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  • 1.  Reliability and Maintenance Project Completion Checklist

    Posted 03-30-2021 02:51 PM


    Does anybody have a "checklist" to validate new projects meet minimum Maintenance and Reliability requirements before acceptance is sign in ? This check list will help to avoid taking over or accepting new projects which do not meet M&R standards which soon will create additional emergency work. 

    Thanks!

    Roberto I Barrera



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    Roberto Barrera
    Houston TX
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  • 2.  RE: Reliability and Maintenance Project Completion Checklist

    Posted 03-31-2021 07:15 AM
    Hi Roberto,

    It might be difficult to comment unless we know what is the asset type. I hail from the Maritime industry and I have faced the same dilemma when performing a technical inspection of used ships before recommending purchase. As you well know, each machinery has its own Failure Modes. For example, if its a diesel engine, the sound and the unbalance of unit exhaust temperatures just as we hike the load beyond 65% would tell me something is wrong . If it's a steam boiler, is it able to build up the rated steam pressures? How long does it take for the air-compressor to fill up the main bottles. So you could start with collecting the machinery Master list and draft your own set of "sticking points" to check for - to be demonstrated in your presence, to your satisfaction , by the previous project operators. Hope I got your context right.

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    MATHEWS VADAKKAKARA
    MSPL Diamond PTE Ltd
    SINGAPORE
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    Original Message


  • 3.  RE: Reliability and Maintenance Project Completion Checklist

    Posted 03-31-2021 07:39 AM
    Good morning Roberto,
    Where I currently work, we currently run into similar issues so I am curious to see the responses that come from your question.​
    Recently, I have started the discussion with our Process Control department and felt that the best way implement meaningful change would to encourage the individuals responsible for running that department to be more involved. While new machines do come with similar issues, the age of the plant I work in results in a majority of the problems stemming from modifications to existing equipment. With the equipment already producing quality material, I informed process control, we should maintain that process as "sacred" and only allow changes to be made that have been properly vetted and all necessary actions followed through (e.g. drawings updated, MRO inventory adjusted, working standards, PM packages, etc.).
    I have recently received the draft control form from Process Control and several of the changes I discussed above have been added to the checklist. So to provide some form of answer to your questions, I would say that the following items should be included in a "project" checklist.
      
    Why or what is the purpose of the checklist?
    How will the project be evaluated?
    What is the path forward if the project is unsuccessful?
    If the project is successful, what supplemental actions need to be taken to ensure the project remains successful?
    Do working standards need to be updated?
    Has there been a change to quality systems and if so, have those quality systems/instruments been updated to be calibrated/verified?
    Have PM packages been updated?
    Is training necessary for production/maintenance of the equipment?
    Have all parts not carried in MRO stock been identified and evaluated to be carried?
    Have associated engineering drawings been updated or created to identify those parts and where they are used on the machine?

    The list above is not all inclusive and I am sure there are additional items that could be added to the list but I feel this would be a good start.


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    Thaddeus Lightner
    Bridgestone Americas Tire Organization
    Trenton
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    Original Message


  • 4.  RE: Reliability and Maintenance Project Completion Checklist

    Posted 03-31-2021 10:47 AM
    Hi Roberto,
    As Mathews said, you need to be more specific about your project type. Adding a new asset to your existing facility can be considered a project and building up a new unit can be a new project as well, but these two need different type of checks and balances.
    In general, I'd say, you need to start with the drawings and specs for your new assets, then you can work on possible failure modes and evaluate your response options to each failure (based on their criticality). If you're using a CMMS platform to keep and record your maintenance activities, then you should be able to set the new asset(s) up in your database by using the drawings and specs you acquired earlier. When you finished that step, you'd be able to establish your PM program for your new asset(s) in your CMMS. depending on the type of equipment (Static/Rotary), you need to gather some baseline data (vibration/Oil/Infrared/Ultrasound/Thickness/...) as applicable to your asset(s).
    This is basically a snapshot of what needs to be done, but of course the details can vary based on the facility/unit/machine/equipment/process/maturity of your  PM program/.....
    Some of these activities can be done in parallel, while some should be done in series. You may defer some until your equipment and process is stabilized, while some should be done before startup or right after it.
    So, that said, there is not a clear cut answer to your question.

