strategic asset management for rail - 캐드앤그래픽스 · ibm maximo asset management ... atm...

© 2009 IBM Corporation

IBM Maximo Asset Management

2009.12.10IBM

(HP. 010-4995-4050)

I

II

IBM III

3 © 2009 IBM Corporation3 © 2009 IBM Corporation

Structures Electrical Environmental Lighting Phys Security Transport LandscapingFaci

lity

Network Voice MainframeStorageWirelessApplications Distributed SoftwareDesktop Mobile

I. T.

Roads PipelinesRails

Line

ar

Bridges

BusesShips Trucks Aircraft MilitaryTrains / Rolling Stock

Tran

spor

t

Space Navigation Avionics Engines

PowerTransmission

Cabling WaterDistribution

Waste & Treatment

Meters & Measurement

Util

ities

Tools

Gen

eral

Signalling Keys Support Equip Manufacturing Recreation Safety & Survival Gear Milling

PersonalSecurity

Ret

ail

ATM / POSScales &

Measurement RFIDVaults

& Safes

Microwave & Satellite

Com

m

Fiber Optics Wire Poles

OffshoreTurbines Reactors

Ener

gy

Fire Suppression

Ventilation DrillingBoilers Generators Wind Turbines Solar

Calibrated Equip

Life

Sci

Medical Supplies

Compressed Cylinders

Pharmaceuticals Lab Equipment

Plan Evaluate and Design

Create / Procure Operate Maintain Modify DisposeAsset

Strategy

Lifecycle


� Leadership, Control Improvement .

� TALM: Total asset life cycle management

� BM: Breakdown Maintenance� TBM: Time Based Maintenance� CBM: Condition Based Maintenance� PM: Preventive Maintenance� FLM: First Line Maintenance� MTTR: Mean Time To Repair� MTBF: Mean Time Between Failure� MDT: Maintenance Down Time� RCM: Reliability Centered Maintenance� FMEA: Failure Mode and Effect

Analysis

Control

Leadership

Improvement

1.Strategy

2.Management/Organization

3.Data Management

4.Maintenance Tactic

7.Running KPI

8.AutonomousMaintenance

9.RCM(Reliability centeredmaintenance)

10.Process redesign

�� /

� KPI �Product line

� Hierarchy, , � ,

�BM, TBM, CBM, PM

�MTTR/ MTBF/ M-Cost, MDT� /

6.Planning &Scheduling

� , � Integration

�FLM: � Partnership

�PM, FMEA� , Root cause

� , , , Process,

5.Material Management

�TCO � ,


MRO Purchases Requisition

Authorization

InventoryDrawings &Instructions

PlannedMaintenance

Repair &Maintenance

ProductionPlanning

Work package Scheduling

Usage

Spares Unplanned Maintenance

Resources

Feedback & closure

KPI Analysis

k k

Receiving Supplier

A

BNon-

comparable reports

Calibration

Little system support

Linkage to assets often missing

No prioritizationto revenue stream

Uncertainty of holdings in decentral

stores

Little feedback



�

�Reliability ( )�Proactive Maintenance ( )�Root Cause Management ( )�

�

DCS

PLC’s

SCADA

�

�

�

� MRO

�

�

�

� RCM

� , ,


� 50%BM( )

� 40%PM( )

� 60%

� 5%

� 24% 24

�

100%

&

CAPEX3-7%

8-15%

10-25%

CAPEX

(AssetUtilization)

(reactive spend)

(operations andmaintenance)

CAPEX(extend asset life)

MRO (2-3 turns)

MRO

(<1 turn)

I

II

IBM III


••••( , )

•••

••••••

•••• Activity Based Cost

•

• Best Practice

•

•

• RCM, Risk Management, DCS, SCADA, ERP

� , ,


••• Process •• Process

(Workshop)

• DB

• Code • Data format •

• Manual• Manual•

• Test• Test•• Test

• Customizing• Process

•• KPI

• Data Collect• Data loading PGM

develop• Data loading &

test

• Project Planning• Kick-off meeting

Kick-Off

Process

Data design

Implementation

Data Building

Test/Training Cut-Over


/ / /

I/F


� Planned & unplanned work� Preventive maintenance

� Asset master data� Asset history

� PR, RFQ, PO, Receipt & invoice� Storeroom management

� KPI & Reporting� User authority

� Asset and spare-part� PM, Job plan

� DCS, HMI� Operating management Sys’

� RCM, FMECA methodology� System maintenance

� Maintenance Work Management

� Asset management

� Inventory & procure Management

� System administration

� Data building

� Interface with other system

� Special service


� Who determine the To-Be process?

