All Member Open Forum

Hi Everyone,

I was curious if anyone had some advice on our situation... 

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Hello Kristine,

I think we need a bit more information. You say you want to "Standardize our current maintenance plan". I am not sure what that means.  Do you mean to standardize your preventive maintenance plans?

Weibull analysis is typically not used to measure any type of performance, it is a statistical tool that sometimes is used to try to predict life of equipment, and in some cases products.  But, we know from experience that most equipment life is random, for example a bearing has a life of 1-25 years, so the data is often not very useful or practical.

Could you explain what you are trying to do?

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC
------------------------------

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

My apologies, I was a bit vague.

We are trying to setup a minimum maintenance standard across all of our sites. Currently, the PM/PdM is handled by each site and there has been no discussion between sites. There has also never been any type of analysis on equipment breakdowns or whether PMs are even warranted. That was why my thought was to begin with a Weibull analysis to compare site breakdowns and maintenance costs against each other (there are slight differences but most sites have the same basic equipment). I believe we need some solid ground to open up discussions on what the minimum maintenance standards should be.

Thanks!

------------------------------
Kristine Moore
Maiden NC
------------------------------

Original Message:
Sent: 09-28-2020 08:09 AM
From: Torbjorn Idhammar
Subject: Weibull Analysis?

Hello Kristine,

I think we need a bit more information. You say you want to "Standardize our current maintenance plan". I am not sure what that means.  Do you mean to standardize your preventive maintenance plans?

Weibull analysis is typically not used to measure any type of performance, it is a statistical tool that sometimes is used to try to predict life of equipment, and in some cases products.  But, we know from experience that most equipment life is random, for example a bearing has a life of 1-25 years, so the data is often not very useful or practical.

Could you explain what you are trying to do?

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Kristine, 

Weibull won't help you that much since you would analyse equipment life, which would lead to fixed time replacements.  You wouldn't get much helpful data for condition monitoring, lubrication, etc.  It would be a tough task too since you would have to do it on a component level (Equipment doesn't break, components do).

I would use a logical PM improvement approach, I would stay away from RCM, it is too expensive to do.  We recently wrote a paper and created a video for how we typically improve PM's, perhaps that can give you some ideas.  It is free. https://www.idcon.com/8-step-pm-implement.  Feel free to contact me if you think I can help.

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC
------------------------------

Original Message:
Sent: 09-28-2020 09:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

My apologies, I was a bit vague.

We are trying to setup a minimum maintenance standard across all of our sites. Currently, the PM/PdM is handled by each site and there has been no discussion between sites. There has also never been any type of analysis on equipment breakdowns or whether PMs are even warranted. That was why my thought was to begin with a Weibull analysis to compare site breakdowns and maintenance costs against each other (there are slight differences but most sites have the same basic equipment). I believe we need some solid ground to open up discussions on what the minimum maintenance standards should be.

Thanks!

------------------------------
Kristine Moore
Maiden NC

Original Message:
Sent: 09-28-2020 08:09 AM
From: Torbjorn Idhammar
Subject: Weibull Analysis?

Hello Kristine,

I think we need a bit more information. You say you want to "Standardize our current maintenance plan". I am not sure what that means.  Do you mean to standardize your preventive maintenance plans?

Weibull analysis is typically not used to measure any type of performance, it is a statistical tool that sometimes is used to try to predict life of equipment, and in some cases products.  But, we know from experience that most equipment life is random, for example a bearing has a life of 1-25 years, so the data is often not very useful or practical.

Could you explain what you are trying to do?

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Hi Kristine,  I had a similar experience when I started working for an internationally owned manufacturing company with many plants/sites in the northern hemisphere, most having similar equipment, operate on different CMMS platforms and no standardization between plants.

We've started our standardization process with 4 simple metrics in place, (first we did standardice all our CMMS/ERP system - SAP):
1) % of PM compliance
2) % of time confirmation to work orders
3 % of corrective W/O vs PMs

Once this was in place for a year, we add some more, all the while trying to create and update the job plans for site specifics. We've added:
4) % parts assigned to W/O - we had lots of issues with understanding where the $ went, as maintenance personnel will pull parts from the storeroom  without attaching/reserving it to a work order (huge mess)
5) % of planned work vs reactive work.
6) Budget $ (maintenance) vs Actual spent.

