SKF Client Needs Analysis Your road map for improving plant reliability

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Good questions. But finding the right answers and imple-menting strategies to address these issues can be daunt-ing. With daily operational challenges and time constraints, identifying and achieving improvement opportunities may seem impossible. SKF can help.

Drawing on years of SKF productivity experience, we can help you identify improvement opportunities that will yield positive bottom-line results, then suggest a strategy for implementing a programme to achieve them.

Consider:• At least 50 % of companies that start a maintenance

strategy project do not implement the results effectively, and as a result, do not realize all potential benefits.

• 96 % of plants that implement condition-monitoring programmes do so to reduce unscheduled machine breakdowns. More than 80 % also want to enhance competitiveness.

• Of those facilities implementing condition-monitoring programmes without proper analysis, 40 % claim they did not achieve the expected return on investment.

• Our goal at SKF is to help you achieve maximum return on your reliability investment. The SKF Client Needs Analysis is a performance benchmarking process with proven success in many industries

How and where can I improve plant performance?

Should I better align my plant with industry benchmarks? How?

How do I assure continual improvement in my plant’s maintenance processes?

SKF Client Needs Analysis: A proven process to identify plant improvement opportunities

An integrated reliability and risk-based asset management strategy starts with an understanding of where you are today, and where you need to be to attain optimum performance. The SKF Client Needs Analysis enables this understanding, combin-ing our experience in reliability-focused maintenance with your knowledge of plant conditions. The goal is to provide useful, actionable information to help you focus on credible perfor-mance improvement opportunities.

The SKF Client Needs Analysis is aligned with the main facets of the SKF Asset Efficiency Optimization (AEO) work management process, which enables a plant to produce the same amount for less cost, or to produce more for the same costs. AEO provides the basis for applying knowledge, improved practices, and technology to achieve the greatest return on investment.

The Client Needs Analysis data can be obtained in just hours. Forty questions covering the four main AEO facets provide a snapshot of your plant’s situation and its position on the main-tenance maturity continuum (see Figure 1).

Beyond the 40 questions, we also consider industry-specific aspects of maintenance and reliability to create a unique, needs-based analysis. Once we know how your reliability maintenance processes are currently working, we then help devise a roadmap to meet your foremost challenges.

Identifying problems: When, where and how they matter

Figure 1: The four phases of maintenance maturity. Moving toward a world-class facility starts with understanding where you stand today, and defining your objectives for the future.

Figure 2: Asset Efficiency Optimization (AEO) is an SKF work management process designed to achieve maximum effectiveness from plant business goal activities. AEO includes four key facets: Maintenance Strategy, Work Identification, Work Control and Work Execution. Within each facet, the interaction of three aspects of your organization – process, culture, and technology – are paramount to your success.

SKF Asset Efficiency Optimization – Work Flow Process

MaintenanceStrategy

WorkIdentification

WorkControl

WorkExecution

Reliability Issues (Design)

Pre-Defined Priorities

Standard Job Plansand Procedures

Maintenance Strategy Project

Plant Asset Managementand Maintenance Programme

(Living Programme)

PRM / ODR Collection and Analysis

PM PRM ODR RTF

RCFA

Information Integrationand Decision Making

Work Order Generation

Planning

Rolling Schedule

Spare Parts Alignment

Business Goals

Corrective Maintenance

OperatorsInitiators

Work Execution

Post Maintenance Testing

Update Living Programme

PM = Preventative Maintenance (time based)PRM = Proactive Reliability Maintenance (predictive and corrective)ODR = Operator Driven Reliability (observations)RTF = Run to Failure (reactive maintenance)RCFA = Root Cause Failure Analysis

PROGRAMME

CHARACTERISTIC

MAINTENANCE

MATURITY

DRIVER

REWARD

BEHAVIOUR

Firefighting

OPTIMIZING

Maintaining

Promoting

Innovating

Breakdowns

Avoid Failures

Uptime

Growth

Overtime Heroes

No Surprises

Competitive

Advantage

WORLD CLASS

Efficiency O

ptimization

Responding

Planning

Disciplined

Organization

Organized LearningSTABILIZING

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The Client Needs Analysis is conducted during a discussion between key members of your organization and a team of SKF professionals. We will guide you through the maze of information that you already have, helping you gain a perspective on your reliability programme that is generally not possible while immersed in daily activities. Once the analysis is complete, you will receive a comprehensive report that includes:

A progressive, structured approach to assessment

Maintenance StrategyA comprehensive maintenance strategy can transform maintenance from a cost centre into a profit centre. Topics investigated are:

• Estimated annual replacement asset value

• Annual maintenance cost vs. budget

• Annual revenue (total sales)

• Stores Inventory Value (MRO supplies and consumables)

• Overall availability of assets

• Reactive vs. proactive maintenance (%)

• Asset register status, accuracy, and depth

• Depth of asset criticality analyses performed

• Planned work from maintenance strategy techniques

• Root Cause Failure Analysis routines

Work IdentificationBeing able to better identify potential faults before they become a problem will decrease unplanned downtime and increase production efficiency. Topics investigated are:

• Work types

• Work order process

• Work order compliance

• Work order priority

• Operator care

• Operators conducting Preventive Maintenance tasks

• Predictive Maintenance programme effectiveness

• Decision support

• Management of change

• Work skills and competence

Main Facet/ Maturity Absent Fire Fighting

Maintaining Promoting Innovating Not Applicable

Not Understood

Totals

Maintenance Strategy 3.97 5.31 3.51 4.91 6.78 .38 0.16 25.0

Work Identification

5.6 3.74 2.44 3.39 8.42 1.3 0.12 25.0

Work Control 4.33 2.87 4.41 5.78 6.68 0.83 0.09 25.0

Work Execution 5.02 6.79 3.46 3.61 5.36 0.71 0.06 25.0

Subtotals per choice of response

18.91 18.71 13.82 17.69 17.23 3.21 0.43 100.0

Table 1 Maturity Matrix Summary The table shows actual overall summary matrix status from 500+ Client Needs Analyses performed by SKF.

