functions. He has spearheaded the implementation of processes and technology in equipment maintenance and risk assessment. Shamir realized early on that to succeed at engineering, he needed to develop his creative abilities. To this end, he has delved into stage and film acting, and won the Workshop Theatre's 2010 Willy Award in the category Outstanding Supporting Actor for his work in Inherit the Wind. Shamir has his Professional Engineer designation through The Association of Professional Engineers, Geologists, and Geophysicists of Alberta (APEGGA), and holds a Masters of Engineering degree in Electrical Engineering. He is also a Senior Member of the Institute of Electrical and Electronics Engineers (SMIEEE).
Value Generated by the Application of Asset Management Basic Practices
Jean Claveau, Rio Tinto Alcan, Canada
Money is everywhere in Asset Management Reliability – one only needs to know where to look for it and how to get it. Based on multi-national industrial plant experiences over several years, this presentation will show examples of value generated through the use of AM practices, and will discuss ways to deliver it.
Executive Sponsor:
|
||
Sponsors: |
||
 |
||
 |
||
NEC Avio Infrared Technologies demonstrates their extensive line of High Performance Infrared Thermal Imaging Cameras. These feature packed Infrared Thermal Imaging Cameras include standard and high resolution OEM & Complete Modules, Handhelds, and Fixed Mount with IP54 Housing versions for Process Control, Preventive Maintenance, R&D, and Security applications. 
