T80 - Asset Intelligence - Rockwell Automation · PDF fileAssessment Critical Spares/ Support...
Transcript of T80 - Asset Intelligence - Rockwell Automation · PDF fileAssessment Critical Spares/ Support...
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T80 - Asset IntelligenceTransforming the value of Maintenance and Storeroom
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Why Are We Here…
What’s your healthy and balanced approach for success?
Leveraging asset intelligence, you too can improve plant productivity;
by using smart devices, reliability professionals and asset strategies!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Manufacturing Operational Challenges
• Pressure on efficiency and reliability
• Shrinking expertise in workforce
• Aging assets
• New assets increasing in complexity
• Increasing regulatory pressures
Manufacturers spend 40% of their time on reactive
maintenance vs. their 12% ideal (Maintenance Technology)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Asset Management Transformation Need
Industry Drivers Business Values
Improved Asset UtilizationAsset and Plant Optimization
Best-in-Class are performing with 3.5% unscheduled asset downtime
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Asset Management Foundation
Integration of Lifecycle and Reliability data
Execute evolving Proactive Asset strategies
Advanced Analytics and Intelligence
Asset Optimization
Maintenance Strategy
Storeroom Processes
Warranty Tracking
Asset Change Mgmt.
Reliability- Risk/ Criticality
Asset Diagnostics
Obsolescence Mgmt.Good Baseline Data Managed Programs
Cross functional teams
Dynamic Data Platform Best in Class results!
Journey toward Asset and Plant Optimization
Operational Excellence
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Asset Management & Reliability Services
6
Understanding the
Asset Baselines
Operational
Continuous
Improvement
Diagnostic Reliability
Data Intelligence
Reliability
Professional and
Program Mgmt. Asset Tracking and
Repair Management
Storeroom
Management/
Operations
Stores and
Plant Floor
Assessment
Critical Spares/
Support Analysis
Equipment
Reliability
Analysis
KPI / Metric
Driven
Performance
Greater Plant Productivity = Asset Performance + Reducing Risks
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Busin
ess V
alu
es
Industr
y D
rivers
Faster Time to Market
Lower Total Cost of Ownership
Improved Asset Utilization
Enterprise Risk Management
People and Asset Safety
Speed andInnovation
Asset and Plant Optimization
The SkillsGap Challenge
IT/OTConvergence
Services & Support Mission
7
Maximize Productivity,
Minimize Risks
In a Sustainable Environment.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Asset Management & Reliability Services
8
Understanding the
Asset Baselines
Operational
Continuous
Improvement
Diagnostic Reliability
Data Intelligence
Reliability
Professional and
Program Mgmt. Asset Tracking and
Repair Management
Storeroom
Management/
Operations
Stores and
Plant Floor
Assessment
Critical Spares/
Support Analysis
Equipment
Reliability
Analysis
KPI / Metric
Driven
Performance
Greater Plant Productivity = Asset Performance + Reducing Risks
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Specific Services and Programs
Reliability & Maintenance
ServicesDiagnostic Reliability
Service
Reliability Consulting & Engineering
Services meet our end-user
customer demand for Asset Uptime
improvements.
• Assessments,
• Reliability solutions,
• Embedded reliability engineers
and program management.
Diagnostic Reliability ‘DR’ Service
provides our clients an improved
risk mitigation and control system
compliance on their most critical
production assets.
• Asset Knowledge
• Risk Reduction
• Asset Performance
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Reliability Consulting & Engineering Service
Reliability Consulting & Engineering Services
meet our end-user customer demand for
Asset Uptime improvements
Mitigating production risks with proactive maintenance
Reducing MRO expenses, updated equipment strategies
Improvement of productivity KPIs (OEE, MTTR, MTBF)
Fostering a culture of continuous improvement
Reliability services available: Assessments: Equipment Reliability,
Maintenance Program
Reliability Solutions, Improvement Projects
Embedded Reliability Engineers, Program
Management.