Targeting four key areas for improvementBy assessing performance indicators against benchmarks, SKF determines improvement opportunities that typically fall under these facets:

Work ControlDetecting problems earlier enables better scheduling of labour and spare parts for repair. Machine uptime increases, while overtime, work backlog, and total costs decrease. Topics investigated are:

• Planning accuracy (time-based)

• Number of planners per craftsperson

• Scheduling horizon

• Preventive Maintenance schedule compliance

• Predictive Maintenance schedule compliance

• Budget compliance

• Spare parts (bill of materials) documentation

• Standard job plans and procedures

• Work backlog

• Overtime levels

Work ExecutionWith an optimum work execution programme, maintenance labour productivity increases, maintenance rework decreases, and total maintenance costs are reduced. Topics investigated are:

• Work orders with no history

• Closing work orders with labour costs, material costs, and actual vs. estimates

• Maintenance labour productivity

• Training allocation per craftsperson

• Supervisor to craftsperson ratio

• Number of crafts designations

• Post-maintenance testing compliance

• Maintenance rework

• Review of breakdown maintenance

• Review of Preventive and Predictive Maintenance

Maintenance Strategy

Work Execution

Work Control

Figure 3 Spider Chart

Standard deviation -1

Standard deviation +1

Segment Average

Fire Fighting

Maintaining

Promoting

Innovating

Work Identification

• A summary of initial set-up details

• A Spider Chart illustrating a micro-level assessment for each question versus the maturity phases (see Figure 3)

• A Maturity Summary Matrix showing a macro-level assessment for all four main facets of the AEO process versus the maturity phases (see Table 1)

• A Risk Deviation Chart illustrating your performance question-by-question versus your industry averages (see Figure 4)

• A detailed roadmap of recommendations for improving plant reliability

And should you wish to implement our recommendations, we can help create a business case to justify your investment.

Figure 4 Risk Deviation Chart

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By obtaining a comprehensive understanding of your plant’s unique requirements, our Client Needs Analysis allows us to identify improvements that can help you achieve optimum results.

Whether conducted at one site, or multiple sites within your organization, a Client Needs Analysis provides a snapshot of current maintenance efficiency. It not only helps you measure performance against benchmarks and best practices within your company or industry – it can even highlight continuous improvement opportunities.

To help your team prepare for a successful Client Needs Analy-sis, you will receive the analysis questions prior to our first data collection meeting. We will provide you with a detailed descrip-tion of the process as well as guidelines on the resources, facts and figures needed to complete the analysis. We will also work with you to identify key individuals within your plant whose participation will enable the most successful result.

Once the analysis is complete and improvement opportunities have been identified, our team will help you craft the solutions) tailored to your needs. Typically, this will involve a combination of internal activities, products, or services you may already be using, along with one or several SKF solutions.

Areas of expertise where SKF can assist:• Asset Efficiency Optimization work management process

• Quick start reliability programme

• Maintenance strategy review

• Proactive Reliability Maintenance programme

• Operator Driven Reliability programme

• MRO supply: spare parts and inventory management

• Machine maintenance: precision alignment, balancing, lubrication, etc.

• EAM/CMMS data population: asset register, bill of materials, standardized job plans, etc.

• Living programme: reliability engineering and root cause analysis of failure data

• Training: competence development and knowledge exchange

• Outsourcing through performance-based service and supply agreements (The SKF Integrated Maintenance Solutions)

Knowledge, the key to a successful reliability programme

While you may already be aware of problem areas in your plant’s reliability programme, consider how an SKF Client Needs Analy-sis can help you identify their root causes and recommend the right steps for improvement.

Backed by almost 100 years of rotating machine reliability expertise, SKF Client Needs

Analyses have helped clients across every major industry. From paper and petroleum to food processing and power, here are just a few examples of how we’ve helped clients around the globe:

g An oil-refining company identified the need for a series of improvements. First, they needed to establish a correct asset register to improve efficiencies in the CMMS process. Second, they discovered the need to better document and communicate instructions that would standardize quality in the execution of maintenance and reliability tasks. This finding also highlighted the need for additional personnel training. Finally, they recognized that involving their operators in the reliability effort could help them attain a significant reduction in downtime and related costs and move them closer to achieving their desired business results.

g An Asian pulp and paper producer participated in a Client Needs Analysis to measure ten of its facilities against each other and industry benchmarks. Key improvements were identified in the areas of work control and execution. A strategy was enacted to better align processes among each plant, and milestones were established to help ensure a consistent progression toward best-practice criteria.

g A global food company conducted a multi-plant Client Needs Analysis to benchmark maintenance practices and establish a company-wide reliability improvement programme.

g A power generation facility identified the need for a more effective maintenance strategy after a work control review, and then implemented the process improvements needed to execute the programme.

g SKF has conducted Client Needs Analyses throughout its own bearing factories to assess varying levels of maintenance maturity and to prioritize areas for improve-ment that would immediately impact factory efficiency.

Success, our mutual goal

For more information on the SKF Client Needs Analysis, contact your local SKF representative, or visit www.skf.com/reliability