� Who is the counter partner?

� Where are data sources?

� Scope of link tag What methodology?

� How many times and person?

� Additional charge request document

� Process

� Consulting Service

� Master Data Building

� Interface

� Training

� After Service


In Korea

At site


Detailed tasksRASIC

Consulting Company EPC Owner

Project setupT.F.T training (On-site) R SPerform workshop (On-site) R S

Implementation (in Korea)CMMS configuration RTo-be maintenance practice design R SDesign customizing details R SCustomizing Rinterface program development R SDevelop additional report R

Data Building (in Korea)Create data format and training for collection RData collection C R RData cleansing & validation R S SData loading R

FAT (in Korea)Conduct FAT C S R

Go-Live (On-site)Transformation & customs R SConstruct on site R SUser Acceptance Test C RPrepare and execute user training R Rsystem open R SHelp desk & additional customizing for user request R S


(Maintenance Management)

•

(ERP) ••

• •

.

••••

•

/

• •

Calendar


BOM

•••

••

• BOM • S/P

• ••

• • ( )• BOM ( )

• BOM Data ( , )

• ,

• ••Output

Phase

Input

(Location)(Equipment) (Specification)

(Job Plan)

(BOM)

(Labor)

•P&ID

•• Receiving from Vendor

• • Manual


� ID –

– I/F

� 100% –

�

–Mapping

– ( + )

�

– Document

Cooling system

Pump

2

3 4

1

Site1 Site2

L1

L2

1

System

2

Roll upRoll up

•• ,

P & ID

•• /

( , )

020004000600080001000012000

W14W15W16W17W18W19W20W21W22W23W24W25W26W27W28W29

•••


21 © 2009 IBM Corporation21 © 2009 IBM Corporation 22 © 2009 IBM Corporation22 © 2009 IBM Corporation



PlannedMaintenance

PM(PreventiveMaintenance) TBM(Time Based

Maintenance)

CM (Corrective Maintenance)

PBM(Planned Breakdown Maintenance)

EM(Emergency Maintenance)BM(Breakdown Maintenance)

Trend

PdM(Predictive Maintenance)CBM(Condition Based Maintenance)

MP (Maintenance Prevention)

P-Cost < F-Cost

P-Cost > F-CostFMEA

P-Cost : Preventive CostF-Cost : Failure Cost

NotePM (Preventive Maintenance) : , , , BM (Breakdown Maintenance) : CBM (Condition Based Maintenance) : TBM (Time Based Maintenance) :

�


/

(IRT)

(ESA)

(AE)

*

Failure Mode Equipment

, , , , …

, ,…

, ,

, , , , Crack,…

, , ,

, , , ,….

Stress Crack , ,

Leak, Crack, Partial Discharge, **

** Hydraulic pump, Air/steam/vacuum system, Power distribution , Electrical switchgear and Overhead transmission, Bearing

* Power Quality Analysis, Partial Discharge, Corona Detection, Gas Detection, …..

Technology



ERP

MES/DCS/SCADA

Factory/Plant ERP

DISCONNECT

•• Shutdown •


Interface Area

Maximo Area

Request Approval In progress Report Complete

FailureMalfunctionExceed limit

DCS

Equipment

Floor equipment

Condition monitoring

FT Transaction Manager

FT View SE Server

FT View SE Client


PDC

A

Short-term

PDC

A

Long-term

Planning and Scheduling Cycle

What When Who How WhyWO Where

Planner................ (What to do)Scheduler............ (When to do it)Supervisor........... (Who to do it)Craftsperson........ (How to do it)

Work 25%

Instruction16%

Work Rules5%

Waiting12%

Travel15%

Personal5%

Idle/Breaks10% Pick/Put Tools

12%•••••••

Work46%Instruction

10%

Work Rules

5%

Waiting6%

Travel10%

Personal5%

Idle/Breaks10%

Pick/Put Tools8%


PR/

,(Bar Code)

•• 1 2 43

E-Procurement Consignment

( )

�

–

–� / /

– Cost Center .

�

– ,

– EOQ( ) ROP()

�� PR( )


• ? vs ?• A ? vs B ?

