Raúl Stegmaier

Advanced model for maintenance management in a continuous improvement cycle: integration into the business strategy

This paper presents an advanced model for the integrated management for industrial plant maintenance and equivalent. The proposed model achieves to align the local maintenance objectives with the overall business objectives. Additionally, the model provides a real operational context and takes consideration of certain restrictions that may affect the efficiency and/or the effectiveness of the industrial maintenance management. First, the importance of a proper maintenance management and its consequences are discussed. Then, the model will describe in seven stages how to manage and optimize in a continuous way all the processes that deal with planning, programming and maintenance execution. This starts from a management process in the design stage or, from an already established management process. Moreover, the model includes fundamental aspects that fully integrate the directives of the business with maintenance activities. This article ends with conclusions and all references used during the research process prior to the drafting of this document.

A case study of GAMM (graphical analysis for maintenance management) in the mining industry

Abstract This paper presents a case for practical application of the GAMM method, which has been developed and published by the authors (Barbera L., Crespo A. and Viveros P.) The GAMM method supports decision-making in the overall maintenance management, through the visualization and graphical analysis of data. In addition, it allows for the identification of anomalous behavior in the equipment analyzed, whether derived from its own operations, maintenance activities, improper use of equipment or even as a result of design errors in the equipment itself. As a basis for analysis, the GAMM method uses a nonparametric estimator of the reliability function using all historical data or, alternatively, part of the history, allowing it to perform an analysis even with limited available data. In the case study developed, GAMM has been used to analyze two slurry pumps in a mining plant located in Chile. Both pumps are part of the same industrial process, which is described in Section 3 , and both pumps had a higher failure rate but one more than the other. GAMM identified deficiencies in each of the pumps being studied, thus improving decision-making and problem solving process related to the maintenance of the pumps. Particularly, this work initially provides a description of the GAMM method ( Section 1 ), and, afterwards, it is depicted with special attention the approach to the problem ( Section 2 ). In Section 3 , a background of the industrial context is presented. Then, Section 4 shows step by step the application of GAMM method. Finally, results and conclusions are presented in Section 5 where the main improvements obtained are summarized.

A Case Study of GAMM (Graphical Analysis for Maintenance Management) Applied to Water Pumps in a Sewage Treatment Plant, Chile

This article presents a case for practical application of the GAMM method, which has been developed and published by the authors. The GAMM method supports decision making in the overall maintenance management, through the visualization and graphical analysis of data. In addition, it allows for the identification of anomalous behavior in the equipment analyzed, whether derived from its own operations, maintenance activities, improper use of equipment or even as a result of design errors in the equipment itself. As a basis for analysis, the GAMM method uses a nonparametric estimator of the reliability function using all historical data or, alternatively, part of the history, allowing it to perform an analysis even with limited available data. In the case study presented, the GAMM method has been used to analyze two existing equipment parts in a sewage treatment plant located in Chile. The equipment analyzed were two progressive cavity pumps (BCP) which are part of the industrial process in the treatment plant. Both pumps are the same make and model and subjected to the same maintenance program, but one had a higher failure rate compared to its counterpart. The application of the GAMM method has identified deficiencies in each of the pumps being studied, thus improving decision-making and problem-solving process related to the maintenance of the pumps. RCM methodology was used to draft a new maintenance plan. Copyright

Integrated Model for Technology Assessment and Expected Evolution: A Case Study in the Chilean Mining Industry

In this paper a 9-step method is proposed to study the evolution of technical systems. Merging the potential of TRIZ and patent analysis, a structured approach is defined to properly analyse the state of the art of a technology and retrieve useful insights to identify and structure new development strategies. Past-present evolutionary dynamics are quantitatively described, while indications for new possible development scenarios can be also extrapolated. Starting from a detailed breakdown of the technology under analysis, a list of evaluation parameters is defined to classify inventions and thus monitor the technology advancements by means of the TRIZ Laws of Engineering Systems Evolution. The aim of this study is to foster the diffusion of more reliable and systematic approaches to innovation especially in those industrial sectors where high risks and investment costs tend to favour short-term technological advances rather than long-term ones. Two case studies were developed within the context of the mining industry. Specifically, the study is part of a research project founded by the Chilean Economic Development Agency (CORFO) whose objective is to support companies of the Atacama region, in the identification of new technological opportunities to renew their production process.

Propuesta de un modelo de gestión de mantenimiento y sus principales herramientas de apoyo

Este articulo presenta un modelo para la gestion integral del mantenimiento, teniendo en consideracion la caracteristica de mejora continua en el tiempo. A modo de introduccion y contextualizacion, se explica la importancia que tiene la alineacion de objetivos a todo nivel organizacional para lograr la integracion y correcta gestion de la unidad de mantenimiento. El modelo a presentar se compone de siete principales etapas, las cuales deben desarrollarse progresivamente segun el escenario actual de la organizacion, haciendo enfasis en la gestion y optimizacion sostenida en el tiempo de procesos asociados a la planificacion, programacion y ejecucion del mantenimiento. Adicionalmente, el modelo presentado complementa herramientas de apoyo para el desarrollo e implementacion de las etapas, y caracteristicas operacionales reales, las cuales podrian afectar el desempeno de la unidad de mantenimiento. Finalmente, se presentan algunas consideraciones generales y respectivas conclusiones.