So far (its been 5 years) the transistion has been progressing, at times slowly, but its a start.

The above is just an overview, there are many other focus in the backgroung that had to be done, lots of trainings & meetings etc.

I hope this helps.

------------------------------
clenton silas
Reliability Engineer
Cary NC
------------------------------

Original Message:
Sent: 09-28-2020 09:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

My apologies, I was a bit vague.

We are trying to setup a minimum maintenance standard across all of our sites. Currently, the PM/PdM is handled by each site and there has been no discussion between sites. There has also never been any type of analysis on equipment breakdowns or whether PMs are even warranted. That was why my thought was to begin with a Weibull analysis to compare site breakdowns and maintenance costs against each other (there are slight differences but most sites have the same basic equipment). I believe we need some solid ground to open up discussions on what the minimum maintenance standards should be.

Thanks!

------------------------------
Kristine Moore
Maiden NC

Original Message:
Sent: 09-28-2020 08:09 AM
From: Torbjorn Idhammar
Subject: Weibull Analysis?

Hello Kristine,

I think we need a bit more information. You say you want to "Standardize our current maintenance plan". I am not sure what that means.  Do you mean to standardize your preventive maintenance plans?

Weibull analysis is typically not used to measure any type of performance, it is a statistical tool that sometimes is used to try to predict life of equipment, and in some cases products.  But, we know from experience that most equipment life is random, for example a bearing has a life of 1-25 years, so the data is often not very useful or practical.

Could you explain what you are trying to do?

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Thanks for the help! I like your approach of breaking it down into smaller steps to build the program gradually. We will have to look at some of the metrics you provided to gauge where our program stands.

------------------------------
Kristine Moore
Maiden NC
------------------------------

Original Message:
Sent: 09-29-2020 08:06 AM
From: clenton silas
Subject: Weibull Analysis?

Hi Kristine,  I had a similar experience when I started working for an internationally owned manufacturing company with many plants/sites in the northern hemisphere, most having similar equipment, operate on different CMMS platforms and no standardization between plants.

We've started our standardization process with 4 simple metrics in place, (first we did standardice all our CMMS/ERP system - SAP):
1) % of PM compliance
2) % of time confirmation to work orders
3 % of corrective W/O vs PMs

Once this was in place for a year, we add some more, all the while trying to create and update the job plans for site specifics. We've added:
4) % parts assigned to W/O - we had lots of issues with understanding where the $ went, as maintenance personnel will pull parts from the storeroom  without attaching/reserving it to a work order (huge mess)
5) % of planned work vs reactive work.
6) Budget $ (maintenance) vs Actual spent.

So far (its been 5 years) the transistion has been progressing, at times slowly, but its a start.

The above is just an overview, there are many other focus in the backgroung that had to be done, lots of trainings & meetings etc.

I hope this helps.

------------------------------
clenton silas
Reliability Engineer
Cary NC

Original Message:
Sent: 09-28-2020 09:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

My apologies, I was a bit vague.

We are trying to setup a minimum maintenance standard across all of our sites. Currently, the PM/PdM is handled by each site and there has been no discussion between sites. There has also never been any type of analysis on equipment breakdowns or whether PMs are even warranted. That was why my thought was to begin with a Weibull analysis to compare site breakdowns and maintenance costs against each other (there are slight differences but most sites have the same basic equipment). I believe we need some solid ground to open up discussions on what the minimum maintenance standards should be.

Thanks!

------------------------------
Kristine Moore
Maiden NC

Original Message:
Sent: 09-28-2020 08:09 AM
From: Torbjorn Idhammar
Subject: Weibull Analysis?

Hello Kristine,

I think we need a bit more information. You say you want to "Standardize our current maintenance plan". I am not sure what that means.  Do you mean to standardize your preventive maintenance plans?

