WAE Generator Data Center (Green belt certificate project)

Mr. Otgontugs U.

Sales engineer,

Power System Division

Agenda

Condition Based Monitoring

Remote monitoring Solution

Six Sigma Approach

Project implementation

Project finance

Conclusion

Pressure to increase productivity

Limited resources

Assets are dispersed and not easily monitored

Experts are not next to equipment

Equipment is more complex

“Proactive analysis process using equipment and application data from multiple sources to make informed maintenance, component replacement, and repair decisions.”

Why Condition Based Monitoring

Perf

orm

ance

Weeks Days Hours

Customer Value Increased Planned Maintenance Lower Labor and Parts Cost Increased Availability

Failure

Machine Alarm

Reactive Extensive Damage

High Cost

Most Downtime

Planned Some Damage

Moderate Cost

Moderate Downtime

Predictive Minimum Damage

Minimum Cost

Planned Downtime

Physical Indicator

Wear material

Operational Change

Prognostic deviation

Condition Monitoring

Equipment Management

Health Monitoring

Asset Management

Why Condition Based Monitoring

How it works

Data logging

and routing

Wired, cell or

satellite transmission

(can be disabled)

CAT secure server

Continuous data

archiving

Customer & Dealer

contacts for emergencies

CAT dealer Condition

Monitoring Specialists

24/7 support

Reports :

- Fleet analysis

- Issues

- Recommended actions

User network

User site

CAT Dealer

Control center CAT Data Centre

Non-CAT

data can be

acquired

0.0

%

0.1

%

0.1

%

0.0

%

0.1

%

74

.2%

25

.5%

0 -

75

0

75

0 -

80

0

80

0 -

85

0

85

0 -

90

0

90

0 -

95

0

95

0 -

10

00

10

00

-1

05

0

Speed

Speed Histogram

1.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.0

%

0.2

%

19

.6%

59

.9%

19

.0%

0.1

%

0 -

50

50

-5

5

55

-6

0

60

-6

5

65

-7

0

70

-7

5

75

-8

0

80

-8

5

85

-9

0

90

-9

5

95

-1

00

10

0 -

10

5

10

5 -

11

0

Percent Rated Torque

Torque Histogram

Reporting

User Benefits

Reduce unscheduled repairs

Increase productivity

Utilize data proactively – Not after failure

Direct maintenance to high value work

Provide visibility of asset performance & health across the enterprise

Condition Based Monitoring Summary

Agenda

Condition Based Monitoring

Remote monitoring Solution

Six Sigma Approach

Project implementation

Project finance

Conclusion

EMCP Monitoring Solution

Netbiter Monitoring Solution

• The Netbiter remote management solution includes communication gateways, secure hosting servers and a web user interface.

Bernini Design Solution

Comparison of Different Solution

Item EMCP / CAT Netbiter Bernini

Cost

Experience

Generator number

Modem

Distance

Server location

Support

Condition Based Monitoring

Remote monitoring Solution

Six Sigma Approach

Project implementation

Project finance

Conclusion

Agenda

What is Our Goal and Strategy

Our Goal: to build Mongolian first and only Diesel Generator Data Center, to provide

Remote Monitoring service for Diesel Generator Owner

Our Strategy: not to lose Our customer to competitor, increase our customers by

Remote Monitoring Service

Turning Remote Control Solution into $$$

DEFINE – set the stage Validate/Identify the remote control business opportunity Establish scope of the project Determine the goals of for this business development MEASURE – collect Information Quantify the remote control opportunity Collect the voice of customer Collect the voice of dealer ANALYZE – determine the areas requiring improvement Define customer critical requirement Understand dealer capabilities Identify the gap in performance and their causes IMPROVE – move forward with a customer focused business strategy Generate new solutions or improve processes to close performance gap Develop Implementation plan CONTROL – sustain the strategic improvement Develop Control plan

A WELL PROVEN 5-STEP APPROACH

Team Selection

No Dept/Div Person responsibility

1 Black Belt Otgon SME

2 PowerSys Otgontugs Project leader

3 Tserenchunt Team member

4 Gantsetseg Team member

5 Janchiv Project Owner

8 Service Sergelenbat SME

9 Khishigbayar Team member

10 IT Bayarmagnai SME

11 Munkh-Orgil SME

12 RUN Batkhishig SME

13 Ariunbold / Andy Project Sponsor

14 Finance ? SME

Support Person from CAT

Agenda

Condition Based Monitoring

Remote monitoring Solution

Six Sigma Approach

Project implementation

Project finance

Conclusion

To do list Date (estimated)

Project kick-off meeting Feb 27 , 2015

Generator Data Center solution May 25, 2015

Introducing to Project Sponsor (RUN) June 15, 2015

Procurement of Hardware & Software July 31, 2015

Installation Generator Data Center Nov 30,2015

Training operator, technician Dec 2015

Pilot test Dec 2015

Official launch of Generator Data Center Jan 2016

Marketing campaign Jan – Mar, 2016

Providing remote monitoring service to End user Jan 2016 -

Project Implementation Schedule

Project team meeting held every Friday

Agenda

Condition Based Monitoring

Remote monitoring Solution

Six Sigma Approach

Project implementation

Project finance

Conclusion

Project Finance

- Cost Analysis - Pugh Matrix - Project Chart

Agenda

Condition Based Monitoring

Remote monitoring Solution

Six Sigma Approach

Project implementation

Project finance

Conclusion

Conclusion

- Project team meet every Friday - Target customer: Diesel generator owner,

specially who bought from WAE - Coverage area: UB - Should have propose cost effective solution. - In pilot stage better use WAE server, it need

to upgrade and add HDD. - Need study Productlink solution from WAT.