Sustaining Reliability
Sustaining Reliability
W
k h
W
k h
Workshop
Workshop
ARC Event
ARC Event –
– Orlando
Orlando
ARC Event
ARC Event –
– Orlando
Orlando
February 2010
February 2010
Augie DiGiovanni Augie DiGiovanni
Topics To Cover Topics To Cover Topics To Cover Topics To Cover Topics To Cover Topics To Cover Topics To Cover Topics To Cover
z Introduction to Asset Management
z Establish Asset Management Program by:Establish Asset Management Program by:
– Key Performance Indicator (KPIs)
– Work flow
– Asset Priority
– Maintenance task design
– Example step-by-step procedure p p y p p
– Maintenance Strategy Blueprint 'matrix'
z CMMS and Asset Management
– Move asset health data to the CMMS for work order generation
– Populate the asset management program with data
Why Plant Asset Management? Why Plant Asset Management? Why Plant Asset Management? Why Plant Asset Management?
z Reliability is becoming a competitive business issue
Quality i i l i i k t
z Quality is a survival issue in many markets
z Increased production demands on older equipment
z Manpower reductions require us to do more with less
z Cost reductions focus in maintenance and operations
z Customer requirements are becoming more stringent
z Environmental, health and safetyEnvironmental, health and safety concerns haveconcerns have
become a total enterprise issue
z Value creation is a motivating factor for management
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 3
A Little Background on the Playing Field A Little Background on the Playing Field
Challenge: To Be More Planned Than Reactive Challenge: To Be More Planned Than Reactive
A Little Background on the Playing Field A Little Background on the Playing Field
Challenge: To Be More Planned Than Reactive Challenge: To Be More Planned Than Reactive Challenge: To Be More Planned Than Reactive Challenge: To Be More Planned Than Reactive Challenge: To Be More Planned Than Reactive Challenge: To Be More Planned Than Reactive
1988 Present Best Cost
Reactive Reactive 55% 55% 10% P ti P ti 30% 31% 25 35% Preventive Preventive 30% 31% 25-35% Predictive Predictive 10% 12% 45-55% Proactive Proactive 5% 2% 5-15%
Source: Maintenance Technology Source: Maintenance Technology
45 8 Limited manpower 53% Percent 38 27 9 7 Budgetary restraints
Too busy reacting to machine problems to be proactive / strategic Lack of management understanding of
47% 34% 22 21 20 7 3 3 Lack of management understanding of
maintenance strategies Level of maintenance employee training
Not sure how to justify improved best maintenance practices 29% 24% 23% BARRIER: Major BARRIER: Insurmountable
[File Name or Event]
20 3 maintenance practices 23%
The Goal: Shift work effort from Reactive
Adding Value over the Life Cycle Adding Value over the Life Cycle Adding Value over the Life Cycle Adding Value over the Life Cyclegggg yyyy
ncy
a
nt Efficie
• Plant performance optimization • Predictive diagnostics services • Monitoring and analysis
services •Turnaround execution • Start up & Commissioning tart up S tart up Pl a services • Repair services S t S
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 5
Asset Optimization Asset Optimization
Technology and Services Technology and Services Asset Optimization
Asset Optimization
Technology and Services Technology and Services Technology and Services Technology and Services Technology and Services Technology and Services
Establishing an Asset
Establishing an Asset
Establishing an Asset
Establishing an Asset
Management Program
Management Program
Key Performance Indicators (KPI) Key Performance Indicators (KPI) Key Performance Indicators (KPI) Key Performance Indicators (KPI) Key Performance Indicators (KPI) Key Performance Indicators (KPI) Key Performance Indicators (KPI) Key Performance Indicators (KPI)
z Typical Corporate KPIs…
– Stock Price
