Toward a World Class Maintenance

Bayer Material Science

Maintenance Basis
Action repair is only taken, when the asset fails in its functionality. Examples: A heat exchanger is repaired when the temperature in the outer line is out of the process specification.

A pump is repaired or replaced when is completely broken or the pumping fluid is not enough for the plant.
BMS Reliability Tarragona & Zona Franca June 2012

Maintenance Basis Basis HIGHLIGHTS: Repairing after Breaking High cost Maintenance Unreliable Long repairs Production looses

Lower Safety due to unreliability

BMS Reliability Tarragona & Zona Franca June 2012

Preventive
Strategy focused in stablishing a systematic and periodic repair or components replacement indenpendently on its condition or performance. Examples: Replacing oil filters each year Bearing change every 4years Cleaning of towers every 6months

BMS Reliability Tarragona & Zona Franca June 2012

Preventive Preventive HIGHLIGHTS: Maintenace Planned So much Maintenance Unreliable Lower Safety due to Unreliable assets Short repairs High Cost

BMS Reliability Tarragona & Zona Franca June 2012

Predictive & Precision

Systematic and periodic revisions of the assets to determine its condition, that define the specific precision maintenance needed in one of its components. Examples: Mesuring Vibration each month and re-grease or replace bearings when is necessary and not other components. Change parts of pipes when the periodic thickness mesure shows corrosion or other defects.
BMS Reliability Tarragona & Zona Franca June 2012

Predictive & Precision Predictive HIGHLIGHTS: Maintenace Planned Short repairs Low Cost

Just Needed Maintenance Reliability Safety Precision R.C.A. High MTBF Improvement!

BMS Reliability Tarragona & Zona Franca June 2012

R.C.M.
Optimum mix of the maintenance strategies focused in the improve to achieve the maximum efficiency of the production and assets. Examples: Mesuring Flow and Pressures we can adjust parameters to operate pumps in its curve or put the correct impeller. When corrosion is detected in pipes we investigate to find and eliminate Root Causes to prevent future and repetitive leaks.
BMS Reliability Tarragona & Zona Franca June 2012

R.C.M. R.C.M. HIGHLIGHTS: Maintenace at better time LongLife &

LowCost. Possibility to adjust! Top of Reliability & Safety Process Improvement T.P.M. Cost Savings

Know-how, All data & equipment

daily checked = TOTAL ONLINE PLANT!

BMS Reliability Tarragona & Zona Franca June 2012