Reference no: EM132311159 , Length: word count : 4000

Question 1. Asset Life Plans

Utilising the Top Down Bottom Up Approach (TDBUA) for a critical asset identify MAXIMUM 50 components and prepare a life plan for the identified components from within your organisation. Both mechanical and electrical components should be incorporated within your answer.

In your response you should include references to discussions with relevant persons within the organisation along with tables and diagrams where appropriate to support your discussion.

1. Construct a process flow diagram and establish an asset inventory for asset determined critical to the organisation.(as per section 8.2.2)

2. Detail the asset/unit operating characteristics and the production policyof the identified asset (as per section 8.2.2)

3. Assemble the identified maintenance tasks in the form of a unit life plan(as per Table 6.9 and Table 8.3)

4. Based upon the implemented maintenance strategy determine and outline the need for spare parts inventory items for the asset/unit.

Question 2. Preventative Maintenance Optimisation

Using an analytical methodology carry out an optimisation of the current preventative maintenance tasks of an asset determined as critical from the criticality analysis of Question 1 of Assignment 2.

1. Outline the optimisationprocess (Reliability Centred Maintenance - RCM, Failure reporting and corrective action system (FRACAS) or Judgement based approach) utilised to determine the most effective PM optimisation methodology for the selected asset.

2. Determine and outline in tabular form the current preventative maintenance schedule for the selected asset.

3. Carry out an evaluation and optimisation of the current preventative maintenance schedule removing elements of,

o tasks that fail to add value or actually create problems through the application of intrusive tasks,

o ambiguity of maintenance tasks,

o elimination of redundant time-directed tasks currently being completed using condition monitoring/predictive maintenance tasks,

o Refinement of tasks to eliminate tasks that can be completed utilising TPM.

4. Provide a tablecomparing the previous preventative maintenance schedule and the optimised preventative maintenance schedules.

5. Provide a discussion and outline in a table the preventative maintenance tasks repositioned within a developed TPM program.

Question 3. Lean Principles

Identify and discuss the application of lean principles within the maintenance strategies of the student's organisation. Your answers should be supported by Diagrams, Figures and Tables,

1. Identify and discuss of 5 lean philosophies,

2. Outline and discuss the application of lean philosophiesutilised within the maintenance strategies of the student's organisation.

3. Utilising root cause analysis techniques determine the root cause of an unplanned downtime event associated with a critical asset within the authors organisation. Your answer should include:

a. Description of asset.

b. Description of the unplanned event along with asset downtime and cost to rectify the downtime event.

c. Description of investigation team and team members.

d. Description of root cause analysis technique.

e. Outcome of root cause analysis.