A Risk Based Approach to Asset Management of Alcoa’s Civil Infrastructure in WA Presented by DENNIS FOO, Industrial Maintenance Roundtable ( IMRt )
• Business Case Across Alcoa’s WA Operations, Civil / Structural assets such as process buildings, workshops, offices, architectural buildings and other plant facilities are at a stage whereby some $10 M is required annually for maintaining the long term structural and functional integrity of these assets in an acceptable condition.
• Mission Statement Develop an Asset Management system to ensure that Alcoa WA civil assets are maintained at the required condition to perform their duties consistent with Alcoa values and strategic direction.
Asset Management in Alcoa …. what is it all about ? RISK ASSESSMENT & PRIORITISATION PROBLEM IDENTIFICATION FUNDS AUTHORISATION YEAR END CLOSURE & FEEDBACK PLAN & EXECUTE WORKS PROGRAM
WA Civil Asset Management Team l WA Equipment Management Team Sponsor l WA Civil Infrastructure Team Sponsor l WA Principal Civil Engineer l WA Senior Civil Engineer l KW Team - Senior Asset Integrity Engineer ( Alcoa ) - Civil Mtce Coordinator ( External ) l PJ Team - Senior Asset Integrity Engineer ( Alcoa ) - Civil Mtce Coordinator ( External ) l WG Team - Senior Asset Integrity Engineer ( Alcoa ) - Civil Mtce Coordinator ( External ) l Mining Team - Civil Projects Manager ( Alcoa )
Where Have We Been ? • • • WA Equipment Management Lead Team sponsorship - 1999 R Longer-term planning & regular reviews R Site based teams R Civil database R Risk Assessment methodology R Projects risk rated & prioritised R Condition Assessment methodology R Internal Customers recognition & acceptance of process R On-line documentation of asset management process R 2003 ASAT AUDIT Best Practice Recognition R
Key Features • Integration with Corporate Risk Mgmnt Tool 6 • Civil Asset health assessment 6 • Best Practice Info sharing/networking - Atlantic, Vic Ops, Mining Group, Electrical, Mechanical assets 6 • Senior Management endorsement & support 6 • Education & awareness 6 • Consistency across Operating Centers, Refineries and Smelter locations 6
The “Big Hits” • • Process Tanks Concrete, sump and drain repairs Structural Steel Repairs Rail Sidings Plant Gas Line Plant Storm Sewers Roads Buildings
Risk Management Tool Are people upset because they think it’s dangerous …. . or do they think it’s dangerous because they are upset ? Risk Assessment Matrices …RM_. xls
Risk Consequences
Risk Likelihood / Probabilities
Maintenance Deferment Legacy
Budget Control and Cost Reporting
Budget Control and Cost Reporting
Budget Control and Cost Reporting
Budget Control and Cost Reporting
In Summary • • • WA-wide process and teams Cross-site communication and info exchange Process recognition and acceptance at all levels Common electronic database Risk rated and prioritised projects in annual works program Condition assessment & rating protocols Budgeting and cost monitoring ( process transparency ) Asset Management Plans Engineering Technology input & support
• Corporate Direction • Leadership • Teamwork • Discipline & Commitment • Snr Management Endorsement • Operation Dept Buy In • Professionalism • Asset Management Team Organisational • Service Providers / Contractors Attributes • Training • Risks Assessments • Condition Assessments , Trending Customer • Asset Performance Requirements Expectations • Risk Prioritisation • Asset Health & Remaining Life Asset Mgmnt • Asset Valuation Know-How Auditing & Reporting Systems Resources EFFECTIVE ASSET MANAGEMENT Inspections and Condition Monitoring • Time Based Inspections • Condition Based Inspections • Risk Based inspections • Informal /routine Local Inspections People Funding - $$$ • IT Hard & Software Systems • Historical & “ Live” Database • Budgeting process • Mgmnt Budget Review & Approval Process Control Systems Intervention Strategies • Statutory / Legislative Requirements • Internal / External Standards • QA and Document Control Systems • Do Nothing • Repair – Strategic / tactical mtce works program • Replace • Dispose
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