© 2008 eventure events. all rights reserved. transformation of plant maintenance systems george...

© 2008 Eventure Events. All rights reserved.

Transformation of Plant Maintenance Systems

George MullerConectiv Energy

A Perspective - Past & Present

Warning!Do not be afraid!

Do not run screaming from the room!

Do not adjust your eyeglasses!

While some of the images you are about to view are shockingly amateurish and the scenes horrifying, the characters are fictitious and present no threat to you, your company, or to the actors guild.

A Perspective - Past & Present

Return on Investment• Results

– 90% reduction in time spent looking for information

– User acceptance shift from 60% -> 90%

– Up to 20% reduction in Emergency Work Orders

– Time Savings for planners and technicians

– CBM IRR > 20%

– Improved accuracy and reduced duplication of problem reports and identify missed issues

– Accountability and completeness of rounds

• Reference SAP Business Transformation Study– “CONECTIV ENERGY: OPTIMIZING OPERATIONS AND ACCELERATING OPERATIONAL

READINESS”

Agenda• The Evolution of the Maintenance Process

– Introductions – Who are we

– The time line

– The journey• Discuss each step, light on the early days

• Describe briefly each technology

• Touch on People & Process

• Get a focus on the products used

• Summarize where we are at

• Describe what is next

– Benefits

– Lessons Learned

A Power Generation CompanyA Merchant Energy Company

About Conectiv Energy

Introductions

About me

The Evolutionary Time LineExamining the evolution of O&M practices and

supporting technologies

• Where we came from…

• Where we are…

• Where we can go from here…

Evolution

Evolution• What is the role of technology?

• How about managing people & process?

The Evolutionary Time Line

The Historical View

20101950 19901970

SAP Live

Punch-card Work Order System

GEMS

Notebooks& Card files

O&M Tech

Compass

WORS

merger

PI

PM Crew & Predictive

The Evolutionary Time Line

Recent Times

20101990 2000

SAP Live

MORNRX ACMVIP

CBM

MAM

Work Nav

merger

KPI

The Evolutionary Time Line

Current & Forward Looking

20122008 2010

CBM2NRX AH

Auto Parts Issue Mobile Content Mobile Performance Auto Time Confirm Dynamic Auto Schedules

Paperless ????

MAMGMS Integration

LOTO

Process Changes (late ’80s early 90’s)• Focus on Preventive Maintenance

– Dedicated PM Crew, self directed with real KPI’s tracking

• On time completion

• Percent hours on PMs vs. non-PM’s

• Transformation from 75% immediate work to > 70% planned work

– Revamped PM Procedures in CMMS

Process Changes (late ’80s early 90’s)• Transition to Predictive Maintenance

– Vibration analysis: non-integrated stand alone system

– Oil analysis: e-reports from external vendor not integrated

– Thermography: hard copy reports from vendor

– Acoustic monitoring: Hand held units and on-line boiler leak sensor

– Originally lead by engineer, then transitioned to mechanical crafts person

IT Technology Enabler…SAP• 1997 – Live on SAP 3.0B

• First (one of the first?) utility using SAP Plant Maintenance

in the US

• 4 generating plants, 14 generating units

• Converted > 5000 preventive maintenance plans from

legacy

• More than 200 users

• Today’s enabler: SAP ECC 5.0

VIP & NRX Asset Hub• Early Generation Asset Content Management

• Implemented in 2004

• Drivers – Build PM Objects for new plant

– Capture extended asset information

– Enable self-managed work force

VIP Visual Navigator

Click any box

NRX VIP Visual Navigator & Work Nav

Get a list of order in that queue And queue information

Click Change and order moves to the next queue in process

Select to view the order

NRX VIP Integration to Asset Hub

The manual and photographs are here!

NRX VIP Integration to Asset Hub

The manual and photographs are here!

