Five Tips for Establishing a Successful Asset Health Programme
Establishing and maintaining a world-class asset health programme is no easy task. Pulling all the moving parts together requires a strong spirit of collaboration and cooperation amongst stakeholders, equipment manufacturers, dealers and business departments.
In this blog, we provide some handy tips on how to get started.
1. Take the stair-step approach
We truly believe that taking a stair-step approach with multiple short, sharp projects can yield significant results. We’ve worked with many operations across the globe who have used this method, resulting in a marked improvement in their equipment availabilities, with minimal stress along the way.
2. Don’t try to run before you can walk
Don’t try and leap forward too quickly. In our experience, this results in a lengthy project, risking scope creep, significant change management and increased chances of failure. A flashy project involving some of the current industry buzzwords like Big Data and Machine Learning may look great in a press release, but simply will not work unless the proper foundations are in place.
3. There is no silver bullet
We’ve seen many companies (who are struggling just to run planned services on time) try to implement hugely complex and expensive Predictive Maintenance programmes which ultimately failed. Why? Because they didn’t ensure the basics were in place.
Ensure you have full buy-in – Technology programmes fail when they are forced upon people who aren’t really interested because they don’t see the value.
Pick the right team for the job – Attitude is everything. Invest in supporting the talent you do have.
Go external for missing technical skills – It will pay dividends if you don’t have internal resources and expertise to get things done on time.
Establish standard workflows and standard operating procedures – These are typically overlooked as unnecessary bureaucracy, but without them, you risk everybody doing their own thing.
World-class people and facilities can easily underperform if there are no parts in the warehouse – For remote sites, this is even more critical.
Invest in the tools, systems, and technology that suit your operation – Are multiple spreadsheets really the best way of mass-communication within large organisations? Is a cloud-hosted solution robust enough for a remote site with sub-optimal network connectivity?
4. Identify and define what you want to achieve
If you cannot measure results, then you cannot manage effectively. When defining a set of metrics to measure performance, consider the following;
Availability – Overall, how much is the machine down for all types of maintenance. What should it be down for during this life period? (i.e., brand-new Vs mid-life).
MTBS – Mean Time Between [maintenance] Stoppages – Ideally this would match or exceed the interval for Preventive Maintenance. This would imply that scheduling and opportune maintenance are occurring.
Unscheduled Downs Vs. Schedule Downs % – Machines have to stop at some point for maintenance but breaking down mid-cycle on the haul road is obviously not desired. This metric is useful to understand where the stoppages are coming from.
Work Hours Expended for Each Down Hour – If you are able to plan and mobilise service work at opportune moments the ratio will be high, which is good.
We recommend that metrics are tailored to each role or team and are balanced to minimise the risk of driving the wrong behaviour. Also, consider establishing a pre-initiative or programme baseline - this can be useful in progress evaluation and demonstrating value to stakeholders later in the project.
5. Establish a Roadmap
When undertaking any mining technology programme that involves substantial investment, change management and multiple stakeholders, we recommend establishing a Roadmap. This is a formal document with clearly defined goals, milestones, roles, resources and risks. The roadmap serves not only as the backbone of the project but also as a platform upon which the project can evolve in a sensible, controlled manner.
We hope that this months blog has given you some points to consider in establishing or reinvigorating your own asset health programme. If you have any comments or would like to know more, drop us a line at firstname.lastname@example.org