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Tools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles
Louw, Andries Barnabas
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The research topic is: Tools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles. This research has specific reference to the SASOL Prillan plant based in SASOL, Sasolburg. The purpose of this research is to identify tools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles. These tools must be aimed to increase the proactive work capacity index, Figure 3, and to identify and/or develop tools that can be used by the engineering team of this explosives manufacturing plant to increase equipment reliability and performance. In this research assets include people. The meaning and application of asset management principles were researched and the tools needed to combine existing efforts and future needs are discussed. The human element to ensure the successful implementation of an asset management culture was researched and attributes of leaders and a change model is presented. This research was done into the wider engineering management discipline and not only maintenance. The method used to gather data was by means of interviews of a sample group within this organization. As this manufacturing unit makes use of subject matter experts, these support functions and plant personnel that were not interviewed, were issued with questionnaires to ensure that the sample group is a fair representation of the total manufacturing facility. To obtain a holistic view of potential shortcomings within the current maintenance strategy, all disciplines and levels within this operation were interviewed and commonalities of various asset management models were determined and used to define existing problem areas. This data was used to determine statistical correlations. The case study presented in Chapter 1 indicates that there is a case for change that can improve the proactive work capacity index of the engineering team. The results of this research confirm that there is in fact a real requirement to increase spares accuracy, improve on technical training as well as a need to establish visual performance indicators (dashboard) to measure overall equipment efficiency with the goal toTools for the revision of a maintenance strategy for an explosives manufacturing plant, using asset management principles increase equipment reliability and performance. The technical training referred to in this research reflects on training of people on equipment after investment in new technology. The current spares holding strategy is lacking equipment description accuracy. Furthermore, it is recommended that the implementation of career paths and development plans for individuals must be developed to create an environment of learning. The use of user status information captured on the computerized maintenance management system (SAP R/3) can add to the management of works orders and indicate where the focus must be to complete overdue work orders. Open work orders should be used to manage expenditure, to measure planning efficiency and to manage the cash flow of the business. The use of overall equipment efficiency and engineering efficiency measures is recommended and must be visually displayed on a “dashboard”. It was recommended that the engineering and operations personnel of this manufacturing plant be trained in asset management principles and that balanced scorecards are developed to ensure that the strategies of the various departments are aligned with the business strategy. Diagram 1 best illustrates the thinking and process flow of this research. The flow diagram shows five distinct stages and the appropriate objectives and/ or elements that were considered. The dissertation is also structured in this manner. All abbreviations, acronyms and definitions used in this document were listed in APPENDIX B
- Engineering