1 2

1 2

�

– , , �

– Cost Center ( / )

�

– ( / / / ) , ,

–


Analyze Design & Build Test Deploy &

Operate

Activity

TFT training1

Admin training2

User training3

Help desk4

Deliverable(s) •User guide •Admin manual•User manual

•Help desk guide

Responsibility Sejoong1 23

4SejoongSejoong

Sejoong

Type How Who

1.TFT training � Manual based training� Scenario based training

� STEC

2.Trainertraining

� Internal training� STEC train trainer who will be internal trainer

� STEC

3.User training � Internal trainer will train user � STEC

4.Help desk � Run help desk for operation in deploy phase for 1 month � STEC


I

II

IBM III


KPIs / /

/ /

& &

PM

/

• IBM Best Practice 1.


(TBM)

(TBM, CBM, BM, CM )••

(CBM)


Multi Site & PM

1( ) 2( )

Site1

( ) ($)

,

, ,

, Company

Site2 Site3 Site1 Site2 Site3

(TBM) (UBM) (CBM) ( )

TBM UBM+ CBM+

KPI

KPI

Level 1

Level 2

250 x 100mm60KVA220V

[ ] [ ]

Item # TIRE100: 4: 0

4Asset # TRUCK10

4Item # TIRE100

: 4: 4

Item # TIRE100: 8: 0

CAPACITOR100RESISTOR2112BRACKETBOLT125

KIT

[ Kit]

TRUCK

Kit

• • •TBM, CBM, UBM

• • • (, Kit )


PipelinesRoads

Rails

•

•••

•

•••

/ /

BOM ( )

••••

( )

• / • •

• • •


� J2EE Component Architecture

, IT

Incident Mgmt

SLA Mgmt

Change Mgmt Asset Mgmt

Knowledge Mgmt

Procurement

Work Mgmt

Contract Mgmt

Maximo

IBM Maximo for Chemicals & Petroleum

Maximo Base

Services

Customer Configuration

Equipment Reliability

Asset Specifications

Condition For Work

Regulatory Compliance

Incident Management

Calibrations

Management of Change

Defect Elimination

Action Tracking

Investigations

Improvements

Benefits and Losses

S-LCD SDI

1

• 100% • MES, ERP • IT , IT

• • 11 1 •


Airports� 100 customers globally� 5 of top 10 busiest� BAA, DIA, Swissport, Schiphol, Las Vegas

Hospitality� 100 top hotels, Casino’s, Amusements Parks� Starwood, MGM, Mohigan Sun Casino, Disneyworld

Freight/Logistics� 70 customers� JB Hunt, Fedex, Coca-Cola Enterprises, Frito Lay, DHL, Albertsons,

Rail & Transit� 100 customers globally� Amtrak, Tube Lines, Washington Metro, Long Island Rail Road, BAM Rail

Aviation� 40 customers globally� 17 maintaining aircraft� Northwest (Compass), Aires, Shanghai, Boeing

Marine, Ports & Terminals� 75 customers globally� 26 maintaining vessels� BC Ferry, Hutchinson Ports, Port of Seattle

Transportation & Travel / Energy, Utilities & Natural Resources

Nuclear� 32 units globally� >25% Market share in N-A� Southern, TXU, Daya Bay, Fortum, DTE

Mining/Metals/Minerals� 30 customers globally� world’s largest steel producer� Peabody,Hyundai Steel,Alcoa

Oil & Gas, Chemicals� 200 customers globally� 8 of top 10 Fortune 500� BP, Flint Hills, Chevron, ADNOC, El Paso

Water / Wastewater�125 customers globally�11 of 30 largest cities� MWRA, MWD, Honolulu, Corpus Christi, LADPW, Thames

Transmission & Dist.� 80 customers globally� Focused Development Team� APS, Keyspan, NiSource, ESKOM, ConEd

Fossil/Hydro Powergen�160 customers globally�17 of 30 Fortune 1000�Duke, Xcel, NYPA, LCRA, Texas Genco


Aerospace & Defence� 50 customers globally� 7 of 9 largest companies� Boeing, EADS, BAE systems, Lockheed Martin

Retail� 40 customers globally� 5 of 10 top companies� Albertson, Target, Sears, Sainsbury, Darty, GAP

Life Sciences� 150 customers globally� 14 of top 15 companies � Abbott, Alcon, Amgen, BMS, Sanofi-Aventis