Common delivery outcomes include:
Strategic roadmap with improvement priorities,
ROI justification and best practices
Solving chronic / acute problems on critical
equipment with optimal maintenance plans
Lead TPM / RCM program and projects
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Reliability Assessment Maintenance - Detailed Checklist 3.2
Reliability Topic Component Score
System Type 5
Data Storage 4
Preventive Maintenance 5
Corrective Maintenance 3
Alerts 2
Metrics 2
MRO 3
Management 4
Maintenance Personnel 3
Operators 1
Coverage 5
Adequacy 4
Execution 4
Review / Maintenance 3
Coverage 5
Training (General) 3
Training (TPM) 1
System 1
Personnel 2
Execution 3
Standards 4
Condition 2
TPM Events, Blitzes Frequency 3 3.0Self-Auditing Process 2 2.0Capital Planning Process 4 4.0
Policies 4
Equipment 5
Maintenance Resources 3.0
Safety 4.5
Equipment Assessment 3.0
Autonomous Maintenance 2.0
Level 1
Impaired
Maintenance Procedures
2.7
4.0
Maintenance Management
System
Culture
3.4
Level 2
Poor
Level 3
Adequate
Level 4
Advanced
Level 5
Expert
Reliability & Maintenance Assessments
Equipment Reliability Assessment
Selected group of equipment (8-10 machines),
Performing reliability analysis, risk profiling,
Failure mitigation strategies, defining areas of
improvement and
Roadmap development with ROI and project plans
Maintenance Program
Assess maintenance program effectiveness, vision,
Performing equipment strategies (CM, PM, PdM),
CMMS utilization analysis, MRO functions/ costs, and
Roadmap development with ROI and project plans
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Reliability Solutions Improvement Projects
Our domain experts use equipment knowledge, proven processes and user requirements
leveraging appropriate reliability techniques* to drive an outcome with sustainable results.
*Common reliability techniques used: criticality analysis, Failure Modes Effect Analysis (FMEA), root cause analysis, Five Whys, spare parts analysis, fault tree analysis, fault code development, training needs analysis,
condition based monitoring, maintenance process gap analysis, maintenance strategy development, work order improvements, standard operating procedures/ process mapping, corrective actions plans, MAAR (monitor,
analyze, act and review) chart development, CMMS utilization analysis, CMMS Data Cleansing, program management and Reliability-Centered Maintenance (RCM)/ Total Productive Maintenance (TPM) program training.
Mitigate equipment risks across
production lines, machines and
control systems.
Build execution plans for modern
maintenance strategies and help
with corrective action plans.
Develop process visuals for data
driven KPIs, MAAR charts and
lead reliability trailered training
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Reliability Resource based Contract
Our Service Experts are available to augment your team’s effectiveness through a dedicated
resource contract; applying the right skillset, experience, process training and support tools,
to help ensure sustainable program results.
Dedicated Reliability Engineer, Program
Manager for a term: 6, 9 or 12 months w/
rolling project list driving results:
Mitigating production risks with proactive
maintenance
Reducing MRO expenses, updated
equipment strategies
Improvement of productivity KPIs (OEE,
MTTR, MTBF)
Fostering a culture of continuous
improvement
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 14
RE
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S Risk / Criticality Analysis – 43 Systems
• Prioritized Resource Utilization
• Mitigated Risk / Unplanned Downtime
• Identification of Reactive, Preventative, Predictive Maintenance Strategies
Failure Mode Effects Analysis (FMEA) – 59 Systems
• Preventative Maintenance Plans – Strategy, Tactics, Frequencies, Spares
High volume manufacturing with high downtime costs
Regulatory concerns for lost production Combination of new and old equipment Undefined and unmitigated equipment risks Limited engineering and maintenance resources;
minimal reliability expertise Compliance and Validation requirements
CHALLENGES SOLUTION
Develop PM Strategies for Automation Devices
• Failure Mode Effects Analysis (FMEA)
• Develop risk mitigation strategy and appropriate preventative
maintenance strategy
Prioritize Activities via Risk / Criticality Analysis
• Quantify risk – safety, environmental, and production
• Production downtime and maintenance labor costs are also
assigned to produce a consequence value ($)
Life Sciences – Medicine ProducerReal Results: Risk & FMEA Solution
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Diagnostic Reliability Service
Diagnostic Reliability Service is a
strategic Asset Management Solution
providing asset intelligence-based
outcomes, to optimize the total lifecycle
value of your electrical control platforms!