Bringing Technology Together

• SAP with R-link

• R-link with OSI

• SAP with Syclo using hand held devices

• SAP with Condition Monitor

Goal: To identify failures “early” on the failure curve allowing for a planned repair approach in a convenient timely manner

CBM - OverviewCounter & Condition Based Maintenance

Solution

• Leveraging existing investments in– SAP

– OSIsoft PI

– Equipment Predictive analysis tools

• Facilitated by a new product – Condition Monitor by DLL Solutions

CBM - Overview• Capturing and codifying the knowledge of

engineers and technicians– Cleanses source information

– English-language rules

• Automating the use of this data to intelligently manage work

CBM - Structure

PI Rlink

CM

• Maintenance Approach- an evolution from– Corrective/Reactive

– To Preventative (Time-based)

– To Predictive / Counter / Performance based

CBM - User Interface Sample RULE for a coal mill

Counts Tons of coal processed and sends to

SAP

Previous counts sent to SAP

Mobil Operator Rounds – Why?

An entire presentation… but in summary…

• Driving accountability and motivation…

• How do to this…. Several options…

• Here is one we came across…

Mobil Operator Rounds – Why?

Mobil Operator Rounds – Overview

• Leveraging investment in SAP

• Using software platform from Syclo, LLC.

• Started out simple– Phased Approach

– Operator Rounds +

– Bar coded Assets

Mobil Operator Rounds – Overview

– Prompted to enter observations – drop-down list selection

– Notifications & Work Orders visible

– Operator can write a new Notification or Work Order

– Operator can capture issues on reading screen

– Any issues or out-of-range conditions automatically email

MOR – User Interface

KPI - IntroductionKey Performance Indicators for Maintenance -

• Leveraging investment in SAP & BW

• Built on BW and Portal

• Defined by plant management for measuring maintenance

• Common across facilities – A Sample– %Costs charged to Equipment

– %Hours used for Emergency or Urgent work

– %Hours used for Preventative / Predictive work

– %House used for Planned, Normal Priority work

– %Hours used for Unplanned, Normal Priority work

KPI - Example

Current Initiatives• Mobile Asset Management

– Operator Rounds

– Environmental & Safety Inspections

– Access to create, search, view, edit, work orders and notifications

– Access to EBOM, MBOM, Material and Inventory

– Access to MSDS for chemicals

– Wireless access

Current Initiatives• Condition Based Maintenance – Expansion

– Additional equipment & rules

– New facilities

– Incorporation of pump curves and other Condition measures

• Assessment and Planning– Review use of SAP and all technologies

– Strategic plan update & Tactical plan for next two years

– Working with Vesta Partners

Future Initiatives• Replace Lock Out Tag Out system

• Provide mobile access to asset content

• Automate Time Confirmations into mobile solution

• Reduce paper

• Automate Parts Issues

• Bar-coding of additional assets, tools & materials

• Automate Parts Issues

• Whatever we dream up in our assessments

What Inhibits the Evolution?• Same thing that enables the evolution: People, processes and

technology

– People• Lack of a coordinated vision between IT and maintenance

• Complacent Culture

• IT may not be focused on EAM, but other company areas

• Perhaps a difficult approval processes for new ideas

– Process • Difficulty to change what may appear to be an effective

process at the plants (work processing and stores)

– Technology• Maintenance inability to articulate a solid ROI and get upper management buy-in

and budget…….………………………..

What Enables the Evolution?

• Vision!

• Cooperation

• Change – often motivated by pain

• Change – how about another model based on vision, excitement, hope and value?

• Change – accompanied by managed RISK– So what! Plan and mitigate.

– There is greater strategic risk in stagnation!

• Play the What If game….

Your Very Next Steps!!!!• Start with this presentation then:

• People – IT and maintenance start a

discussion, build trust and develop a roadmap

for continuous improvement

• Process – Involve end users in the evolution

process, not just managers

Your Very Next Steps!!!!• Technology – First, identify the pain points

where people and processes need to be

addressed. Then develop your very own

technology roadmap and plan for improvements

• Approach – Start small, proof of concepts and

pilots. What works - expand, what doesn’t -

reevaluate

• Good Luck!!!!!

© 2008 Eventure Events. All rights reserved.

George MullerConectiv Energy

george.muller@conectiv.com