SKF Client Needs Analysis

Your road map for improving plant reliability

 SKF Client Needs Analysis:
A proven process to identify plant improvement opportunities
How and where can I improve Consider:
plant performance? At least 50 % of companies that start a maintenance
Should I better align my plant with strategy project do not implement the results
industry benchmarks? How? effectively, and as a result, do not realize all potential
benefits.
How do I assure continual improvement in my
plants maintenance processes? 96 % of plants that implement condition-monitoring
programmes do so to reduce unscheduled machine
breakdowns. More than 80 % also want to enhance
Good questions. But finding the right answers and imple- competitiveness.
menting strategies to address these issues can be daunt-
ing. With daily operational challenges and time constraints, Of those facilities implementing condition-monitoring
identifying and achieving improvement opportunities may programmes without proper analysis, 40 % claim they
seem impossible. SKF can help. did not achieve the expected return on investment.

Drawing on years of SKF productivity experience, we can Our goal at SKF is to help you achieve maximum
help you identify improvement opportunities that will yield return on your reliability investment. The SKF Client
positive bottom-line results, then suggest a strategy for Needs Analysis is a performance benchmarking process
implementing a programme to achieve them. with proven success in many industries.

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ARD
REW
ding
pon
Res
UR Figure 1: The four phases of maintenance maturity.
AVIO Moving toward a world-class facility starts with understanding
BEH
where you stand today, and defining your objectives for the future.

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 SKF Asset Efficiency Optimization Work Flow Process
Figure 2:
Maintenance Strategy Project Business Goals
Asset Efficiency
Maintenance Reliability Issues (Design) PM =

Preventative Maintenance
(time based)
Optimization (AEO) is
Strategy Plant Asset Management
and Maintenance Programme PRM = Proactive Reliability an SKF work management

RCFA
(Living Programme) Maintenance (predictive
and corrective) process designed to achieve
Pre-Defined Priorities PM PRM ODR RTF ODR = Operator Driven
Reliability (observations) maximum effectiveness
RTF = Run to Failure (reactive
maintenance) from plant business
RCFA = Root Cause Failure Analysis
goal activities. AEO
includes four key facets:
PRM / ODR Collection and Analysis
Maintenance Strategy,
Work Information Integration Work Identification,
Identification and Decision Making
Work Control and Work
Corrective Operators
Execution. Within each
Work Order Generation Maintenance Initiators facet, the interaction
of three aspects of your
organization process,
Standard Job Plans culture, and technology
Work and Procedures Planning Spare Parts Alignment
are paramount to
Control your success.
Rolling Schedule

Work Execution
Work
Execution Post Maintenance Testing

Update Living Programme

Identifying problems: When, where and how they matter

An integrated reliability and risk-based asset management The Client Needs Analysis data can be obtained in just hours.
strategy starts with an understanding of where you are today, Forty questions covering the four main AEO facets provide a
and where you need to be to attain optimum performance. The snapshot of your plants situation and its position on the main-
SKF Client Needs Analysis enables this understanding, combin- tenance maturity continuum (see Figure 1).
ing our experience in reliability-focused maintenance with your
knowledge of plant conditions. The goal is to provide useful, Beyond the 40 questions, we also consider industry-specific
actionable information to help you focus on credible perfor- aspects of maintenance and reliability to create a unique,
mance improvement opportunities. needs-based analysis. Once we know how your reliability
maintenance processes are currently working, we then help
The SKF Client Needs Analysis is aligned with the main devise a roadmap to meet your foremost challenges.
facets of the SKF Asset Efficiency Optimization (AEO) work
management process, which enables a plant to produce the
same amount for less cost, or to produce more for the same
costs. AEO provides the basis for applying knowledge, improved
practices, and technology to achieve the greatest return on
investment.

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A progressive, structured approach to assessment
The Client Needs Analysis is conducted during a discussion between key members of your organization and a team of SKF
professionals. We will guide you through the maze of information that you already have, helping you gain a perspective on your
reliability programme that is generally not possible while immersed in daily activities. Once the analysis is complete, you will
receive a comprehensive report that includes:

A summary of initial set-up details
A Spider Chart illustrating a micro-level assessment for
each question versus the maturity phases (see Figure 3)
A Maturity Summary Matrix showing a macro-level
assessment for all four main facets of the AEO process
versus the maturity phases (see Table 1)
A Ranked Deviation Chart illustrating your performance
question-by-question versus your industry averages
(see Figure 4)
A detailed roadmap of recommendations for improving
plant reliability
And should you wish to implement our recommendations, we
can help create a business case to justify your investment.

Main Facet/ Maturity Absent Fire Maintaining Promoting Innovating Not Not Totals Table 1
Fighting Applicable Understood
Maturity Matrix Summary
Maintenance Strategy 3.97 5.31 3.51 4.91 6.78 .38 0.16 25.0 The table shows actual overall
Work 5.6 3.74 2.44 3.39 8.42 1.3 0.12 25.0 summary matrix status from
Identification
500+ Client Needs Analyses
Work Control 4.33 2.87 4.41 5.78 6.68 0.83 0.09 25.0
performed by SKF.
Work Execution 5.02 6.79 3.46 3.61 5.36 0.71 0.06 25.0

Subtotals per choice 18.91 18.71 13.82 17.69 17.23 3.21 0.43 100.0
of response

Targeting four key areas for improvement

By assessing performance indicators against benchmarks, SKF determines improvement opportunities that
typically fall under these facets:

