Diagnostics Management for maximum Process Reliability · SM-K3/Dipl. Ing. Eberhard Klo tz, MBA...
Transcript of Diagnostics Management for maximum Process Reliability · SM-K3/Dipl. Ing. Eberhard Klo tz, MBA...
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics Management for maximum Process Reliability
Subjects:
1.Basic Definitions2.Management Topics, Objectives3.Technical Solutions today/tomorrow4.Projects with customers
13. November 2007Dipl. Ing. Eberhard Klotz, MBA
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – How are “we” today?Diagnosis (Greek διάγνωση, pronounced di´əg no´sis, …)• investigation in the sense of “differentiation”, “decision”; from δια-, dia-, “by-” and • γνώση, gnósi, in the sense of knowledge, judgement• Health care, medicine …the precise allocation of findings • Differential diagnostics – combined expert knowledge on several symptoms
In the broader sense, diagnostics is the classification of phenomena to a category.
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – Basic Terminology for Technical ApplicationsDiagnostics • Person already ill, machine already down • How quick can we be back to work • Which diagnostic functions in the machine/device can help
e.g. upgrade from module to single channel-oriented diagnostics
Time based Maintenance• Usual since years, restrictions: maintenance work is
executed too early, too late or unnecessarily
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – Basic Terminology for Technical ApplicationsCondition Monitoring (System – CMS) • Persons checked regularily, machine values continuosly• What and where should be measured?• Which conclusion can we make
Preventive and predictive Maintenance• When will the machine / a device / a component be down • How should CMS data be interpreted best • Which process knowledge and experience do we need• How precise and reliable are our forecasts• Where are the critical success factors in the machine / production site
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – Summarising Basic Trends and DevelopmentsDiagnostics within Festo Products&Services: • 1990: Diagnostics in all valve terminals• 2000: Integrated CMS, advanced diagnostics,
Ethernet, broad sensor portfolio• 2001: Intelligent air preparation incl.
flow and pressure sensors• 2002: Compact camera and vision systems • 2003: Web-Monitor, E-Mail/SMS alarm …• 2004: Energy saving products and services• 2005: SCADA software, touch panels FED• 2006: Function integration (pressure sensors)• 2007: Diagnostic controllers & software…..• 20xx: Expert systems for full pneumatic
sub-system diagnostics
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – why is it a Management Topic
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – why is it a Management TopicTypical key data for production costs and
downtime:
Power plant: €90,000 per minuteAMI: 97 seconds amount to
one car (manufacturing costs) Capital goods: €10,000 per minuteMachinery mfg.: €250 to €1000 per minutePaper machinery: €333 per min.,
€20,000 per h.
IT-Production: 5.000 … 10.000 $ / min
IT availability 99,5% 24/7 shift
System down time 43,8 h p.a.
99,9% 8,8 h p.a.Financial risk: 2,6 Million $in case of an IT production
99,99% 260.000 … 520.000 $
+++++++++++++++++++++++++++++++++++Overall system efficiency (GEFF):85% for „traditional maschine“
99% Quality x 95% speed x 90% operation hours
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
24/ 7 shift min p.a. h p.a. Day p.a. IT / Capital goods Machines Power100,00% 525600 8760 365 - € 99,90% 525,6 8,76 0,365 5.256.000 € 525.600 € 47.304.000 € 99,50% 2628 43,8 1,825 26.280.000 € 2.628.000 € 236.520.000 € 90,00% 52560 876 36,5 525.600.000 € 52.560.000 € 4.730.400.000 € 85,00% 78840 1314 54,75 788.400.000 € 78.840.000 € 7.095.600.000 €
16/ 5 shift min p.a. h p.a. Day p.a.100,00% 211200 3520 146,799,90% 211,2 3,52 0,1 2.112.000 € 211.200 € 19.008.000 € 99,50% 1056 17,6 0,7 10.560.000 € 1.056.000 € 95.040.000 € 90,00% 21120 352 15 211.200.000 € 21.120.000 € 1.900.800.000 € 85,00% 31680 528 22 316.800.000 € 31.680.000 € 2.851.200.000 €
8/ 5 shift min p.a. h p.a. Day p.a.100,00% 105600 1760 73,399,90% 105,6 1,76 0,1 1.056.000 € 105.600 € 9.504.000 € 99,50% 528 8,8 0,4 5.280.000 € 528.000 € 47.520.000 € 90,00% 10560 176 7 105.600.000 € 10.560.000 € 950.400.000 € 85,00% 15840 264 11 158.400.000 € 15.840.000 € 1.425.600.000 €
max. Risk of Downtime p.a.
Diagnostics – why is it a Management Topic
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – what Management should considerA machine/system is only as good as its construction (and as the weakest part in the
whole chain) !
Think about:• Reliability • Cycle time• ….• Downtime• Ease of maintenance• Diagnostics / Visualisation• Condition Monitoring• …• Consumption• Direct and indirect costs• …Overall system efficiency
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – a Management Topic between OEM and End User
Life cycle costs (LCC) versus procurement costs
Important arguments for manufacturers as well as with end users:
• How high is the proportionate share of procurement costs in your case, and for how long should the system run?
• If procurement costs amount to XX%, how much of this is attributed to pneumatics? (perhaps 1 to 7%)
• How high are the additional costs for comprehensive diagnostics – e.g. in the pneumatic system?
(less than 10% for Festo flagship CPX/MPA)
1. In an actual case (with/without diagnosis), how greatly does engineering influence overall system efficiency – direct and indirect operating costs?