z Typical Production KPIs
– Uptime % (vs total possible)
– Return on Assets
– Gross Profit
– Market Share
– OEE (Overall Equip Effectiveness)
– First Pass Yield (scrap)
– Maintenance Cost (%PRV)
– Customer Satisfaction
– Safety Record
– Product Unit Cost
( )
– Downtime (% available)
– Labor Overtime %
– MTBF Mean Time Between Failure Product Unit Cost
– On-time Deliveries
– Product Quality
ITO Inventory Turn over
MTBF Mean Time Between Failure
– MTBR Mean Time Between Repair
– Recordable Injuries
Training / Employee
– ITO Inventory Turn-over
– Sales Growth Targets
– Training / Employee
Work Flow
Work Flow –– ObservationsObservations Work Flow
Work Flow –– ObservationsObservations Work Flow
Work Flow ObservationsObservations Work Flow
Work Flow ObservationsObservations
Specific Acti ities General
Work Flow Characteristics of Best Cost Producers…
z Specific Activities
– Work Orders have priority assignment
KPIs posted
z General
– Able to plan 6 weeks out
– Change is expected
– KPIs posted
– Low Overtime (<5%)
– Strong adoption of CMMS E l f db k
• Continuous improvement programs
– CMMS Systems are integrated
– Early adaptors of technology
– Employee feedback
– Training / Cross-Discipline / Cross-Area
CMMS procedures reflect
• Strategy to Competitive Advantage
– Statements of Department Goals / Objectives
– CMMS procedures reflect technology utilization
– Asset failure history records
– Proactive root cause program
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 9
Asset Priority Concepts Asset Priority Concepts Asset Priority Concepts Asset Priority Concepts Asset Priority Concepts Asset Priority Concepts Asset Priority Concepts Asset Priority Concepts
Maintenance cares about this number… Operations cares about this number…
If I lose this, what is result to the ‘process’.
as it keeps OPS running without reacting
Maintenance Task Maintenance Task
Example of a re
Example of a re--designeddesigned
Maintenance Task Maintenance Task
Example of a re
Example of a re--designeddesigned Example of a re
Example of a re designeddesigned Example of a re
Example of a re designeddesigned
z Installation procedures for common activities that
involve AMS™ Suite
– Structured instructions
– Illustrations where possible
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 11
HRS p hy g n o ff p ec ti o n e me n t p er Y e a r
Asset Maintenance Blueprint
M=Monthly W=Weekly D=Daily Number= X months AR = As Required
Predictive Diagnostics Time-Based PM & Inspection Life Renewal PM
rat io n an al ys is A n a lysi s a re d The rm og ra p a s oni c s for m a nc e ni to ri ng/ Tr e ndi ng o r A n al ys is g n o s ti c S can hanca l o ff in e pe c ti o n c tr ic a l In s p e c tio n o ke T e s t te m T est E I n sp ec ti o n ef V a lve T e s ti n g c ti ona l Te s ts e rn al V isu al I n s p rn al I n sp ec ti o n br a ti o n ri c a ti o n o r P M o r P M m pone nt R e p la c e rh a u l a l M a in t. H o u rs p AR = As Required PlantWeb Services Vi b r O il A In fr a Ul tr a per f Mo n Mo t Di a g Me c In s p El e c li n e St ro Sy s ND E Re li Fu n Ex te In te Ca li Lu b Mi n o Ma jo Co m Ov e To ta
Asset Description Asset ID # MPI Exis
t
5 Control Air Compressor ER-67-CA-AC-5 762 M 6 3 12 12 12 M 16.5
5 Control Air Compressor Motor ER-67-CA-M-5 738 M 12 6 3 12 36 12 12 7.2
6 Saltwater Booster Pump ER-6-SW-P-6 562 M 3 6 AR 12 12 AR 60 8.7
6 Saltwater Booster Pump Motor ER-6-SW-M-6 562 M 12 6 12 36 12 12 7.2
4 Traveling Screen Wash Water Valve V54 ER-67-SW-V54 423 D AR 12 24 48 96 9.1
4 Traveling Screeng ER-67-SW-TS-4 410 3 12 12 38.3
4 Screen Wash Pump Motor ER-67-SW-M-4 410 M 12 6 12 36 12 12 7.2
70 East Air Preheater ER-70-CBA-AH-70E 323 M 6 W M 12 12 43.5
70 West Induced Draft Fan ER-70-FG-F-70WID 302 M 6 12 12 3 W 12 24 32.0