Weibull analysis is typically not used to measure any type of performance, it is a statistical tool that sometimes is used to try to predict life of equipment, and in some cases products.  But, we know from experience that most equipment life is random, for example a bearing has a life of 1-25 years, so the data is often not very useful or practical.

Could you explain what you are trying to do?

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Original Message:
Sent: 9/28/2020 9:27:00 AM
From: Kristine Moore
Subject: RE: Weibull Analysis?

My apologies, I was a bit vague.

We are trying to setup a minimum maintenance standard across all of our sites. Currently, the PM/PdM is handled by each site and there has been no discussion between sites. There has also never been any type of analysis on equipment breakdowns or whether PMs are even warranted. That was why my thought was to begin with a Weibull analysis to compare site breakdowns and maintenance costs against each other (there are slight differences but most sites have the same basic equipment). I believe we need some solid ground to open up discussions on what the minimum maintenance standards should be.

Thanks!

------------------------------
Kristine Moore
Maiden NC
------------------------------

Original Message:
Sent: 09-28-2020 08:09 AM
From: Torbjorn Idhammar
Subject: Weibull Analysis?

Hello Kristine,

I think we need a bit more information. You say you want to "Standardize our current maintenance plan". I am not sure what that means.  Do you mean to standardize your preventive maintenance plans?

Weibull analysis is typically not used to measure any type of performance, it is a statistical tool that sometimes is used to try to predict life of equipment, and in some cases products.  But, we know from experience that most equipment life is random, for example a bearing has a life of 1-25 years, so the data is often not very useful or practical.

Could you explain what you are trying to do?

------------------------------
Torbjorn Idhammar
President & CEO
IDCON, Inc.
http://www.idcon.com
Raleigh NC

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Kristine.

Start with PM optimization or as some call it RCM across all sites.  All similar equipment should have very similar PM/PDM's.  You can use Weibull's on just two data points, but it will give you nothing of value at this point.   Weibull's will give you failure rate (B10 life).  I have attached a file that may help.  I gave a Wiebull presentation at last years SMRP conference.

Dale Uitto
dale.uitto@yahoo.com

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA
------------------------------

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Thanks for the power point! It contains a lot of valuable information. We may need to start with RCM lite until everyone is comfortable with the method. We can then shift to the higher level stuff.

------------------------------
Kristine Moore
Maiden NC
------------------------------

Original Message:
Sent: 09-29-2020 08:18 AM
From: Dale Uitto
Subject: Weibull Analysis?

Kristine.

Start with PM optimization or as some call it RCM across all sites.  All similar equipment should have very similar PM/PDM's.  You can use Weibull's on just two data points, but it will give you nothing of value at this point.   Weibull's will give you failure rate (B10 life).  I have attached a file that may help.  I gave a Wiebull presentation at last years SMRP conference.

Dale Uitto
dale.uitto@yahoo.com

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Dale's presentation contains a lot of valuable information, indeed. Richard Lamb has shared some valuable information on the subject, too if you are interested. R has convenient tools to perform Weibull analysis

------------------------------
Erem Ugras
Maintenance and Reliability Consultant
Lloyd's Register Energy, Inc.
Houston TX
------------------------------

Original Message:
Sent: 09-29-2020 12:04 PM
From: Kristine Moore
Subject: Weibull Analysis?

Thanks for the power point! It contains a lot of valuable information. We may need to start with RCM lite until everyone is comfortable with the method. We can then shift to the higher level stuff.

------------------------------
Kristine Moore
Maiden NC

Original Message:
Sent: 09-29-2020 08:18 AM
From: Dale Uitto
Subject: Weibull Analysis?

Kristine.

Start with PM optimization or as some call it RCM across all sites.  All similar equipment should have very similar PM/PDM's.  You can use Weibull's on just two data points, but it will give you nothing of value at this point.   Weibull's will give you failure rate (B10 life).  I have attached a file that may help.  I gave a Wiebull presentation at last years SMRP conference.

