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MSC Maintenance Management Systems and Life Cycle

Management

MSCHQ N711 & PM 1

Agenda

Maintenance Management Policy Reliability Initiatives Life Cycle Management Planning N7 Maintenance Management ProgramsUSFFC Maintenance Initiatives

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Policy:Framework ~ MSC Mission (Guiding Document)

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Policy:

MSC’s Maintenance PhilosophyThe people:

• Providing skilled, career, licensed marine shipboard engineers

• Maintaining trained, motivated and forward thinking shoreside management

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The tools: • Providing technology and tools to analyze

existing conditions and enhance maintenance planning and execution

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Policy:

MSC Maintenance Policy Documents

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Policy:

MSC Maintenance Policy DocumentsCOMSC Instruction 47XX.X Ashore Maintenance Management

Policy• Planned Maintenance Development Process • Maintenance Effectiveness Reviews • Maintenance Feedback Process • SAMM Audit • Post Availability Analysis • Work Item Library Management • Root Cause Analysis Implementation Process

COMSC Instruction 3540.6A Engineering Operations and Maintenance Manual (EOMM)

• Preventive Maintenance • Corrective Maintenance

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More simply put, the 3-Rs:

The Right Maintenance on the Right Equipment,

at the Right Time,

Employ an efficient and cost-effective maintenance approach that strives to ensure safety, meets regulatory requirements and supports reliability in support of MSC mission.

Maintenance: The set of actions taken to ensure that components, equipment and systems provide their intended functions when required.

Reliability: The ability of an item to perform a required function when needed.

Function: The intended action or operation which it is intended to perform.

Policy:

Maintenance Strategy

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Design/Build

Storage MaintainOperateInstall/Startup

Root Cause AnalysisLoss of Ship Availability and Equipment Downtime

Unnecessary Maintenance and Repairs

Defects DefectsDefects DefectsDefects

Reliability:THE RELIABILITY PROCESS

Source: Making Common Sense Common Practice 3rd Edition

By Ron Moore

Reliability Centered Maintenance

Uptime&

Necessary Work

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Reliability:

MSC Maintenance Technology Adoption Lifecycle

“Prove to me that failure won’t occur if you change this.”

“Prove to me that failure will occur if I change this.”

Limits of Applicable and Effective Maintenance

CM Cost

PM Investment

Total Maintenance CostCost $

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Reliability:

Paradigm Shift

DO WE HAVE THE RIGHT MAINTENANCE?How does this equipment effect our Maintenance Cost?

• Total Maintenance Cost • Annual Cost of Maintenance as a Percent of Asset Replacement

Cost• PM cost vs. CM cost

Does this equipment perform when I need it? • Operational Availability

• Mean Time Between Failure• Mean Time To Repair

What is the Reliability of the equipment at X hours of operation?

• Reliability R(t)• Mean Time Between Failure

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Reliability:

Measures

LCM:

Background Life Cycle Plans intended to assist with Life Cycle

Management of all NFAF ships and to refine POM and budget development.

Development of Life Cycle Plans for all NFAF ships identified as a FY 10 Corporate Plan Initiative, removed mid-year to be picked up in FY 11-12.

Life Cycle Plan development will be coordinated with MSFSC and N7.• Plans will also include regulatory body life cycle requirements.• Will benchmark with US Navy and commercial industry practices

where possible• Reviewing Integrated Class Maintenance Plans (ICMP), met with

Maersk Lines Limited

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LCM:

Current Status Way Ahead brief presented to COMSC Multi-year effort with contractor support required. Activation/Deactivation schedules identified for all classes

SHIP CLASS EXPECTED SERVICE LIFET-AKE 40 YEARST-AOE 40 YEARS*T-AO 35 YEARST-ATF 40 YEARST-ARS 20 YEARS**T-AH 30 YEARS***

Critical equipment/systems (as found in SMS and SAMM records) have been identified for all ship classes

T-AOs identified as first class for Plan development• Contain most mature data, largest ship class and at midpoint of life cycle• As reported in POM 12 class beginning to experience life cycle issues

* T –AOE Class commissioned 1994, MSC Operation 2001** T-ARS Class commissioned 1986, MSC Operation 2006*** T-AH Class commissioned 1976, MSC Conversion 1986

LCM:

Current Status (continued)

Benchmarking with Commercial Industry and NAVSEA Surface Ship Life Cycle Management (SSLCM) Activity continues Mtg held end of Aug with Surface Maintenance Engineering Planning Program

(SURFMEPP) formerly SSLCM to share information and ideas Reviewing Technical Foundation Papers and Ship Sheets for methodology and

processes

T-AKE Equipment Life Cycle Matrix being mapped to T-AO configuration

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LCM:

Way-Ahead

Conduct market research to identify COTS software and contractor support for Life Cycle Management planning Shipping and Stationary Plant Industries

Conduct solicitation for software and contractor support if identified from market research