70 West Induced Draft Fan Motor ER-70-FG-M-70WID 302 M 12 6 6 6 24 24 12 12 24 120 19.1
77W HP Feed Water Heater ER 70 FDW EX 77W 302 M 60 36 60 9 9
77W HP Feed Water Heater ER-70-FDW-EX-77W 302 M 60 36 60 9.9
60 East Self Sustaining Aux Steam Regulator ER-60-AS-PCV-410 281 12 D 12 AR AR 24 24 24 AR AR 9.1
70 Main Feed Reg Valve ER-70-FDW-LCV-1010-2 258 12 D 12 AR AR 24 24 24 AR AR 9.1
70 Main Gas Supply Solenoid Operated Valve (BER-70-G-SOV-47 258 D 24 AR 60 1.6
CO To Storage Reg Valve LCV75 ER-7-CO-LCV-75 250 12 D AR AR 24 24 24 AR AR 9.1
[File Name or Event]
Main Fuel Oil Isolation Valve ER-60-FO-V-178 239 AR 24 48 96 2.5
CO Hotwell Recirc Reg Valve LCV78 ER-7-CO-LCV-78 215 24 D AR AR 24 24 24 AR AR 8.7
CMMS and Asset
CMMS and Asset
CMMS and Asset
CMMS and Asset
Management
Management
AMS Asset Portal 4.0 Powered by Meridium AMS Asset Portal 4.0 Powered by Meridium Key Value Points
Key Value Points
AMS Asset Portal 4.0 Powered by Meridium AMS Asset Portal 4.0 Powered by Meridium Key Value Points
Key Value Points Key Value Points Key Value Points Key Value Points Key Value Points
z Incorporates AMS Suite into Meridium for asset
strategy management
Define and measure optimal maintenance and
z Define and measure optimal maintenance and
operational strategies that affect company KPI’s
z Provides advanced analytics and decision support
I t t i f ti i t CMMS t
z Integrate information into your CMMS system
z Combine online diagnostics from AMS Suite with
mobile data collection with Operator Rounds.
P id l t l ti t i l t h li ti
– Provides a complete solution to implement a holistic
monitoring program
– Aligns the ‘Tag world’ with the ‘Asset world’
z Deploy PlantWeb Services and the AMS Suite to
z Deploy PlantWeb Services and the AMS Suite to
improve performance and best practices in your plant
AMS Asset Portal v4.0 AMS Asset Portal v4.0 Powered by Meridium Powered by Meridium AMS Asset Portal v4.0 AMS Asset Portal v4.0 Powered by Meridium Powered by Meridium Powered by Meridium Powered by Meridium Powered by Meridium Powered by Meridium
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 15
AMS Asset Portal 4.0 AMS Asset Portal 4.0 AMS Asset Portal 4.0 AMS Asset Portal 4.0 AMS Asset Portal 4.0 AMS Asset Portal 4.0 AMS Asset Portal 4.0 AMS Asset Portal 4.0
z Create customizable home page based on user responsibility
and group membership
z Email notifications
– Automated rule based notification
– Facilitates online collaborationFacilitates online collaboration
z Link essential work practices and procedures
z Query any information stored in the system and track and
h ifi bl i l
graph specific problems in your own template
z Create and schedule reports and have them automatically sent
to homepages or via email
z Segment data for specific users or groups
Asset Portal 4.0 Provides Additional Asset Portal 4.0 Provides Additional Value
Value
Asset Portal 4.0 Provides Additional Asset Portal 4.0 Provides Additional Value Value Value Value Value Value
z Metrics & Score Cards
– Create KPI’s in graphical format to see how assets are performing and potential issues
p
– Use the results to improve best practices, optimize utilization, and reduce costs
z CMMS Interface
Create manual work notifications when needed with your own
– Create manual work notifications when needed with your own recommendations
– Obtain work order history to understand past solutions that worked on assets
Operator Rounds
z Operator Rounds
– Define assets strategies and implement a monitoring program in operations
– Handheld application executes aspects of the asset strategy by
it i i t f d t i diti d t
monitoring equipment performance and capturing condition data electronically in the field
z Asset Health Indicators
– User defined health values assigned to both assets and actions
[File Name or Event] Emerson Confidential 27-Jun-01, Slide 17
g