Dale Uitto
dale.uitto@yahoo.com

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

David Lamb and I have been collaborating on this any many other subjects for years.  Using R was just one of them.  You will find my presentation is based on R

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA
------------------------------

Original Message:
Sent: 09-29-2020 01:44 PM
From: Erem Ugras
Subject: Weibull Analysis?

Dale's presentation contains a lot of valuable information, indeed. Richard Lamb has shared some valuable information on the subject, too if you are interested. R has convenient tools to perform Weibull analysis

------------------------------
Erem Ugras
Maintenance and Reliability Consultant
Lloyd's Register Energy, Inc.
Houston TX

Original Message:
Sent: 09-29-2020 12:04 PM
From: Kristine Moore
Subject: Weibull Analysis?

Thanks for the power point! It contains a lot of valuable information. We may need to start with RCM lite until everyone is comfortable with the method. We can then shift to the higher level stuff.

------------------------------
Kristine Moore
Maiden NC

Original Message:
Sent: 09-29-2020 08:18 AM
From: Dale Uitto
Subject: Weibull Analysis?

Kristine.

Start with PM optimization or as some call it RCM across all sites.  All similar equipment should have very similar PM/PDM's.  You can use Weibull's on just two data points, but it will give you nothing of value at this point.   Weibull's will give you failure rate (B10 life).  I have attached a file that may help.  I gave a Wiebull presentation at last years SMRP conference.

Dale Uitto
dale.uitto@yahoo.com

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Original Message:
Sent: 9/29/2020 8:18:00 AM
From: Dale Uitto
Subject: RE: Weibull Analysis?

Kristine.

Start with PM optimization or as some call it RCM across all sites.  All similar equipment should have very similar PM/PDM's.  You can use Weibull's on just two data points, but it will give you nothing of value at this point.   Weibull's will give you failure rate (B10 life).  I have attached a file that may help.  I gave a Wiebull presentation at last years SMRP conference.

Dale Uitto
dale.uitto@yahoo.com

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA
------------------------------

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

I have attached my PMO spreadsheet for your use.  Some of the tabs may not work anymore, its been a long time since I used it as an interactive spreadsheet.

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA
------------------------------

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Thank you, Dale. It works perfectly and is very helpful!

------------------------------
Kristine Moore
Maiden NC
------------------------------

Original Message:
Sent: 09-29-2020 03:27 PM
From: Dale Uitto
Subject: Weibull Analysis?

I have attached my PMO spreadsheet for your use.  Some of the tabs may not work anymore, its been a long time since I used it as an interactive spreadsheet.

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Hello Kristine,

Given all that has been said, another route to take is to query the local tribal knowledge. How long have your seasoned maintenance technicians have been working on the equipment? They may have a wealth of practical knowledge that doesn't exist anywhere other than in an illegible notebook or tablet or in their heads - pre-CMMS Work Management System. Hear them out.

Next, I would look to the manufacturer of the equipment, the OEM and possibly the OEM's designated/authorized vendor for the equipment. What does the OEM manual say to do and just as important, what is the statistical basis for their recommendation? Which component fails the most and why? Can the vendor state what is the inherent reliability if you do x, y and z? And can you measure this quantitatively at this juncture? If any of this leads to a dead end, commence an all encompassing PdM program sooner rather than later.

Now look at the present operating context. Is there any mention by the OEM about this subject. Think of this as oil change schedule for your car under different operating conditions, light, average, or harsh driving. One size does not fit all.  RCM is data dependent and you stated that the CMMS has one year run time so I would not expect there to be much data-minable/actionable WO information.  You have to start somewhere so go with the lowest hanging fruit and build on that. 


------------------------------
Ed Espinosa, CMRP, CRL, PMP
Sr. Performance Analyst
Puget Sound Energy
Bellingham WA
------------------------------

Original Message:
Sent: 09-29-2020 04:27 PM
From: Kristine Moore
Subject: Weibull Analysis?

Thank you, Dale. It works perfectly and is very helpful!

------------------------------
Kristine Moore
Maiden NC

Original Message:
Sent: 09-29-2020 03:27 PM
From: Dale Uitto
Subject: Weibull Analysis?

