gary peacock global solution marketing manager, asset ... · global solution marketing manager,...
TRANSCRIPT
Sustain.Ability.
2012 Honeywell Users Group EMEA
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Gary Peacock
Global Solution Marketing Manager, Asset Management
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Agenda
1. Industry drivers
2. Time for a paradigm shift
3. Asset Management
4. RAMP solution
5. Product overview:
• Asset Manager & Field Advisor
6. Next steps
3
Industry Concerns and Drivers
Common Asset Management concerns heard within Industry
Aging assets and infrastructure
Shrinking pool of experienced people
Robustness of Reliability System
Data and information overload
Market volatility and competition
4
The Data and information Problem
Reliability Maintenance Operations
EAM/CMMS (SAP, Maximo,
etc.)
Process Data (DCS, Historian,
etc.)
Control Loop Performance Monitoring Visual
Inspections
Smart Instruments (HART, FF, etc.)
Corrosion Monitoring
Condition Monitoring
Users try to determine asset status from disparate data sources
no common understanding of true status
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Sensor
Fu
sio
n f
rom
Wik
ipedia
art
icle
Data and information: Sensor Fusion
“…combining data derived from disparate
sources so that the resulting information is better
than when these sources are used individually.”
DATA
INFORMATION
KNOWLEDGE
WISDOM
SENSE MAKING
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Robustness of Reliability System
100% Maximum “relevant” utilization
One calendar year
Visualization of OEE and TEEP
TEEP
Not
scheduled to
run
Excess
capacity
Net % of Max Potential Rate (MPR) (@ best consecutive period production rate)
Rate
Loss
Lack
of
sales
de-
rate
Net % UPTIME Unplanned
Downtime
Lack
of
Sales
Down-
time
Planned
Down-
time
Net % of First Time Prime Quality Recycle or
Scrap
all TEEP Gaps are
considered, including
Scheduled Outages
OEE = 100% Maximum Scheduled utilization
TEEP = 100% Maximum Potential utilization
Total Effective Equipment Productivity
Overall Equipment Effectiveness
OEE
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Overall Equipment
Effectiveness (OEE) Best-in-Class Middle 50% Bottom
Asset Management with
Predictive Failure Analysis 28% 17% 6%
Standardized KPIs
across enterprise 53% 40% 18%
Asset Downtime 3% 13% 34%
Plant Floor Automation 61% 45% 23%
Integrated EAM/CMMS 79% 56% 48%
Benchmarking
Table sources: 2010 Solarsoft Manufacturing Benchmark Study and Aberdeen Group, Enterprise Asset Management
Join STAN GRABILL for OEE Seminar on FRIDAY morning
OEE: Industrial Processes 90% 56% 42%
OEE: Food & Beverage 78% 62% 42%
OEE: Pharmaceuticals 45% 31% 23%
OEE = 100% Maximum
Scheduled utilization
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To
Proactive / Predictive
Real time data
Reliability Centric
Online & Automated
Integrated RCM, CBM &
CMMS Solution
Proactive & Predictive
Asset Management with Predictive Failure Analysis
Real-Time Decision Making: A new paradigm
From
Reactive / Run-to-failure
Historical data
Inspection Centric
Paper Operator Rounds
CBM as a Point Solution
Fire fighting
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Enterprise Asset Management Work-stream & Relationships
Think of Asset Management as 3 Distinct Areas
Many Data Sources
•Condition Based Maintenance
(CBM)
•Real-Time & Off-Line Data
•Field Inspection and rounds
•Wired & Wireless
•Reliability Centric Maintenance
(RCM)
•Enterprise Asset Management
(EAM)
•Computerised Maintenance
Management Systems (CMMS)
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Enterprise Asset Management Work-stream & Relationships
Maintenance Management: EAM and CMMS
Maintenance Management
•Work Execution Management
•Work Order Generation
•Document Management
•Financial Management
•Purchasing Management
• Inventory/MRO Management
•Planning & Scheduling
• Integration with EAM and CMMS
such as SAP and IBM Maximo
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Alliance Partner (GP Allied)
•≈ 400 Consultants Globally
•Excellent Industry Reputation
•Experience in all Industrial sectors
• iReliability Suite of tools
Reliability Programs & Strategies
•RCM / RCA
•Asset Health Matrix
•Equipment Maintenance Plan
•KPI/Benchmarking
•Change Management
•Training (including craft skills)
Enterprise Asset Management Work-stream & Relationships
Reliability: GP Allied
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Enterprise Asset Management Work-stream & Relationships
Condition Based Monitoring
Real-Time
Condition Monitoring
•Real-Time Corrosion monitoring
•DCS & Historian
•Simulation (UniSim)
•Real-time Vibration Monitoring
•Smart Instruments (FDM)
•Operator Rounds (Field Advisor)
•Oil Analysis
•Other Condition Monitoring
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CMMS / ERP
Integration
Corrosion Monitoring
Smart Instruments
Visual Inspections
DCS & Historian
Process and Alarm Data
Downtime Reporting
Control Loop Monitoring
Equipment Condition
Monitoring
Asset Performance & Health Assessment
Rotating
Machinery
Monitoring
Management
Reporting & KPI’s
Maintenance &
Reliability Users
Integrating Real-time Asset Management
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Single view of Asset Performance and Health
Data Management Applications
Very Clear & Easy to Understand
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Asset Manager
info used in
Reliability programs
Asset Manager
Notifications sent to EAM/CMMS
Reliable Asset Management Performance
RAMP
DATA SOURCES
• Condition Monitoring
• DCS & Historian
• Smart Instruments
• Operator Rounds
• Corrosion Data
• Simulation (UniSim)
• Oil Analysis
• Vibration Monitoring
OUTPUTS
• Alerts & Notifications
• Management
Reporting & KPI’s
• Maintenance &
Reliability
Scorecards
• Downtime Reporting
• Health Assessment
• Automatic Work
Order Generation
Honeywell
Asset Manager
EAM/CMMS
• Work Execution Mgmt
• Maintenance Mgmt
• Workflow
• Document Mgmt
• Financial Mgmt
• Purchasing Mgmt
• Inventory/MRO Mgmt
• Scheduling
Programs & Strategies • RCM/RCA
• Asset Health Matrix
• Equipment Maintenance Plan
• KPI/Benchmarking
• Change Management
• Training
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Asset Manager offers a single view of performance and health
Integrating Real-time Asset Management
Equipment
Condition
Monitoring
Downtime
Reporting
Visual
Inspections
Corrosion
Monitoring
Smart
Instruments
DCS &
Historian
Asset
Manager
Downtime
Reporter
Corrosion
Field
Advisor
Vibration
Products
Smart
Instruments
UniSim
Wireless Asset Health
Management
Process
Reliability
KPI /
Benchmarking
Trending
RCM
Rotating
Machinery
Monitoring
RCM
Partners
and tools
Integration
with CMMS Integration
with EAM
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Asset Manager
Real-Time Condition Based
Maintenance (CBM)
Reliability Centred
Maintenance (RCM)
Total Effective Equipment
Productivity (TEEP)
Overall Equipment
Effectiveness (OEE)
Computerized Maintenance
Management Sys. (CMMS)
Enterprise Asset
Management (EAM)
Real-Time Data Acquisition
STRATEGIC
TACTICAL
BENCHMARKING
TECHNOLOGY
INFRASTRUCTURE
Abnormal Situation
Management (ASM)
Operator Driven Reliability
(ODR)
Asset Health Monitoring
(AHM)
Risk Based Inspection
(RBI)
Reliability Centred Design
(RCD)
Work Execution Management
(WEM)
Reliability & Maintenance
Engineering (RME)
Operational Performance
Monitoring (OPM)
Scalable Solutions integrated through Asset Manager
Applying RAMP
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Abnormal Situation
Management (ASM)
Operator Driven Reliability
(ODR)
Asset Health Monitoring
(AHM)
Risk Based Inspection
(RBI)
Reliability Centred Design
(RCD)
Work Execution Management
(WEM)
Reliability & Maintenance
Engineering (RME)
Operational Performance
Monitoring (OPM)
Scalable Solutions integrated through Asset Manager
Applying RAMP: Tactical AHM
“accurate view of asset health”
•Field Advisor
•SKF Vibration
•Corrosion Monitoring
•Field Device Manager
•OneWireless
•Mobile Equipment Monitoring
…………..
STRATEGIC
TACTICAL
BENCHMARKING
TECHNOLOGY
INFRASTRUCTURE
Real-Time Condition Based
Maintenance (CBM)
Reliability Centred
Maintenance (RCM)
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Abnormal Situation
Management (ASM)
Operator Driven Reliability
(ODR)
Asset Health Monitoring
(AHM)
Risk Based Inspection
(RBI)
Reliability Centred Design
(RCD)
Work Execution Management
(WEM)
Reliability & Maintenance
Engineering (RME)
Operational Performance
Monitoring (OPM)
Scalable Solutions integrated through Asset Manager
Applying RAMP: Tactical OPM
“one view of the truth”
•UniSim Design
•Downtime Reporter
•Corrosion Monitoring
•Well Performance
Monitoring
•OMPro
•………….
STRATEGIC
TACTICAL
BENCHMARKING
TECHNOLOGY
INFRASTRUCTURE
Real-Time Condition Based
Maintenance (CBM)
Reliability Centred
Maintenance (RCM)
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1. Relentless integration of all aspects of people,
processes, and technology
2. Applied across the entire asset life cycle:-
Capital Delivery (CapX)
Operations (OpX)
Maintenance (MaintX)
3. Includes the management of all assets
mechanical, electrical, stationary, process automation and
control assets
4. Modular and scalable
5. Change Management is woven into the deployment
RAMP Underlying Principles
Integration of People, Processes and Technology
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Asset Manager R410
• Built on the Intuition Platform
• Single Location for Asset Management
– Wired & Wireless Vibration Monitoring
– Real-time Corrosion management
– Control System & Instrumentation Monitoring
– Inputs from OPC, PHD, any Experion site, ………..
• Integration with Honeywell and 3rd Party Products & Solutions
– Aptitude Analyst & DMx (SKF Corp)
– iReliability Suite; including a fault model library (GP Applied)
See these in the
demo room!!
Integrate information
•Multiple sources
•Future proof
Fault Models
•Based on integrated information
Alerts
•Based on the fault model execution
Alert-based Automatic Actions
•Operator notifications
•E-mail notification
Problem Solving
•Collaboration between teams
•Historical information
•Link to relevant documentation
Another bridge between Operations and Maintenance
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Field Advisor R200 and R201 (2012 releases)
• Technology Refresh
– Honeywell Intuition framework and modernized handheld user interface
– Microsoft SQL Server Standard edition
• Updated configuration tools with graphical configuration
• New rounds scheduling, tracking and reporting calendar
• Efficient Installation/Migration and Integrated Security
• Automatically trigger and track operator tasks
Select Work
Execute Tasks
• Enter comments
Review Consequences
• When limits are exceeded
Review History
Corrective Actions
• Execute reconditioning tasks
Upload Work
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Tremendous Benefits Received
–Reduce incidents by up to 40%
–Increase operator competency
–Support continuous improvement
Improve Safety
– Reduce off-spec material up to 50%
–Reduce transition material up to 30%
–Catalyst consumption down by 1%
–Improve throughput 2-8%
–Reduce energy use 5-10%
–Improve forecast accuracy 4-20%
–Reduce inventory 15-30 %
Improve Efficiency
–Improve plant availability 3-8%
–Preserve and extend asset life
–Reduce maintenance costs 3-5%
–Improve customer service 5-15%
Improve Reliability
– Green house gas emissions
reduced by 25%
–Ensure compliance standards
–Reduced total cost of ownership
–Reduce energy consumption
Improve Sustainability
Typical Return on Investments are 3 Months to 1 Year
>$5B US in measurable benefits has been
added to our customers’ bottom-line
*Results based on past customer experience
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Recommended Next Steps (At HUG)
• Visit the demo room – Honeywell
• Asset Management and RAMP
• Asset Manager R410
• Field Advisor
• Corrosion
– SKF
• Vibration
– GPAllied
• iReliability
• RCM
• Attend the OEE Seminar – Friday 16th November, 09:00 – 12:00
– Presenter: Stan Grabill
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Recommended Next Steps (When you get back)
• Ask for an assessment at your site
• Start small if needed – Solutions are scalable
• Be a champion for your company
• Must get operations and management involved
• Do something…