“Equipment Data Disappointment”

 “Equipment Data Disappointment”

 

The Importance of a Well Structured and Accurate Equipment Hierarchy By Dave Bertolini, CRL and Ricky Smith CMRP, CRL

One of the biggest contributors to data disappointment in a CMMS/EAM is an incomplete or inaccurate equipment/asset hierarchy. The hierarchy establishes the structure for numerous aspects of system functionality. A majority of system disappointments can be corrected with a properly defined hierarchy through use of an internationally recognized equipment taxonomy or natural grouping of equipment. 

It’s all about the parent child relationships established that enable; cost roll-ups, equipment/asset identification, data analysis, reporting for metrics, and failure threads (MTBF, Failure Rates, etc.). Typical hierarchies are routinely void of all assets, lack defined parent child relationships, and many times lack logical flow. Organization need to manage their assets with accurate equipment taxonomy is a requirement.

Once the functional location of the area and the sub functions are identified the equipment/assets can be inserted established with their respective parent. All maintainable equipment/assets should be identified and/or those that have a defined maintenance strategy. “Press In-feed” has the following equipment associated with it. A roller conveyor, an electric motor, a gearbox, and a VFD (Variable Frequency Drive).

In a manufacturing environment the most logical approach is to follow an internationally used equipment taxonomy. Start at highest level required for your organization and define the hierarchy (sometimes referred as the functional location) down to the component or maintainable item level. What are the functions? Let’s say we define an “Equipment Unit” as “Press #1” and one of its sub units is “Hydraulic System”, next “Electric Motors” are one of the type components/maintainable items in this system. The hierarchy structure would be represented as shown using Equipment Taxonomy (natural grouping of equipment).

Using the equipment taxonomy example shown above, one can identify similar failure issues on all “Electric Motors” for the assets at the “Eastover Plant”. One such pattern one may want to know is the Mean Time Between Failure (MTBF) for all electric motors in the “Eastover Plant” or electric motors on the “Hydraulic System”. Once the hierarchy is accurate and aligned according to an equipment taxonomy then Mean Time Between Failure, Failure Rate, Cost, effectiveness of the maintenance strategy, etc. can be identified with a few key strokes of the computer.

Identifying what is causing the majority of any type component or maintainable item failures begins with knowing you have a problem.  Shown in the graphs below which is the MTBF of over 500 electric motors (50-500 horsepower) at one site and how one engineer made a few adjustments to the maintenance strategy (lubrication and alignment) which impacted MTBF in a positive direction along with reducing cost for new motors and the rebuilding of motors. This is just one example for why equipment hierarchy must be established according to a standard so one can optimize asset reliability and cost.

An assessment of a CMMS/EAM must be used to ensure your current system has standardization of equipment descriptions, equipment types and classes, and functional location data. Once completed a walk-down validation should be performed to ensure all assets are included in the system. Getting this correct enhances the capabilities and functionality of the system and helps eliminate data disappointment. Now go look at the hierarchy contained within your system. Is it complete and all assets included? Data standards applied? If not you might want to start with getting it right to get rid of data disappointment. 

If your equipment hierarchy is not set up to provide the results you expect email Tammi at [email protected] and ask for a review of your current CMMS/EAM. 

The Author: Ricky Smith CMRP, CMRT, CRL

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