I have attached my PMO spreadsheet for your use.  Some of the tabs may not work anymore, its been a long time since I used it as an interactive spreadsheet.

------------------------------
Dale Uitto
VP Maintenance and Reliability
Delek US Holdings
Lake Charles LA

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Hi Kristine, 

There is definitely some great feedback on this thread. If you're going to do a deep dive into equipment performance I suggest you consider a criticality analysis, as you want to make sure you do it on the equipment that matters to your business objectives. An excellent and concise resource on this is "Criticality Analysis Made Simple" by Tacoma Zach. Hope this helps.

------------------------------
John Helwig
Senior Asset Management Consultant
KCI Technologies
Sparks MD
------------------------------

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

I'd like to wrap up this discussion by thanking everyone who contributed to the conversation. It's been an insightful thread, and I hope I am not the only one who got something out of it.

------------------------------
Kristine Moore
Maiden NC
------------------------------

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Kristine,

Thanks for starting this, I enjoyed following along. Many good reference materials and information shared here.

I agree with starting small, employ change management along the way, and define the program from the beginning. I hope you have clear objectives, an asset management plan AMP or SAMP, and that part of it includes data definitions and governance (what data is needed, what will be generated, how will it be used), and that you have a measurement plan. I say that because I wanted to add that I would decide on what can be measured today, given the available data (regardless of quality or definition) and set your own benchmarks.

Anytime we change anything this is a variable, performance management works well when we think about scientific method, if we are changing a variable we should measure it. Also, remember not to change too many variables at one time. Ensure everyone understands the changes (communication, transparency, what's in it for me WIIFM, why do it, does it support our strategic objectives). 

I would document the process first, then apply it to a small sample set, then follow up and see how it worked, adjust and go again. Plan, Do, Check, Act. 

I would love to know how things work out for you. Kudos for working to improve your organization!

------------------------------
Joe Lonjin
Performance Management Consultant
Cohesive Solutions
------------------------------

Original Message:
Sent: 09-30-2020 02:53 PM
From: Kristine Moore
Subject: Weibull Analysis?

I'd like to wrap up this discussion by thanking everyone who contributed to the conversation. It's been an insightful thread, and I hope I am not the only one who got something out of it.

------------------------------
Kristine Moore
Maiden NC

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------

Kristine:

Have each site evaluate their equipment in depth.  Once this information is gathered look at PM's. operating hours, downtime per week, month.  You have to know the health of the equipment and who is operating it before you can create a great program.  Have each site maintenance manager complete the evaluation and give recommendations. The maintenance plan should be fluid and flexible.  I take on manufactures who do not have maintenance in place and develop the program and department from scratch.  I have learned that the plant culture impacts and influences maintenance success.  They are right start small.  Pick the fruit until their is no more fruit to pick.  Over communicate and get buy in from everyone.  Without buy in and support it will be difficult to be successful.  You are going to here," Here we go the flavor of the month has started."  That is why you over communicate and explain in detail why the change.  Tom Moriarty explains this very well and in detail in his book.  It may help you.  Good luck on you program!!  Be assertive, and pay attention to detail.  Those little details can set you back when missed.

------------------------------
Wayne Offermann
Maintenance Manager
Lawrenceville GA
------------------------------

Original Message:
Sent: 09-28-2020 06:26 AM
From: Kristine Moore
Subject: Weibull Analysis?

Hi Everyone,

I was curious if anyone had some advice on our situation...

We are looking to reassess and standardize our current maintenance plan, but one of our biggest problems is a lack of historical data. Some of our sites have been around for ten years, but a CMMS was only implemented less than a year ago. My suggestion was to conduct a Weibull analysis as a starting point for discussions, so I guess my questions are:

1) Is 6 months to a year of data adequate for a proper analysis?
2) Is there a better method to compare where our sites are now to open up discussions for standardization?

Thank you for any advice you can offer!

------------------------------
Kristine Moore
Apple
Maiden, NC
------------------------------