Achieving Reliability from Data at Cerrejón Coal

CIM Montreal 2011
Daming Lin, Gerardo Vargas, Juan Carlos Consuegra,
Abstract Without an adequate data sample there can be no reliability analysis (RA). Without analysis there can be no systematic, verifiable improvement in reliability or in operational economy. A sample is a collection of life cycles. A beginning and ending event define a failure mode life cycle. Well known obstacles impede the reliability engineer in his role as analyst of maintenance data. The main problem lies in the difficulty to obtain analyzable data samples. Although modern CMMSs can provide the needed information they rarely deliver samples of adequate quality. Cerrejon, an integrated mining operation in Colombia, South America solved the reliability information management problem by applying a "Living Reliability Centered Maintenance (LRCM)" process to its fleets of Trucks, Graders, Dozers, Scrapers, and Shovels. This paper describes a method where work orders in Ellipse capture reliability analysis enabling information. The 'right' maintenance observations reference significant failure modes and mark the event appropriately as a failure or suspension. Work orders link to records in a continuously growing RCM structured knowledge base. Grouped and filtered knowledge-to-work order links, being instances of failure modes, provide the samples required by reliability analysis software tools and methods. LRCM and related procedures facilitate the growth of knowledge, manage the work order-to-RCM relationship, and generate samples for subsequent reliability analysis.
Keywords: RCM, Prognostics, Effective, CMMS, predictive, Dynamic, Analysis, Reliability, Ellipse, CBM
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