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How Risk-Based Maintenance Optimizes Plant Maintenance

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How Risk-Based Maintenance Optimizes Plant Maintenance

Your maintenance team’s number one priority is to prevent unexpected equipment failures, ensuring production continuity and occupational safety. Thousands of pieces of equipment — big, small, critical and trivial — comprise an industrial environment with each requiring the right attention to avoid production disruptions, poor quality outputs and fatal accidents.

But how do you decide where to start and which machine deserves top priority?

Proper planning and scheduling of maintenance activities help companies optimize maintenance operations. Risk-based maintenance (RBM) is a popular strategy that uses risk principles to prioritize maintenance tasks and enable optimal resource allocation. Assets that have a high probability of failure and severe consequences get top priority and low-risk assets get low priority. how-risk-based-maintenance-optimizes-plant-maintenance-graphic-1

What is Risk-Based Maintenance?

A risk-based maintenance approach enables maintenance teams to identify possible failures and their impacts on production, occupational safety and regulatory compliance. Based on these risks, assets are given priorities and their maintenance activities are scheduled according to the level of risk. The approach uses a risk assessment matrix, which includes seven steps:

  1. Data collection: Risk assessments are based on data including equipment in a facility, parameters that determine their health, factors that might affect the equipment, possible risk of failure, triggers of such failures, previous maintenance history and more. A mobile Connected Operator Rounds can help here by connecting frontline technicians in a facility with systems that perform risk evaluation. Since the solution is directly connected to the evaluation systems, they offer real-time visibility into asset health.
  2. Risk evaluation: Companies need to analyze the data collected from the assets and other resources to determine the probability of failures and their impact. Based on the data, assets can be classified into four categories: very good, good, operational, and unstable.

    The risk assessment matrix takes two factors into account- the probability of failure and impact of it. The probability of failure is measured on a five-point scale, from rare to certain, while impacts are measured on a similar scale from insignificant to catastrophic.
  1. Planning: Companies can deal with these risks in four ways: avoid them, transfer them, work on them in-house, and ignore them. The approach depends on the severity of the risk. If the risk is trivial and will not disrupt your business, you can ignore the risk. If the risk should be addressed by in-house teams but doing so will affect an important part of the production line, it is better to transfer it to another party. If the risk can be handled by an in-house team without any impact on production, it can be assigned to them. If the risk level is too high, it is better to avoid it by controlling factors that can lead to the risk.
  2. Execution: The key to efficient plant maintenance is performing the maintenance or repair at the right time with the right information. A mobile Connected Maintenance Execution solution is a great solution to avoid common challenges like real-time visibility into asset data, network unavailability, skills gap, etc. Mobility provides plant managers with better visibility and improved analytics that help in quick decision-making. It also allows maintenance technicians to capture real-time data directly from the field and enables them to feed it into the ERP systems such as SAP and IBM Maximo.
  3. Reassessment: The landscape of risk is dynamic and changes over time as facilities get upgraded with modern equipment and processes. Asset-intensive industries are highly regulated. With the changing regulatory environment, they may need to adopt a different risk assessment approach. Some external factors such as temperature and humidity may impact the asset performance that will change the risk landscape. Maintenance teams should constantly monitor asset health and reassess the risk matrix. Continuously monitoring the existing plan will also give a chance to optimize resource planning.

Innovapptive, a configurable mobile EAM solution provider, simplifies risk assessment to help companies streamline their risk based maintenance strategy. The solution can seamlessly connect with ERP systems like SAP or IBM Maximo to establish a digital ecosystem across a plant environment. 

To learn more about Innovapptive’s mobile EAM solution, click here and book a free live demo. Or, call 1-844-464-6668.

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