Maintenance Strategy Work Identification

A comprehensive maintenance strategy can transform Being able to better identify potential faults before they
maintenance from a cost centre into a profit centre. become a problem will decrease unplanned downtime and
Topics investigated are: increase production efficiency. Topics investigated are:
Estimated annual replacement asset value Work types
Annual maintenance cost vs. budget Work order process
Annual revenue (total sales) Work order compliance
Stores Inventory Value (MRO supplies and consumables) Work order priority
Overall availability of assets Operator care
Reactive vs. proactive maintenance (%) Operators conducting Preventive Maintenance tasks
Asset register status, accuracy, and depth Predictive Maintenance programme effectiveness
Depth of asset criticality analyses performed Decision support
Planned work from maintenance strategy techniques Management of change
Root Cause Failure Analysis routines Work skills and competence

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 Work Maintenance
Execution Strategy
Figure 3
Spider Chart
Standard deviation -1
Standard deviation +1
Segment Average
Fire Fighting
Maintaining
Promoting
Innovating

Work Work
Control Identification Figure 4
Ranked Deviation Chart

Work Control Work Execution

Detecting problems earlier enables better scheduling of labour With an optimum work execution programme, maintenance
and spare parts for repair. Machine uptime increases, while labour productivity increases, maintenance rework decreases,
overtime, work backlog, and total costs decrease. Topics and total maintenance costs are reduced. Topics investigated
investigated are: are:
Planning accuracy (time-based) Work orders with no history
Number of planners per craftsperson Closing work orders with labour costs, material costs,
and actual vs. estimates
Scheduling horizon
Maintenance labour productivity
Preventive Maintenance schedule compliance
Training allocation per craftsperson
Predictive Maintenance schedule compliance
Supervisor to craftsperson ratio
Budget compliance
Number of crafts designations
Spare parts (bill of materials) documentation
Post-maintenance testing compliance
Standard job plans and procedures
Maintenance rework
Work backlog
Review of breakdown maintenance
Overtime levels
Review of Preventive and Predictive Maintenance

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Knowledge, the key to a successful reliability programme
By obtaining a comprehensive understanding of your plants
unique requirements, our Client Needs Analysis allows us to
identify improvements that can help you achieve optimum
results.
Whether conducted at one site, or multiple sites within your
organization, a Client Needs Analysis provides a snapshot of
current maintenance efficiency. It not only helps you measure
performance against benchmarks and best practices within
your company or industry it can even highlight continuous
improvement opportunities.
To help your team prepare for a successful Client Needs Analy-
sis, you will receive the analysis questions prior to our first data
collection meeting. We will provide you with a detailed descrip-
tion of the process as well as guidelines on the resources, facts
and figures needed to complete the analysis. We will also work
with you to identify key individuals within your plant whose
participation will enable the most successful result.
Areas of expertise where SKF can assist:
Asset Efficiency Optimization work management process
Quick start reliability programme
Maintenance strategy review
Proactive Reliability Maintenance programme
Operator Driven Reliability programme
MRO supply: spare parts and inventory management
Machine maintenance: precision alignment, balancing,
lubrication, etc.
EAM/CMMS data population: asset register, bill of
materials, standardized job plans, etc.
Living programme: reliability engineering and root
cause analysis of failure data
Training: competence development and knowledge exchange

Once the analysis is complete and improvement opportunities Outsourcing through performance-based service and supply
have been identified, our team will help you craft the agreements (The SKF Integrated Maintenance Solutions)
solution(s) tailored to your needs. Typically, this will involve
a combination of internal activities, products, or services
you may already be using, along with one or several
SKF solutions.

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Success, our mutual goal
While you may already be aware
of problem areas in your plants
reliability programme, consider
how an SKF Client Needs Analy-
sis can help you identify their
root causes and recommend the
right steps for improvement.
Backed by almost 100 years
of rotating machine reliability
expertise, SKF Client Needs
Analyses have helped clients across every major industry.
From paper and petroleum to food processing and power,
here are just a few examples of how weve helped clients
around the globe:
 n oil-refining company identified the need for a series of
gA
improvements. First, they needed to establish a correct
asset register to improve efficiencies in the CMMS process.
Second, they discovered the need to better document and
communicate instructions that would standardize quality
in the execution of maintenance and reliability tasks. This
finding also highlighted the need for additional personnel
training. Finally, they recognized that involving their
operators in the reliability effort could help them attain
a significant reduction in downtime and related costs
and move them closer to achieving their desired
business results.
For more information on the SKF Client Needs Analysis, contact your local SKF representative,
or visit www.skf.com/reliability
g An Asian pulp and paper producer participated in a Client
Needs Analysis to measure ten of its facilities against each
other and industry benchmarks. Key improvements were
identified in the areas of work control and execution. A
strategy was enacted to better align processes among each
plant, and milestones were established to help ensure a
consistent progression toward best-practice criteria.
g A global food company conducted a multi-plant
Client Needs Analysis to benchmark maintenance
practices and establish a company-wide reliability
improvement programme.
g A power generation facility identified the need for a more
effective maintenance strategy after a work control review,
and then implemented the process improvements needed
to execute the programme.
g SKF has conducted Client Needs Analyses throughout
its own bearing factories to assess varying levels of
maintenance maturity and to prioritize areas for improve-
ment that would immediately impact factory efficiency.
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 SKF is a registered trademark of the SKF Group.

SKF 2006

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Publication 5532 EN

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