Computerized Maintenance management systems reduce Preventive Maintenance task management by 40-70%, increase available manpower by 20% without additional crew, and reduce emergency work up to 32%.
Reliability Centered Maintenance (RCM)
Lightship believes in a Reliability Centered Maintenance (RCM) approach. We define the equipment, perform a Failure Modes Effect and Criticality Analysis (FMECA) and perform a selection of appropriate preventive and predictive maintenance tasks for that equipment. This typically involves large amounts of various types of data to be analyzed. In order for this methodology to be effective, it needs to be iterative and tailored based on ongoing data collection, analysis and maintenance costs. An appropriate computerized reporting method must also be utilized in order to document and disseminate information between plants or vessels, maintenance, administrative, engineering design and manufacturing personnel.
Proactive Maintenance
A comprehensive Proactive Maintenance package takes advantage of all of the data gathered from the RCM, PMS and the available condition monitoring programs. This includes results of PMS actions, existing maintenance and OEM technical manuals, combined with logs and history. The ability to analyze this data and turn it into useful information is what is necessary to make confident decisions that may allow you to "...reduce PM tasks from 40-70%, increase available manpower by 20% without additional crew, and reduce emergency work up to 32%...", all while simultaneously increasing productivity, performance, and maintaining the highest state of safety.
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Equipment Survey and Applicability
The equipment is surveyed, entered into the system, reviewed and preliminary decisions are made concerning the applicability of maintaining that equipment. Lightship personnel meet with the crew or plant personnel to review the equipment decisions and modify them accordingly. Additionally, manufacturer's technical manuals would be referenced.
Develop PM Actions
If the equipment is determined to have an insufficient PM or none at all, PM actions are developed to be reviewed by the crew, plant personnel, or a designated point of contact to ensure accuracy.
| The developed PM includes: |
- Required maintenance actions and frequency
- Maintenance narratives for each action
- Required tolerances and limits
- Safety precautions to follow
- Mandatory and potentially required spare parts
- Required special tools and test equipment
- Applicable technical manuals and vendor drawings
- Man-hour estimate for each maintenance action
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Additionally, the PM is reviewed to ensure ISM requirements are included. Vibration monitoring system and lube oil analysis system planned maintenance requirements are identified and incorporated into the system. Once the PM is utilized for a period of about six months, the results of these technologies will be used to refine other PM task frequencies and requirements. Some of the more important information updated during the development of PM actions are:
Personnel Assignment
Billet numbers and assignments for all personnel will be obtained and incorporated into the CMMS. Each PM action is assigned to a specific billet.
Assign PM Frequency
Planned maintenance actions are scheduled on a calendar or running hour basis. Equipment PM will be assigned a frequency based upon manufacturer recommendations, crew recommendations, and/or recommendations taken from Lightship's library. This is the maintenance baseline. In time, each PM action is examined and the frequencies adjusted based on the results of the data.
Man-hour Estimates
A man-hour estimate for each PM action is developed. These estimates include allowances for time required to perform maintenance considering potential interference's due to equipment location, crew size and skill levels. Maintenance is scheduled, balancing the required man-hours for each month accordingly.
Assign PM Actions
The equipment included in the PMS is reviewed and the maintenance actions are entered into the database at this time. Lightship relies on it's library of maintenance actions, numbering in the thousands. At this time, daily or weekly actions are identified. Daily and weekly actions are not usually incorporated into a CMMS schedule, which primarily operates on a monthly basis.
Spare Parts Inventory
Spare part information from each ship's or plant's system is obtained and integrated into the program database. A list of spare parts required or potentially required for maintenance of each piece of equipment is developed. In addition, a separate physical inventory of spare parts may be performed.
Personnel Training
Lightship also offers training for personnel with varying levels of computer experience in the use of CMMS systems.
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| Many benefits are realized after a successful implementation of Lightship's CMMS program. Some of these benefits include: |
- Low cost - Only $99
- Direct reduction of maintenance and repair costs through the reduction of unnecessary overhaul and repair and strategic deferral of the normally scheduled maintenance.
- Direct reduction of maintenance and repair costs through the reduction of unnecessary open and inspect surveys and potential reduction in regulatory body inspection costs.
- Direct reduction of operating costs by confidently deferring the normally scheduled maintenance calling for part renewal.
- Increased Mean Time Before Failure (MTBF) of equipment.
- Direct reduction of maintenance and repair costs by scheduling equipment repair when convenient.
- Decreased need for long outages or shutdowns based on equipment condition based assessments and recommendations.
- Reduced maintenance parts inventories from improved scheduling of repairs.
- Identification and replacement of poor maintenance practices or procedures. For example, if the PdM program identifies numerous alignment problems, this points toward the need for a review of the alignment procedures and training of personnel performing the alignment.
- Increased maintenance personnel efficiency; the appropriate personnel are assigned a repair task prior to the need for the repair.
- Improved documentation of maintenance performance and costs.
- Improved standardization and improved life cycle management.
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