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RCM2 – Decision Worksheet
HOJA DE TRABAJO EQUIPO No. Realizado por Fecha Hoja
1
DE DECISIÓN
RCM II COM PONENTE Ref. Revisado Fecha de
Concentrator: Pilot
RCM2 Project
Formal Start Date: November 2002
Actual Start Date: March 2003
End date: December 2004
18 month of effective activity
Stages:
• Qualification and Training:
RCM2 Introductory 3 days Course
RCM2 Facilitators 10 days Course
RCM2 Basic Seminars, half day
• Analysis Groups:
Meetings with Consultant support
Meetings without Consultant support
• Audits
• Activating strategies into SAP-PM
• Implementing strategies (Start up of activities)
RCM2 Project
Courses & Consultancy
Facilitators
3 Day Course Course
Basic Seminars Man Days
2003 13 4 10 330
2004 18 2 16 490
Total
Corp 31 6 26 820
Analysis Groups - Performance
Number of Groups
Started as New
56 Groups
64% Started as Advanced
17 Groups
19%
Started as Veteran
15 Groups
17%
17
Advanced
15 Groups
Veteran
Groups
Project Goals
Subsystems Analized During Project Time
600
Summer
Hollidays
522
500
455 453
Goal Done Check 6
420
Number of Subsystems
640 days
400
Check 8
340
Check 4 720 days
Mar / 2004
300 540 days
Dic / 2003
261
227
200 Check 2
Mar / 2003
Nov / 2004
Dic / 2004
161
143
111
Nov / 2002
113 111
100
46 43
0 0 0
0 100 200 300 400 500 600 700 800
Calendar Days of the Project
Professionals
CLIENT CUSTOMER Number
Contract Manager 1
General Coordinator of the Project 1
Divisional Coordinators 4
Facilitators 90
Group Members 750
ELLMANN, SUEIRO & ASSOCIATES
Project Director 1
Area Leaders 2
RCM2 Consultants 5
Human Resources Consultants 3
Quality Consultants 1
IT Consultants 1
Comercial Manager 1
Total of ES&A Professionals active in the Project 14
Analysis Groups - Performance
Failure Mode Rate per Hour
4,0
Average = 3,15 FM/h
3,5 3,8
3,0
2,9 3
2,5
2,0
1,5
1,0
0,5
0,0
Started as New Started as Advanced Started as Veteran
Analysis Groups - Performance
Supports by Analysis Cycle
8 8
7 7
5 5 5
4 4 4
3 3
3
2 2
1 1 0,8
0
1st Cycle 2nd Cycle 3rd Cycle and later
Analysis Groups - Performance
Performance of Full Time Groups
Divison I
5,4 FM/h
3,7 FM/h
Division I
57%
20%
4108
2204
1064
840
25000
15000
77500
7000 46500
3000 21500
9500
400
350
Include 39
Number of Subsistems
Full Time
300
250
411
200
150
100
111
50 48
0
Previous 2003 2004
Stage
Analysis Groups - Performance
Finished in each Stage by Division
400
350 Include 39
Full Time
Number of Subsistems
228
300
200
48 Previous Analysis
150 94
100 72 48
50 29 26
13 6 49 41
0
Previous 2003 2004
Stage
Analysis Groups - Performance
Analysis by Cycle
250
218
200 Analysis
158
150
146 Analysis
Analysis
100
50
0
1st Cycle 2nd Cycle 3rd Cycle and later
Analysis Groups - Performance
Meetings by Analysis
16
14
Include 39 Full Time 14,2
12
Average = 11,9
11,3
11,1
10
New
Adanced
Veteran
Management of Change
Labor Perception Surveys
Introductory Communication Seminars
Communications Campaign
• Posters
• Articles in Company Magazines
Recognition Forums for Group Members
570
477
260
167
133 225
133
149
52
52 30
56 26 520 17 1
12
Finished Audited In SAP On Duty
Stage
Tasks to be Done
3 Days Facilitators Basic Seminar Man Days
Course Course
Division I 6 2 12 160
Division II 5 2 8 80
Division III 2 1 5 40
Division IV 2 1 5 40
Total 15 6 30 320
Future Recommendations
Spread RCM2 concepts allover the Client Company
• Reach “Critical Mass”
Huge involvement of Management
Implement new strategies in a participative way
Sample Analysis
Division IV:
• 54 Analysis
• 4320 Failure Modes
• Sample
• 42 Failure Modes
Division II:
• 134 Analysis
• 14740 Failure Modes
• Sample
• 46 Failure Modes
Relevant Economics
SALVADOR Results
Division IV Cant. U$S U$S U$S % de FM Benefits of
FM Mainte- Operatio- Total Implemen- FM
nance nal Benefits Benefits ted Implemen-
Savings ted
Concentrator 9 7.300 66.600 73.900 100 % 73.900
CONCLUSIONS
Division IV:
• Extrapolating to the Division with 54 Analysis and 4320
Failure Modes
• Estimates of FM:
• 5 % (216) generates a benefit like the calculated
• 20.000 U$S/FM
• 20 % (864) generate 1000 U$S/FM total annual benefit
• The other FM do not generate any benefit
Relevant Economics Results
CONCLUSIONS
Division IV:
Annual Benefit
Maintenance U$S 600.000
Global (O+M) U$S 5.000.000
Relevant Economics Results
CONCLUSIONS
División II:
Beneficio Anual
Maintenance U$S 14.300.000
Global (O+M) U$S 141.500.000
Relevant Economics Results
COMMENTS
• Production of Division II is 6 times bigger than Division IV.
• Copper Law in Division II is much higher than Division IV.
• Production costs in Division IV are much bigger than Division
II, due to technology used in each Division.
• Probably, these are part of the reasons why operational
benefits generated by the increased availability and
reliability of Division II appear as much higher than the
ones generated in Division IV.
• All values are calculated with copper price at December
2004 – March 2005.
Conclusions
Highly Profitable Project
Internal Cost 3 M U$S