Digital Transformation: Asset Performance Management€¦ · Reduce unplanned downtime 3. Reduce maintenance costs • Improved asset uptime & availability: 20-30% • Improve labor
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The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company.
The Schneider Electric and Life Is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.
Digital Transformation: Asset Performance
Management
Confidential Property of AVEVA Group plc.
Luca Bruni, Sr. Technical Sales Consultant
APM Solutions EURSA
InteroperabilityVisualization
Asset Model AnalyticsOperations and
Optimization
Planning and
Scheduling
Monitoring and
ControlEngineering
Asset
Performance
STRATEGIZE ANALYZE MAINTAIN
Workforce Enablement
Industrial Workflow
Enterprise Asset
Management
Business Intelligence
Optimization
Predictive/Prescriptive
APM Assessment
Risk-based
Maintenance
APM Consulting
Cloud
IndustrialIOT
AI
AR and VR
Cyber-security
Page 2Confidential Property of Schneider Electric |
Asset Performance ManagementMaximize Return on Asset Investment
Page 3Confidential Property of Schneider Electric |
Maintenance ExcellenceAn ongoing journey
Page 3Confidential Property of Schneider Electric |
ARC studies show only 18% of asset failure is age-related. Based on these data,
preventive maintenance provides a benefit for just 18 percent of assets, and
monitoring for predictive maintenance is a recommended option for the rest.
Reactive and
Preventive Programs
Predictive Technology
for Early Warnings
www.arcweb.com/Lists/Posts/Post.aspx?ID=260
Page 4Confidential Property of Schneider Electric |
Challenges Customers FaceHow can we help?
1. Become more proactive in approach to
maintenance
2. Reduce unplanned downtime
3. Reduce maintenance costs
• Improved asset uptime & availability:
20-30%
• Improve labor utilization: 20-30%
• Reduced maintenance cost: 10-20%
3TOP
Challenges
Results with
Asset Performance Management
A Digital Maturity Model
• No consistent digital
strategy
• Opportunistic and
tactical investments
• Investment in
technology
• Automation of existing
business processes
• Company wide strategy
• Optimization and
improvement of
processes
• Cultural change
• Focus on data, contextualized information
• KNOWLEDGE
• New business models and processes
Opportunistic
Digitize
Digitalization
Digital
Transformation
Digital Asset Transformation Unlocking Value Across the Asset Lifecycle
Applying Digital Technology to APM
Pre
scri
pti
ve
Risk-based
Predictive
Achieve the Next Level of Digital Maintenance MaturityWith Comprehensive Enterprise APM
Preventive
Condition
World Class EAM is the Foundation of an APM StrategyClosing the Business Loop to Optimize the Availability of All Assets
Materials
Management
• MRO Inventory
optimization
• Supply chain
efficiency
Mobile Work
Execution
• GIS Location
• Work order execution
• Inspections
Planning &
Scheduling
• Operator rounds
• Work order execution
• Inspections
Preventive
Maintenance
• Time and condition
based
• Forecasting
Asset
Information
• Costs and statistics
• Work history
Industrial
Workflow
• Collaboration of
people, processes and
data
• Customer defined
business flows
Frito Lay Increases
Asset Availability and
Improves Maintenance
Planning
Page 10Confidential Property of Schneider Electric |
Client:
Frito Lay
Location:
Plano, TX
Closing the Loop:
Frito-Lay is PepsiCo’s largest North
American division, representing 33% of
PepsiCo’s revenues and 38% of PepsiCo’s
profits. Frito Lay selected Schneider EAM
software to improve reliability, performance
and environmental and safety compliance.
SE enabled Frito to standardize work
processes and data collection for improved
labor efficiency.
Results:
We’re Closing the Loop to help the
Frito Lay:
• Increase equipment availability
and reduce unscheduled
downtime
• Improve workforce
collaboration and labor
productivity
• Continuously improve plant
performance, safety and
reliability
Achieved
89% Planned maintenance, increased 9%
Controls roughly
65% of Savory snack market generating more
than $10billion in annual sales
Inventory transfer resulted in
$4 Million Costavoidance due to replenishment
set points reduced
$
%
Risk-based
Predictive
Condition
Achieve the Next Level of Digital Maintenance MaturityWith Comprehensive Enterprise APM
Preventive
Pre
scri
pti
ve
Condition-based Maintenance
• Optimize maintenance execution based on the
assets operational experience and current
condition
• Reduce preventative maintenance tasks
through the implementation of more proactive
condition based maintenance
• Configurable software based maintenance
triggers and notifications
• Automate initiation of maintenance work
orders based on run hours, limit violations and
defined rules
• Simplify and standardize the connectivity of
business systems with plant operations
2
Predictive
Achieve the Next Level of Digital Maintenance MaturityWith Comprehensive Enterprise APM
Pre
scri
pti
ve
Risk-based
Condition
Preventive
• Software based modeling of equipment using advanced pattern
recognition
• Uses historical data to describe how a piece of equipment normally
operates and build a model
• Continuously monitors behavior in real-time
• Alerts when the operation differs from the historical norm
• Early warning detection of equipment problems
• