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AV-17 Risk and PM Analysis: How effective is my current PM program?
“Big Data” Meets
Equipment Reliability and
Maintenance
Stan Shantz
Principal & Managing Partner
Meir Soft Tissues Solutions (MeirSTS)
@InvensysOpsMgmt / #InvensysSWConf13
/yourbrandsaddress
/InvensysVideos
/your group or brand
social.invensys.com
Slide 3
Meir Soft Tissue Solutions • Core competency in Asset Management cultural change
• Primary focus on:
• Business Processes – Maintenance, Production & Inventory (Lower operating costs)
• Profitable lean manufacturing (Increase production throughput)
• Asset reliability
• Effective proactive maintenance programs (Eliminate unexpected outage & Manage corporate
risk)
• Effective troubleshooting approaches to automated equipment (Find problems earlier &
Shorten outage duration of unexpected outages)
• Effective Inventory management program
• Continuous improvement culture based on respectful communication and trust
• Lower energy costs
• Global trade knowledge and skills shortage
• End user software functionality
• Maximizing software investment
• Partnership agreements with: Engtech Industries Inc., Invensys Inc. Mhyar
International Consulting, Pattern Discovery Technologies Inc.
Slide 5
Monitoring
Equipment Health
Equipment Health
Maintenance Effectiveness
Failures
Failure Prediction
Diagnostics
High Resolution Detection and Troubleshooting
Predictions
Remaining Useful Life (RUL)
Accuracy
CMMS
ERP
Smart
Sensors Historian
Production Drivers
Turnaround Maintenance
Marketplace Drivers
CM
Equipment Health 1
2
4
3 Session
Av-17
Session
Av-24
Session
Av-25
Session
Av-26
PDT Pattern Hub
Patterns
Operational Data (Wonderware)
Human Expertise
Equipment
Human Expertise
Equipment
Slide 6
The Problem:
1. Rising cost associated with
maintaining capital investments.
2. Ineffective proactive maintenance
programs.
3. Increased cost and risk associated
with unexpected failures.
4. How do you extract valuable large
amounts of “Meaningful Unrelated
Data (MUD)” from various
manufacturing unrelated
databases, to continuously lower
maintenance costs, increase
sustainable reliability and, lower the
exposure to corporate risk
The Causes:
A. Expense pressures on
maintenance dept’s
B. Proactive maintenance programs
are rarely monitored for
effectiveness.
C. Aging infrastructure
D. Engineering and maintenance
planning pool stretched thin
E. No connectivity between large
software databases
Concern Maintenance Effectiveness
“1/3 of the cost is waste”… due to “Improper or Unnecessary maintenance” (Topic- maintenance budget) 2009 Study of maintenance practices and results for 217 North American companies - : Improving Cost of Ownership: Integrated Predictive Maintenance Laine Mears, Ph.D., P.E. Clemson University presentation
“Every year, companies in the United States spend over $700 billion on equipment maintenance within plants and facilities, with upwards of 40% wasted on ineffective preventive and predictive maintenance activities.” www.peopleandprocess.com
Slide 7
How effective is my current PM program?
Preventative
Maintenance (Frequency)
Predictive
Maintenance (Frequency)
Condition
Management (Real Time)
Operator Equipment
Wellness – 5S, Visual
management
(Frequency)
Slide 8
How effective is my current PM program?
Preventative
Maintenance (Frequency)
Predictive
Maintenance (Frequency)
Condition
Management (Real Time)
Operator Equipment
Wellness – 5S, Visual
management
(Frequency)
Multiple
Inspect /
Overhaul
PM Job’s
Multiple
PM Job’s
Multiple
Inspections no
work order
Multiple Condition
Management Points
Slide 9
PM Program to Risk Analysis
Identify Corrective
Work
Execution
Manpower
Restraints
Reliability
Expectations
Budget
Restraints
Slide 10
Example: PM Program for Single Entity
Inspection PM Job # 221
Frequency 30 days
Inspect guards condition for
• loose or missing bolts
• damage
Check oil levels to ensure all are with-in acceptable range
• Hydraulic tank # 212
• Auto lubricator # 9823, 9976, 9811, 9845, 9866, 9861
Inspect Entity 445632 drive belt for deflection (1/2” maximum
deflection)
Check all bearing for noise
Replace wear bar on entity 445632
Etc.
Slide 11
Example: PM Program for Single Entity
Predictive PM Job # 33425
Frequency 45 days
Performed by Outside contractor
Vibration Analysis
Inspect VA disc points on the following Entities
• 445632 – disc 44, 45, 46
• 657634 – disc 40, 41, 42, 43
• 876354 – disc 36, 37, 38
• 981566 – disc 33, 34, 35, 39
• 665123 – disc 30, 31, 32
• Etc.
Provide report with-in 2 days, Anything out of the ordinary contact
Jane Doe at 765-765-7764 immediately
Slide 12
Example: PM Program for Single Entity
Condition Based Real Time Monitoring
Coolant Alarm Level 1
Tag 32 (<500f) & Tag 54 (>400psi) & Tag 87(>40cfm & <45cfm) =
Generate Inspect work order
Coolant Alarm Level 2
Tag 32 (<510f) & Tag 54 (>450psi) & Tag 87(>35cfm & <39.9cfm) =
Generate Urgent work order
Coolant Alarm Level 3
Tag 32 (<520f) & Tag 54 (>5000psi) & Tag 87(<34.9cfm) = Shutdown
machine and generate Emergency work order
Slide 13
How effective is my current PM program?
Time
Example: PM Program for single entity
PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221
PM
PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425
PdM
CM /
CbM
Slide 14
How effective is my current PM program?
Time WO # 366889 WO # 367034 WO # 368917
WO # 366787 WO # 368002
WO # 368556
WO # 366291
WO # 369103
Inspect Corrective Emergency
WO # 365714 Emergency
Urgent Urgent
Emergency
Urgent
Emergency
PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221
PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425
PM
CM /
CbM
PdM
Example: PM Program for single entity
Slide 15
How effective is my current PM program?
Time WO # 366889 WO # 367034 WO # 368917
WO # 366787 WO # 368002
WO # 368556
WO # 366291
WO # 369103
Inspect Corrective Emergency
WO # 365714 Emergency
Urgent Urgent
Emergency
Urgent
Emergency
PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221
PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425 PM Job # 33425
PM
CM /
CbM
PdM
What component
failed?
Why callback?
Inventory problem?
Trade problem?
New problem?
Why ?
What component
failed?
What component
failed?
Glad we
caught that
one?
Why was it not
caught in PdM
WO ?
Why did
we miss it
again?
PM Failure
Frequency?
PM Failure
Frequency?
Example: PM Program for single entity
Why ?
What component
failed?
Slide 16
Remaining Useful Life (RUL)
Failure Prediction
Maintenance Effectiveness
High Resolution Detection and Troubleshooting
Operational Data (Wonderware)
Equipment Health
Production Drivers
Turnaround Maintenance
Failures
Patterns Diagnostics
Predictions
Accuracy
CMMS
ERP
Sensors Historian
Marketplace Drivers
CM
PDT Pattern Hub
AssetInsight
Software
Slide 17
AssetInsight Multi-site input – Single output
Site A
Avantis.Pro
Site B
SAP PM Site C
Maximo
Site D
Oracle
1 Extract, Transfer, Load
2 Natural Language Process Free Text Fields & PM Program
3 Star Schema
PDT Pattern Hub
Current PM
Program
Work Order
History
Inventory &
Procurement
History
Information
from EAM
Slide 18
AssetInsight
All Work
Order Free
Text Fields
Each PM
Program 2 Natural Language Process
Free Text Fields & PM Program
3 Star Schema
PDT Pattern Hub
1 Extract, Transfer, Load
NLP tags each work order with
•Component
•Action
•Type of Work
•Etc.
Slide 19
PM Frequency Understand how often
the equipment is failing
and adjust frequency
PM Inventory Understand parts being
used by PM and how often
PM Bottlenecks Understand top 10 worst
entities based on cost,
labour hours and
frequency
PM Opportunities Highlight the amount of effort
being spent on Emergency and
Urgent work on entities covered
by PM
PM Trades Understand quality of
workmanship, knowledge,
skills and tasks
Custom Reports
Data Tables and Star Schema
Pattern Discovery Pattern Hub
Preprocessing
Natural Language Processing
Engine
Verification and
Validation
WO Number
Type
Entity Name
Entity Number
Date
Date Work Complete
SKU#
Part Used
Category
Task
Priority
Trade Name
Trade Category
Inventory Cost
Time Worked
PM activities
PdM activities
PM Job
Etc.
Sample of
Process
Slide 21
PM Optimization Sample List of Standard AssetInsight Best Practice Reports
PM Health Index - Benchmark able Index
PM Financials – Understand True PM costs (Year To Date to Budget, Select time frame, Ratios & Risk)
PM Hours – Understand manpower utilization and efficiency (Year To Date to Budget, Select time frame, Ratios & Risk)
PM Effectiveness – Understand corrective work found to effort
PM Repairable Spares – Understand individual location concerns & Repairable Spare PM Effectiveness
PM Frequency - Understand how often the equipment is failing and adjust PM frequency (improve efficiency)
PM Inventory - Understand parts being used by PM and how often
PM Bottlenecks - Understand top 10 worst entities based on cost, labour hours and frequency
PM Opportunities – Amount of effort being spent on Reactive work that is covered by the PM program
PM Trades - Understand quality of workmanship and training opportunities (match trade skills to equipment needs)
PM Custom Reports
Slide 22
Inventory Optimization Sample List of Standard AssetInsight Best Practice Reports
Inventory Effectiveness
• ABC – Emphases % - Value of Consumption
• VED – Criticality for production
• FSDN – Frequency of use
• HML – Unit value of stock
• XYZ – Emphases $ - closing value of different items
• JIT – Purchase only when demanded
• Repairable Spares – Usage serialized and non-serialized
• Reported Stock-outs – SKU’s (parts) not available when required
• Item Classification Report – Summary by SKU
• Inventory Frequency Report – Frequency of usage by SKU
Inventory Custom Reports
Slide 23
Trade Optimization Sample List of Standard AssetInsight Best Practice Reports
Maintenance Manpower – Utilization & Ratio’s
Maintenance Human Resource - Culture trends & Opportunities
Trade Custom Reports
Slide 24
Monitoring
Equipment Health
Remaining Useful Life (RUL)
Failure Prediction
Maintenance Effectiveness
High Resolution Detection and Troubleshooting
Operational Data (Wonderware)
Equipment Health
Production Drivers
Turnaround Maintenance
Failures
Patterns Diagnostics
Predictions
Accuracy
CMMS
ERP
Sensors Historian
Marketplace Drivers
CM
1
2
4
3
Equipment Health
Session
Av-24
Session
Av-25
Session
Av-26
PDT Pattern Hub PDT Pattern Hub
Slide 25
Contact Information
Paul Sheremeto
President & CEO
1-519-888-1001 x249
Stan Shantz
Principal and Managing Partner
1-519-503-4201
http://www.patterndiscovery.com/products/assetinsight/