Model Development of a Total Integrated Maintenance System




НазваниеModel Development of a Total Integrated Maintenance System
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THE LOGISTICS INSTITUTE


Model Development of a Total Integrated Maintenance System


Research Report

- For Pine Bluff Arsenal Distribution Only -


Julia A. Watson

Earnest W. Fant

Mia Petre-Ungerank


TLI-MHRC-AR00-3a


July 2, 2001

University of Arkansas

Fayetteville, Arkansas


TABLE OF CONTENTS

1 PROJECT DESCRIPTION 6

2 APPROACH 7

3 MAINTENANCE MODEL DEVELOPMENT 8

3.1 Benchmarking 8

8

3.2 Total Productive Maintenance (TPM) 8

3.3 Organizational 9

3.3.1 Mission/Objective 9

3.3.2 Structure 10

3.3.3 Maintenance Categories 11

3.3.4 Safety 12

3.3.4.1 Mechanical Integrity 13

3.3.4.2 Management of Change 14

3.3.4.3 Process Safety Information 15

3.3.4.4 Visual Reinforcement 15

3.3.5 Training 16

3.4 Customers 16

3.5 Maintenance Areas 17

3.5.1 Facilities 17

3.5.2 Equipment 17

3.6 Processes 18

3.6.1 Work Order System – The Maintenance Method of Control 18

3.6.2 Planning 20

3.6.3 Scheduling 20

3.6.4 Maintenance Inventory and Purchasing 20

3.6.5 Performance Measurement Metrics 21

3.7 Information Systems 25

3.7.1 Reporting and Analysis 28

3.7.2 Enterprise Resource Planning (ERP) 30

4 TOTAL INTEGRATED MAINTENANCE MODEL 32

5 PINE BLUFF ARSENAL – CURRENT SYSTEM 35

5.1 Department of Public Works (DPW) – Organization 35

5.1.1 DPW Mission 35

5.1.2 DPW Structure 36

5.1.3 Maintenance Categories 38

5.1.4 Safety 39

5.1.5 Training 40

5.2 Customers 40

5.2.1 Internal Customers 40

5.2.1.1 Director of Manufacturing Operations (DMO) 41

5.2.1.2 Director of Conventional Demilitarization , Storage, and NBC Defense (DMMD) 41

5.2.1.3 Engineering &Technology (E & T) 41

5.2.2 External Customers 41

5.3 Maintenance Areas 41

5.3.1 Facilities 42

5.3.2 Equipment 44

5.4 Processes 45

5.4.1 Work Order (Control) System 45

5.4.2 Planning 47

5.4.3 Scheduling 48

5.4.4 Maintenance Inventory and Purchasing 48

5.4.4.1 Tools 49

5.4.5 Other Automated Systems Supporting Work Order System 50

5.5 Information Systems 50

5.5.1 Information Mediums 50

5.5.2 Decision Support 50

5.5.3 Computer Systems 51

5.5.4 Tool Room - Oracle 52

5.5.5 FAMIS (Prism) Preventive Maintenance 53

6 RECOMMENDATIONS 54

7 COMMERCIAL ACTIVITIES AND CONSEQUENCES 56

7.1 Goal of Commercial Activities 56

7.2 Goal of a CA Study 56

7.3 Why a CA (A-76) Study 56

7.4 Sourcing Decision Process 56

7.5 Procedure of CA Study 57

7.6 Private Enterprise 57

7.7 Methods used to reduce staffing in an organization: 58

7.8 Functions Conversion to Private Enterprise [10] 58

7.9 Benchmarking 59

7.9.1 Red River Army Depot 59

7.9.2 Follow-up on Red River Army Depot: 60

7.9.3 University of Arkansas 61

7.9.4 Follow-up on University of Arkansas 63

7.9.5 Tinker Air Force Base 64

7.10 Summary for PBA's Consideration 64

8 REFERENCES 67

9 APPENDIX 1: MAINTENANCE SITE VISIT – INTERVIEW GUIDE 70

10 APPENDIX 2: REAL PROPERTY 72

11 APPENDIX 3: PBA DATA ELEMENTS 76

12 APPENDIX 4: PBA REPORTS 77



TABLE OF TABLES

Table 1 - Benchmarking Visits 8

Table 2 - Craft Organization Structure 10

Table 3 - Process Safety Management (PSM) Individual Elements 13

Table 4 - Mechanical Integrity Areas 13

Table 5 - Process & Equipment Integrity Components 14

Table 6 - Special Work Permits 14

Table 7 - Change Management – Important Elements 15

Table 8 - Process Safety Information – Coverage Areas 15

Table 9 - Customer Satisfaction Surveys 17

Table 10 - Nameplate Data 18

Table 11 - Administrative Metrics 23

Table 12 - Effectiveness Metrics 23

Table 13 - Efficiency Metrics 23

Table 14 - Cost Metrics 24

Table 15 - Daily Metrics 24

Table 16 - Reliability Maintenance Metrics 24

Table 17 - Miscellaneous Metrics 24

Table 18 - Real Property Metrics 25

Table 19 - Metric References 25

Table 20 – Major ERP Vendors 30

Table 21 - Indicator Benchmarks 33

Table 22 - The Maintenance Organizational Maturity Grid 34

Table 23 - Workload for Non-Mission Maintenance by Craft Shop 42

Table 24 - Workload for Non-Mission Maintenance by Type of Work 43

Table 25 - Workload for Non-Mission Maintenance by Work Order Type 44

Table 26 - Work Order Priorities 47

Table 27 - Tool and Parts Rooms 49

Table 28 - PBA Information Systems 51

Table 29 – Available Government Systems 52


TABLE OF FIGURES

Figure 1 - PBA Information Systems 52



The authors would like to extend two specific acknowledgements of contribution to this report. Admiral Jack Buffington (retired), University of Arkansas – Civil Engineering, shared his extensive expertise and literature in the areas of real property maintenance and Military Commercial Activities Studies. Mr. Phillip Vick, Pine Bluff Arsenal, provided the original Pine Bluff Arsenal Information Systems chart that was extended to detail maintenance data sources (found in Figure 1.)

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