Using SAMM, PENG, and CMLS data for T-AO MPDE determine Total Maintenance Cost and Mean Time Between Repair (MTBR) To include data external to systems such as service order data, tech

reports, etc. for period prior to implementation of CMLS Apply MTBR methodology to rest of critical equipment

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LCM:

Way Ahead (Continued)

Identify all Operational, Intermediate and Depot Level Maintenance for T-AO Class from SAMM/PENG/Service Orders and Port Engineers to Establish Baseline LCM Plan

Integrate T-AO OERA results, MSFSC 5-YR M&R data, and planned TRANSALTs into Life Cycle Plan

Present Life Cycle Plan for T-AO Class to All Stakeholders Continue development for next ship class: T-AKE

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Integrate, Execute, Document and Feedback (MSFSC/PM1)

Technical Requirements

Execute

Plan Long Range Requirements into Availabilities (PM1/N7/MSFSC)

Document & Feedback

Class LCM Requirements Ship LCM Baseline Schedule & POM

Integrate Package Plan Availability

Balancing Technical, Operational, and Financial Risk to increase Ao and decrease $$

LCM:

Life Cycle Management Plan

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SAMM 5.07 Service Pack 3 Development• Internet Browser Interface

• Dashboard

• Machinery History and Condition Monitoring Module Integration

• Workbook, Maintenance, and Repair Module Integrated

• Depot Level PM visible in Maintenance Module

• Virtual Tech Library Integration

PENG Web Development MSC IS Portal Development

• Corrective Maintenance (Ashore PM Tool, TRANSALT Manager)

• Condition Based Monitoring Analysis

• Data Maintenance Manager

• PENGWeb Integration in Corrective Maintenance

• Virtual Tech Library Integration

SnapShot Development to combine SMART and OCI Inspection

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N7 Maintenance Management Programs:

MSC IS Portal

Life Cycle Management Voyage Repair Request

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Life Cycle Management Voyage Repair RequestIndustrial Maintenance (Depot & Intermediate)

N7 Maintenance Management Programs:

MSC IS Portal

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Life Cycle Management Voyage Repair RequestIndustrial Maintenance (Depot & Intermediate)Service Orders

N7 Maintenance Management Programs:

MSC IS Portal

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February 2011:TRANSALTs PENGWeb

N7 Maintenance Management Programs:

MSC IS Portal

USFFC:

Maintenance & Supply Working GroupIT EXCOMM

The MSWG vision is to develop an integrated naval maintenance and supply IT solution set that aligns capability development to mission needs and delivers affordable enhancements through standardization of processes and tools, and cost efficiencies through IT automation.

Enterprise Options A: All SAP B: Some Maintenance in SAP / Some Bolt-Ons (w/Navy ERP

Supply and Financials) C: Existing IT Consolidation Plan (w/Navy ERP Supply and

Financials) D: Single GOTS Maintenance Solution (w/Navy ERP Supply and

Financials) Due to time constraints in support of POM 12 decision, options B

and C will be the primary focus of the MSWG strategy

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USFFC:

Maintenance & Supply Working GroupIT Applications

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•Common Technical Requirements•Drives to Single Processes•Reduces “Stovepipes”•Increases Functionality•Classified/Unclassified•Shore and Deployable

Enterprise Solution(ERP + bolt-ons)Enterprise Solution(ERP + bolt-ons)

USFFC:

MSWG Maintenance StrategyN

umbe

r of A

pps

Num

ber o

f App

s

400

300

200

100

0

400

300

200

100

020092009 20162016

MFOMMFOM

SMLISSMLISNALCOMISNALCOMIS

NDMSNDMS

20122012 20142014

Transition to ERP Transition to ERP

Group Apps into “Family of Systems”Group Apps into “Family of Systems”

Reduce # Apps to Support Transition to Enterprise Solution

Reduce # Apps to Support Transition to Enterprise Solution

Identify ERP Early AdoptersIdentify ERP Early Adopters

Requirements

ERP early adoptersERP early adopters

MSC ITMSC IT

Align with ERP Align with ERP Reduce Apps Reduce AppsGroupGroup26

USFFC: MSWG Maintenance Strategy

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Purpose : “ …to provide guidance on the most cost effective standardize maintenance requirements and assessment procedures across Carrier, Submarine and Surface Ship Enterprises….

Activities — Identify Maintenance Requirements for Review — Conduct Maintenance Reviews using principles of RCM— Identify best practices for cross-enterprise implementation — Develop policies and other documentation to institutionalize the

strategies and practices

USFFC: Common Maintenance Planning Working Group

Common Areas of Interest with MSC Upcoming NAVSEA Maintenance Effectiveness Reviews

• Cargo/Weapon Elevators – Dec 6 – 10, 2010 • Reverse Osmosis – Aug 8 – 12, 2011• Start Air Compressors – Sept 12 – 16, 2011

Upcoming Best Practices Sessions • Piping Nov 8 thru 11

Upcoming CMPWG briefing • CFFC – March 2011

USFFC: CMPWG Events

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