Kooperationspartner

Zellstoff Pöls AG
A-8761 Pöls

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Criticality assessment and risk analysis

Goal

In this project, a process methodology for identifying critical systems is being developed (criticality determination using the CAP tool developed by the wBw chair in cooperation with BOOM-Software). Subsequently, detailed analyses and an exemplary risk analysis on the rotary kiln as well as the introduction of an evaluation for external service providers will be carried out for risk and/or cost-critical plants. In a follow-up project, the assessment was rolled out to all departments of Zellstoff Pöls AG.

Benefit

  • Identification of the critical components of selected departments
  • Cost analysis of the individual departments and identification of the biggest cost drivers
  • Risk analysis to reduce the system risk
  • Derivation of measures as the basis for a plant-specific strategy selection and dynamic budgeting
  • Minimised use of resources by automating the assessment

Project content

As a progressive industrial company, Zellstoff Pöls AG is intensively involved with the topic of "sustainable plant management". In order to obtain a transparent and meaningful assessment of the plant status, a research project is being launched with the aim of analysing the current status and comparing existing management systems and associated documents with the necessary certification requirements of ISO 55001. The next step is to derive measures for successful certification:

 

Procedure methodology for successful ISO 55000 certification

This first implementation project began with the introduction of a standardised system assessment and an assessment of external service providers. Both areas can be found in Chapter 9 of ISO 55000 (evaluation of performance) and are a basic requirement for certification.


The standardised system assessment is essential, above all, for dynamic adjustment of the maintenance strategy, to increase planning reliability and for targeted weak point analysis and criticality-based budgeting. The asset is also becoming increasingly important due to the rising level of automation and digitalisation. This makes it all the more important to ensure appropriate data recording and evaluation at plant level in order to be able to carry out targeted, plant-specific maintenance strategy planning, which is also the aim of Zellstoff Pöls.


The criticality assessment process is a 5-stage process that is carried out continuously, but should also be adapted to the prevailing plant conditions:

 

Criticality assessment process

In the case of Zellstoff Pöls AG, this evaluation is to be fully automated after a one-off definition of the criteria and the definition of the levels of severity for each criterion and their weighting. For this reason, a prototype of a lean smart maintenance tool for criticality assessment, which was developed in co-operation with BOOM Software AG (Leibnitz), is being tested as part of this project. In the future, this tool should enable such a fully automated evaluation at Zellstoff Pöls AG through SAP interfaces. The result of the criticality assessment is visualised in the so-called plant priority portfolio:

 

Asset priority portfolio

This portfolio, in which the asset index is compared with the maintenance costs, illustrates the critical position of the assets. The most critical investments can be found at the top right of the portfolio. All investments in this quadrant are categorised as critical in terms of both risk and costs. Investments in the upper left-hand part of the portfolio are very cost-intensive, while investments in the lower right-hand part are characterised by a high level of investment criticality. The aim is to move the assets to the bottom left by deriving suitable maintenance strategies, as these assets are categorised as non-critical.


Based on this portfolio, the detailed analyses of a critical plant - the rotary kiln - are started in order to specifically identify current and potential faults in the plant components. These are assessed on the basis of the extent of damage, the frequency of occurrence and the probability of detection. This allows targeted measures to be derived for risk reduction and fault prevention. Furthermore, an evaluation form for a standardised assessment of external service providers is being introduced in order to ensure consistent service provider quality and long-term company cooperation, as well as to build up a database for external service providers. The aim is to obtain a permanent overview of qualification levels and training programmes as well as current and previous activities.


In the course of workshops, the quality requirements of external service providers are defined and their requirement profiles drawn up. On the basis of these quality requirements, an evaluation form is created that enables a standardised evaluation in a resource-saving manner and, using a traffic light system, enables a person-specific but also company-wide trend prediction regarding changes in the qualification levels of external service providers.


In the follow-up project, the main aggregates in the BOOM software tool will be evaluated department by department, with the aim of integrating a fully automated system evaluation at Zellstoff Pöls AG in the future. The aim of this automated plant assessment is to be able to start the risk identification and assessment of critical plants directly on the basis of the plant priority portfolio (result of the plant assessment).


Contact person

Dipl.-Ing. Theresa PASSATH   |   +43 (0) 3842 402 6013   |   theresa.passath(at)unileoben.ac.at

 



Literature
  • Biedermann, H. (2017): Lean Smart Maintenance Controlling: The weak point analysis as a central element in the maintenance management system. In: Biedermann, H. (ed.): Success through Lean Smart Maintenance: Building Blocks and Paths of Change: 31st Maintenance Forum. Cologne: TÜV Media. ISBN 978-3-7406-0243-7, PP. 23-36.
  • Bernerstätter, R.; Kühnast, R. (2017): Vulnerability analysis to ensure the ability to act in complex systems. In: Biedermann, H. (ed.): Success through Lean Smart Maintenance: Building Blocks and Paths of Change: 31st Maintenance Forum. Cologne: TÜV Media. ISBN 978-3-7406-0243-7, PP. 163-184.
  • Bernerstätter, R.; Kühnast, R. (2019): Data Maturity Assessment - Evaluating the maturity of data management for smart maintenance. In: BHM Berg- und Hüttenmännische Monatshefte, Vol. 164, No. 1, pp. 21-25.