2. Where does it pay for itself to invest in more diagnostics or condition monitoring?
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – manage a win-win situation for OEM and EUSimplified calculation (example) of LCC
effects:
Procurement (installation):
15%
Pneumatics: 2% è 0.3% of LCC
Additional costs for diagnosis:
10% è 0.33% of LCC**
**based on Festo CPX/MPA
OE M
Please note:35% of downtime can be avoided by CMS !65% can be reduced by better diagnostics !
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – Technical Solutions today/tomorrow
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Needs of enduser / EUReduce machine downtime► Identification of defective
components a.s.a.p.► Data collection and storage► …
Enhance reliability/safety► Diagnosis of crucial drives ► New safety concepts
using diagnostic …
Improve productivity ► Leakage detection► Recording of Energy
consumption data► Preventive maintenance
Benefits from additional machine functionality►New components : easily integrated into machine►Increasing performance of pneumatic
Improve customer service► Remote service by
specialist in pneumatics► Support of local
maintenance teams …► Productivity garantuees
Basis for new business models► Operating, maintenance,
repair of systems, Leasing,► Pay-per-use, …
Needs of machine builder/ OEM
Requirements of EU/OEM and contribution of the pneumatics
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ 14
Requirements out of a typical F&P application?►Example: A manufacturer of packaging
machinery►Striving to increase reliability and quality of
their blister production process through new diagnostic concepts
► 5% of total cost of a machinary** will be accepted by customers!
Air amount for blister process
Monitoring of positioning time of cylinders for the transportation unit
Detailed fault-diagnostics for servo controlled cylinder
2
3
4
1Condition Monitoring of whole pneumatics system i.e. fingerprint of pneumatics by pressure and flow monitoring
** Pneumatics are often less than 7% of machine costs
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Festo Solutions for maximum Diagnostics: Valve Terminal CPX/MPA
CPX/MPA offers max. possible diagnostics and condition monitoring in the market.• Single channel diagn.
(or module oriented) • Analogue values:upper/lower limits
• Pilot valve diagnostics• Pressure sensors int./ext.• Operating voltages
according to 3 tolerances• SMS-/E-Mail Alarm• Web-Monitor • Integr. Controller for
pre-processing of diagn.• ….
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
CPX Web-Monitor as an integrated IT solution
Web-Monitor within CPX/MPA – remote Diagnostics & Services
è START Live-Demoè click
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Festo Diagnostics Solutions bottom-up - and Pricing Example---------------------------------------------------------------------
------CPX/MPA 24IN, 12 M/J-Valves: € 1770,--Module oriented diagnosticsOrder code 1: 50E-F13GFQSERERER-D
Order code 2: 32P-SGL-R-MAABB-8M4J
dto. with single channel-oriented € 1930,--
Price premium: € 160,-- oder 9%---------------------------------------------------------------------
------
High Quality Compact Camera or High Speed Camera:
below € 3000,--
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ 18
Festo - Components for Diagnostics provided now!
► Sensors:Pressure, flow rate, position, optical
► Compact camera “high speed” and “quality”
► Controller:“Embedded“ and “standalone“
► Intelligent components:- Valve terminals - Air supply units - Drives with sensors and controllers
► Software for simulation and engineering
► HMI elements, SCADA systems
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ 19
Festo - System approach for customer specified diagnostic solution tomorrow
Service products (engineering, assem
bly, operation
System diagnostics(fault localisation)• valve or cylinder• Leakage detection
Monitoring(fault notification)► Counting functions, monitoring of cycle times and Basic units: pressure, flow rate, temperature►Energy management►Electrical parameters (voltage, wiring)
Component diagnostics(fault identification)
•Load, friction• int./external leakage• switching error
Integration in standard autom
ation structures(controller, H
MI, SC
ADA system
s)
Realised by a assembling kit for diagnostics• Existing products with
advanced diagnostic features
• New product solutions: Controller and Software for diagnostics
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics – Projects with customers
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Co-operation with Partners - Example
Common project Condition Monitoring of packaging machines
Focus points:
►Analysing faults for downtime, critical process conditions!
►Development of diagnostic methods, defenition for sensors
►Development of an interdisciplinaire system plattform(MECHANICS-ELECTRICS-PNEUMATICS ---)
►Test on different types pf packaging machines
http:\\www. zupack.de
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Packaging machine
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Packaging machine: pneumatic functions with monitored values
Draw down• Cylinder for
pressing of draw down(force + wear of belt)
Knife• Cylinder for cutting
(cutting time, cutting force)
Cooling air• Valve – type
MPA(sum of cooling air)
Vertical sealing• Cylinder for pressing
(positioning times, stroke counter)
Generally:
• Air consumption, energy monitoring
• Monitoring of supply pressure
• Monitoring of valves
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Packaging machine
Siemens - PLC
Additional sensors
Valve terminal MPA with CPX, fieldbus module, controller FEC
HMI, Visualizing(Machine panel or additional FED)
Diagnostic results via Fieldbus
E/A via Fieldbus(End switches-/ control signals)
calculation at the CPX-FEC
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Integration of pneumatics und sensors
CPX-fieldbus-module + controller
MPA-valve terminal
Pressure sensor SDE1force of belt
Pressure sensor SDE1 supply pressure
Flow sensor MS6 supply (total air consumption)
SMAT Sensor wear of belt
Analog/digital input -modules
Pressure and flow sensors for monitoring of cooling air
SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ
Diagnostics Management for maximum Process Reliability
Conclusions• Advanced diagnostic systems reduce downtime (65%)• Condition Monitoring Systems avoid downtime (35%)• Critical success factors in the application have to be well known• End users significantly increase productivity• OEMs can differentiate & reduce service costs • Considering the life cycle costs and the potential risk
of downtime, pay-back on advanced diagnostics is very short, especially in fast running machines of F&P businesses.
Win-Win for OEM and EU possibleThank you for your kind attention
Dipl. Ing. Eberhard Klotz, MBA