A case study of GAMM (Graphical Analysis for Maintenance Management) applied to water pumps in a sewage treatment plant, Chile

Abstract This article presents a case for practical application of the GAMM method, which has been developed and published by the authors. The GAMM method supports decision-making in the overall maintenance management, through the visualization and graphical analysis of data. In addition, it allows for the identification of anomalous behaviour in the equipment analyzed, whether derived from its own operations, maintenance activities, improper use of equipment or even as a result of design errors in the equipment itself. As a basis for analysis, the GAMM method uses a nonparametric estimator of the reliability function using all historical data or, alternatively, part of the history, allowing it to perform an analysis even with limited available data. In the case study presented, the GAMM method has been used to analyze two existing equipment parts in a sewage treatment plant located in Chile. The equipment analyzed were two progressive cavity pumps (BCP) which are part of the industrial process in the treatment plant. Both pumps are the same make and model and subjected to the same maintenance program, but one had a higher failure rate compared to its counterpart. The application of the GAMM method has identified deficiencies in each of the pumps being studied, thus improving decision-making and problem solving process related to the maintenance of the pumps.

Design of Performance Indicators Based on Effective Time and Throughput Variability. Case Study in Mining Industry

The following paper proposes a method on how to analyze productive systems to achieve performance indicators that allows to know the state of the system. In particular, the objective of the paper is to analyze performance indicators that allow to understand the state of the production line in systems that present variability conditions in the performance of their equipment, and in their operational conditions that will not allow direct calculation of the effective time. It is proposed to begin with the utilization of a methodology to increase the understanding of the system, which will generate a conceptual model that will concentrate the required knowledge through a logic structure that will ease the subsequent analysis. Then, a step by step process is proposed to define the system, its performance indicators of interest, and the most efficient and effective way to obtain those, considering the existing restrictions. Finally, system and subsystem level indicators will be obtained, which will be a representation of the real state of the process, by representing the effective times, and variable throughput. All of the above will be applied in a case study in the mining industry from Chile.

A Single-source Weber Problem with Continuous Piecewise Fixed Cost.

This paper analyzes the location of a distribution center in an urban area using a single-source Weber problem with continuous piecewise fixed cost to find a global optimal location. The fixed cost is characterized by a Kriging interpolation method. To make the fixed cost tractable, we approximate this interpolation with a continuous piecewise function that is convex in each piece, using Delaunay triangulation. We present a decomposition formulation, a decomposition conic formulation and a conic logarithmic disaggregated convex combination model to optimally solve the single-source Weber problem with continuous piecewise fixed cost. Although our continuous approach does not guarantee the global optimal feasible location, it allows us to delimit a zone where we can intensify the search of feasible points. For instances we tested, computational results show that our continuous approach found better locations than the discrete approach in 23.25% of the instances and that the decomposition formulation is the best one, in terms of CPU time.

A Support System for Selecting the Most Suitable Spare Parts Strategy

This paper reports an algorithm to create a decision support system for the most suitable spare parts strategy. It is developed based on risk and cost analysis. The algorithm decision support system makers includes information about the possible scenarios in the maintenance field; moreover, this information is useful to support future strategies, helping to decide the number of the spare parts necessary to increase at the maximum process/equipment availability rate. In this task, the algorithm is based on risk analysis considering two main aspects. The first, related to success and failure probabilities is estimated through Poisson distribution; the second one is related to the expected total cost, considering: storage costs, capital tie-up costs, repair costs, purchase order costs (normal and emergency), opportunity costs, and others.

Career Employability Development Through a Specialized Asset Management’s Degree: An Exploratory Analysis for a Chilean Program

Asset Management as a growing discipline is being incorporated into the Chilean Industry, especially into the mining Industry; however, there is a need to provide the necessary skills and knowledge regarding these new positions. In that regard, since 2005 we have successfully incorporated a master’s program scheme entitled Master of Asset Management (MGA, currently in its 9th offering). Up to date, more than 300 postgraduate students from different industries have attended this MGA, becoming the leading program in Latin America. In the training field we have developed a Diploma on Asset Management (DGA—140 h). With the present study, we have analysed the students’ profiles to identify the industry distribution and, at the same time, to measure the extent to which the skilled labour (graduates) have moved between different job positions and/or companies, be it as a horizontal mobility (does not result in a change in the worker’s grading or status) or a vertical mobility (if it does). Additionally, we regularly test the influence of the market-value and scholastic and social dimensions of the human capital on the alumni. The scope is mainly the Chilean industry.