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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

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.

Sample MeirSTS Client Experiences

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

http://www.google.ca/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=Q8T4KzJyNKq8NM&tbnid=lGb190NKGc86FM:&ved=0CAUQjRw&url=http://www.kollmorgen.com/en-us/products/machine-controls/&ei=9YNMUom_CIT-9QSD3oCYCA&bvm=bv.53371865,d.eWU&psig=AFQjCNEaXtRLZVB9Oi0eogSdsISYDXMXRg&ust=1380832580360193

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

How effective is my current PM program?

Preventative

Maintenance (Frequency)

Predictive


Condition

Management (Real Time)

Operator Equipment

Wellness – 5S, Visual

management

(Frequency)


Preventative


Predictive


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

PM Program to Risk Analysis

Identify Corrective

Work

Execution

Manpower

Restraints

Reliability

Expectations

Budget

Restraints

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.


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


Condition Based Real Time Monitoring

Coolant Alarm Level 1

Tag 32 (<500f) & Tag 54 (>400psi) & Tag 87(>40cfm & <45cfm) =

Generate Inspect work order


Tag 32 (<510f) & Tag 54 (>450psi) & Tag 87(>35cfm & <39.9cfm) =

Generate Urgent work order


Tag 32 (<520f) & Tag 54 (>5000psi) & Tag 87(<34.9cfm) = Shutdown

machine and generate Emergency work order


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


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

CM /

CbM

PdM



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

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?


Why ?

What component

failed?


Failure Prediction




Equipment Health

Production Drivers


Failures

Patterns Diagnostics

Predictions

Accuracy

CMMS

ERP

Sensors Historian

Marketplace Drivers

CM

PDT Pattern Hub

AssetInsight

Software


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

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.

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

AssetInsight

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

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

Trade Optimization Sample List of Standard AssetInsight Best Practice Reports

Maintenance Manpower – Utilization & Ratio’s

Maintenance Human Resource - Culture trends & Opportunities

Trade Custom Reports

Monitoring

Equipment Health


Failure Prediction




Equipment Health

Production Drivers


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


Contact Information

Paul Sheremeto

President & CEO

1-519-888-1001 x249

[email protected]

Stan Shantz

Principal and Managing Partner

1-519-503-4201

[email protected]

http://www.patterndiscovery.com/products/assetinsight/

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