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    Yaser Sahebi PhD
    Air Liquide Large Industries
    Houston TX
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    Original Message


  • 5.  RE: Reliability and Maintenance Project Completion Checklist

    Posted 04-01-2021 10:43 AM
    Hi all and thanks! Thaddeus, Mathew and Yaser 

    I work for a Battery Manufacturer and Recycler (Clarios)
    The project is for a new battery assembly line. The issue we want to avoid is to have a new system without the right information  (e.g. drawings updated, MRO inventory adjusted, working standards, PM packages, etc.). 

    So, yes what I was looking for was a generic list providing guidelines to assure we don't inherit a problems but a value added system. Here below something I started to do: 

    Documentation

    • Job plans for AM, PM, CM and PdM are available.
    • Vendor manuals are updated and meet equipment design and characteristics
    • Job plans have been reviewed and validated with Maintenance.
    • Technical drawings are reviewed and meet design.
    • Etcc

     

    CMMS:

    • Job plans are added into CMMS.
    • Hierarchy and Asset registry has been updated. 
    • BOM adjusted. 
    • Maintenance schedule established 
    • Naming convention follows standards.
    • Etc…

     

    Maintenance

    • Equipment installation meets maintainability requirements (maintenance ergonomic).
    • Equipment works as designed
    • PdM program is included
    • Special tools are added into workshop?
    • Oils and lubricants are added
    • Etc…


    Thanks again!

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    Roberto Barrera
    Houston TX
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    Original Message


  • 6.  RE: Reliability and Maintenance Project Completion Checklist

    Posted 04-08-2021 09:06 AM
    Hi Roberto,

    Just to add, ( without me having any knowledge of the asset-value of a battery recycling and manufacturing unit), it might help to ask for the breakdowns history and Insurance claim submissions/ recoveries. The same would tell you what problems you would be inheriting... Good luck !

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    MATHEWS VADAKKAKARA
    MSPL Diamond PTE Ltd
    SINGAPORE
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    Original Message


  • 7.  RE: Reliability and Maintenance Project Completion Checklist

    Posted 05-05-2021 05:37 PM
    Edited by James Wade 05-05-2021 05:38 PM
    I've been trying to refine this process at my plant for quite a while.  We keep adding and adjusting our lists as each project completes and we find something new.   Because we get information from different groups (inside and outside the org) and it can take quite some time after the project is done before we get deliverables (drawings, manuals etc).  We use work orders with job plans to help track the status of the "close out".  The work orders get created once we get word the project is starting.   

    A lot our job plans have the items you listed but some other things to consider;
    Labels - Are valves, switches etc labeled and in accordance with plant standard?
    Keys - Has the equipment added any keys? If so add to key(s) to appropriate key boxes and update key inventory.  Remove any outdated keys and update inventory.
    Confined Space - Does the current plan need updated due to addition, removal or modification of spaces?
    Pressure Vessels - Did the project add or remove pressure vessels?  Update applicable job plans and lists for State Inspection/Certification
    Regulatory Concerns - Does the new project add or remove equipment governed by a Regulatory Body ie EPA, NERC
    SOPs -  Do any SOPs need updated?  Do new ones need to be created?
    Warehousing/Spares - What needs to be added to Warehouse stock? Not just spares but think about PM consumables.  What old parts/spares need to be removed from stock?
    Training - Training needed for Maintainers and/or Operators beyond the initial familiarization training?
    Arc Flash & Panel Books - Do Arc Flash Studies and labels need to be done?  Have Power Panel Books (we maintain a book of all panel schedules in 2 locations) & Panel Schedules been updated




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    James Wade
    Maintenance Control Specialist
    US Army Corps of Engineers
    Pomeroy WA
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    Original Message


  • 8.  RE: Reliability and Maintenance Project Completion Checklist

    Posted 04-13-2021 06:50 AM
    Hi Roberto, I previously worked at a place where high level checklist type questions were reviewed at the start of the project by the MOC screening committee. The MOC committee had a standard checklist, would review the proposed project scope and then identify items that need to be ensured by the project ( for example training and capital spares for a new piece of equipment, Maximo updates etc.).
    The MOC checklist would be reviewed again for action completion at the pre-startup stage.

    While it would be great to come up with an all exhaustive checklist, it may be prudent to just keep it high level at the inception of the project and then ensure that actions have been completed prior to energization/start-up.

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    Joy Iyer
    Paton Engineers and Constructors
    Sarnia ON
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    Original Message