Food & Beverage� 75 customers globally� 5 of top 10 companies � Cargill, Nestle, Sara Lee, Coca Cola, Gen’l Mills

Electronics & Industrial� 85 customers globally� 6 of 9 largest companies� Samsung, Philips, Motorola, Intel, TI, Tyco

Automotive� 80 customers: OEM / Tier1 � 7 of top 10 companies� GM, Ford, Toyota, VW-AUDI, Hyundai-Kia

Manufacturing & Distribution / Government & Public Sector

Federal (Civil)� 56 customers� Department of the Treasury, NASA, GSA, Veterans Affairs

Healthcare� 92 customers globally� Mass General Hospital, Barnsley District Hospital, Baptist Hospital - Louisville

Education� 127 customers globally� Cornell University, Johns Hopkins University, Detroit Public Schools, Perdue Univ.

Government (non-US)� 48 customers globally� Dutch Army, Royal Saudi Air Force, Royal Canadian Mint, Israeli Army

State / local� 125 customers� AK Dept. of Admin., State of CA, GA Dept. of Admin. Svcs., Maryland DOT, LA County DPW

Federal (Defense)� 84 customers� US Air Force, US Army, US Marine Corps, US Navy


Banking & Securities� 50 banking customers� 15 securities customers� State Street, Freddie Mac, AMEX, Merrill Lynch, HSBC

Service Providers (ITSM)� 15 customers globally� Managed Svcs, Outsourcing� CSC, Getronics, Accenture,� HP

Service Providers (EAM)� 110 customers globally� Facilities & Industrial� Honeywell, ABB, Johnson Controls, UNICCO

Media & Cable� 17 customers globally� Mainly facilities asset class� BBC, Turner Broadcasting, Universal Studios

Telecommunications� 20 customers globally� Success w/Mobile Providers� T-Mobile, Vodafone, Proximus, Qualcomm

Insurance� 10 customers globally� Early ITSM story - Amerus� Allstate, Mutual of Omaha, AmerUs, Banque de France

Financial Services / Telecom / Service Prov.


A Maximo portfolio to meet the needs of Chemicals & Petroleum clients

Exploration /Production

Shipping Crude / NGPipelines

Storage Refining /Petrochem

ProductPipelines

Trucking ServiceStations

Maximo for Chemicals & Petroleum

Solutions

Maximo for Transportation Maximo for Transportation

Linear AssetManager

Linear AssetManager

Maximo Asset Management and Tivoli Asset Management for IT

Maximo Spatial

Maximo Mobile


Service Provider

Customer

Internal Resources External Resources

AssetAssetAssetAsset

Assign

Buy From (Pay)

Owns

Assign / Schedule

Customer Agreement

Customer

AssetAssetAssetAsset

Owns Multi-Customer

Customer 1 LocationsCustomer 2 Locations

Org A Org B

Site B1Site A1

Site A2

Site A3

Site B2



FacilitiesManager

• Assets• Surveys • Work• Help Desk• Operations• Space• Occupancy

EstatesManager

• Portfolio List• Acquisitions• Disposals• Real Estate (Freeholds)• Leases• Valuations• GIS

EnvironmentalManager

• Environmental Impacts• Energy Impacts• Utilities• Waste• Carbon• Health & Safety

Data Books”Global

Areas

Regions

Countries

Geos’

PropertyLevel Roles”

LandBuildings

Properties• Property Estates Manager• Property Facilities Manager

• Property Space Manager• Property Environmental Manager

• Property Utilities Manager• Property Waste Manager

Roles• Area Estates Manager• Area Facilities Manager• Area Environmental Manager



Summary

�– Only vendor that can manage all asset classes on a single, unified architecture, to

support production, facility, fleet, linear and IT assets

�– Deep industry knowledge across a broad spectrum of asset intensive businesses –

Government, Transportation, Utilities, Life Sciences, etc.

�– Built-in configuration tools allow for easy, on the fly changes to UI, workflows,

processes, reports. Configurations readily upgrade from one version to the next.

� Standards-based technology– Web-architected platform built on J2EE with advanced business process

management; based on SOA, web services and XML.

� Total Cost of Ownership– Validated benefits for customers in all industry segments, reducing operational costs

through productivity increases, cost avoidance and system consolidation


Q & A

???

Maximo : (HP 010-4995-4050)Maximo : (HP 010-4995-4238)

strategic asset management for rail - 캐드앤그래픽스 · ibm maximo asset management ... atm...

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