The core service-based outcomes are: Evergreen spare parts and support plans
Mitigating control equipment reliability risks
Driving proactive maintenance strategies
This packaged service provides:
Automated central asset intelligence system
Reliability program improvement specialists
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Common User Scenarios
Asks from engineering/maintenance team:
Locate/ Identify status of troubled devices
Obtain proactive notice of device change/ history
Track device service cycle/ utilization
Identify/ manage device and system firmware
Determine product safety/ service advisories impact
Mitigate high-risk equipment risks/ failures
Perform a critical/ spare parts gap analysis
Verify migration plans to reduce legacy obsolescence
Asks from leadership team:
Improve asset uptime/ utilization/ assurances on critical infrastructure (i.e. controls platform) through proactive maintenance, continually mitigating risks and acting on performance/ reliability opportunities
Develop a data-driven solution for managing control assets over their lifecycle, enabling us to optimize capex/ Opex budget allocations with business units and plants
Diagnostic Reliability Service streamlines manual activities previously performed in isolation, packaging it to drive Asset Intelligence!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Diagnostic Reliability Service
Automated Central Asset Intelligence System
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Diagnostic Reliability Service
They are well trained on Rockwell Automation products,
processes and commonly used applications, as well as
products from other manufacturers, enabling them to provide
comprehensive support strategies
Our engineers and program managers
provide a critical role in the Diagnostic
Reliability Service, through proven
processes and resource tasks!
Reliability program improvement specialists
Our domain experts have
diverse industry and
applications backgrounds,
and are certified by the
Society for Maintenance
and Reliability
Professionals
Annual reliability strategy workshop
Quarterly reliability improvement
project working sessions
DR Service startup/ commissioning
Expertise availability to further
augment your team towards your
asset and plant optimization goals
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Diagnostic Reliability Service
The packaged service combines the right people,
processes and technology to maximize the total
lifecycle value of your electrical control platforms!
Connected Information Asset baseline review and solution feasibility
DRS system startup and commissioning
System infrastructure and support as a service
Monitoring & Improving Three year strategy roadmap with smart milestones
Configuration of analytical triggers/ event rules
Specialist working sessions; executing strategies
Sustaining & Optimizing Annual workshop prioritizing improvement projects
Reliability specialists leading optimization initiatives
Delivering a packaged service solution
Analyze Act ValidateIdentify
Power Devices
Control Systems Maint./ Prod.
Systems
Connected Information
Monitoring & Improving
Sustaining & Optimizing
Device changes
Faults, Limits
Failure rate/ modes Firmware Compl.
PSA impact Health
Evergreen
spare parts
and support
plans
Mitigate
control
equipment
reliability
risks
Drive
proactive
maintenance
strategies
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Diagnostic Reliability Service implemented on 6 site locations
(~500 devices per site)• Online monitoring and auditing
• Ongoing equipment health trending within dashboards
• Proactive maintenance activities that are driven by analysis
• Asset Management improvement plan roadmap to drive operational and
maintenance efficienciesRESULTS
• Accurate management of control assets• Accuracy and completeness of control asset records
• Spares inventory correctly supports installed base
• Sustainability of enterprise system data records
• Verify asset lifecycle management
• Multiple sites within a region with many layers of
devices and systems
• Regulatory and Compliance requirements
CHALLENGES SOLUTION
Large Producer and Refiner of OilReal Results: Diagnostic Reliability Service
• Implement Rockwell Automation® Diagnostic
Reliability Service
• Including network assessment
• System implementation to IT requirements
• User training with specific dashboard design
• Ongoing service contract
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
DR Service – Benefits Summary
Benefits and Value Justification…
Reduce Inventory/ Device data collection time
and accuracy
Optimize controls critical spare parts inventory
Unscheduled downtime prevention with early
alerts/ notification
Shrink MTTR on Equipment using Asset
Information system
Reduction of engineering time due to
emergency downtime burden
Reduction in failure costs on legacy parts
through hyper-care & proactive replacement
As our clients are working toward executing their Total
Productive Maintenance, Reliability Centered Maintenance
and/ or Operational Excellence Initiatives, the DR Service is
ready to be an integrated into your program framework.
Uptime, Productivity
Mfg. Risk, MRO Costs
Proactive Maintenance using Asset Intelligence provided by DRS to Minimize Risk and drive greater Productivity!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Why Are We Here…
Accelerating High Performance Operations by Empowering people to make smarter, more informed decisions
Leveraging Asset Intelligence you too can improve plant productivity; utilizing smart devices,
reliability professionals and asset strategies!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC
PUBLIC - 5058-CO900H
www.rockwellautomation.com
T80 Wrap Up