August 29th 2007 Sydney Roundtable Meeting with Sydney Water Malabar Sewerage Treatment Plant
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Return to NSW Industrial Maintenance Roundtable (IMRt)
Some great presentations, an interesting site tour and a good time had by all. The morning session was held at the Airport Stamford.
Morning Presentations
The first presenter was by Grant Nelson from Fonterra who was the main driver for a 13% increase in OEE and an 8% increase in throughput achieved in only 18 months period at their Te Rapa plant. This took it from one of the worst performers in their group to one of the best. A fantastic example of how a strong people manager with good improvement process knowledge and good management support can achieve dramatic results on a poorly performing plant. Grant's main points were Build your Strategy, Beat the Blame Mentality, Change your Culture and Remove the Blinkers. The basis of the improvement was a strong plan involving improvements to Planning and Scheduling, Communication Loops, RCAs (getting the facts right), PM Routes and New Projects being Done Correctly. As an example of the level of activity, they did 675 RCA's in the 18 month period.
View Presentation Media:Champion_the_Champions_GNelson.pdf
The second presentation was by Peter Reed the Asset Manager External Plant at Delta Electricity Western Region and Aaron Halverson Asset Management Group Leader from CCI Pope. Peter is leading a project to install some new power station Air Compressors with the committment to have detailed Asset Reliability Life Cycle Plans in place before commissioning. This project is a partnership between Delta Electricity, Champion Compressors (OEM) and CCI Pope, Delta’s Condition Monitoring service provider. The project used a simplified RCM approach and has been highly successful. It is already being extending into other area of plant. It has also received good acceptance by Delta Electricity Management.
View Presentation Media:Delta_New_Asset_Reliability_Life_Plan.pdf
The Third presentation titled 'Stop Talking and Start Lubricating' was by William Versfeld the Reliability Coordinator from the OneSteel Rod Mill in Newcastle. William is very experienced in the area of maintenance and achieving reliability improvement to plant. The presentation was on lubrication improvements that he has been facilitating at the Rod Mill. The changes they are in the process of implementing is not high tech stuff but just basic good practices that often companies fail to implement well. The success of the project is mostly driven by the engagement and ownership taken by the local Lube Technicians.
View Presentation Media:ONE_STEEL_ROD_MILL_LUBE_JOURNEY_WVersfeld.pdf
Breakout Session
Breakout Discussions on Suggestions fo NSW CIWG Topics for 2008
Site Tour of the Sydney Water Malabar Sewerage Treatment Plant
The first highlight of the tour was Kel Taylor the Malabar Sewage Treatment Plant Manager taking the group through the models of the plant in the visitors centre and then going out onto site and actually seeing the huge scale of the facilities that handles the effluent from 1.8 million people. The other highlight was seeing the cogeneration facility powered by digester gas from the collected waste that is used to generate electricity for site usage. This Cogen facility reduces the overall production of greenhouse gas. Jeff Hughes from WorleyParsons, the service provider maintaining the system gave an excellent overview of how it works and the key maintenance issues involved.
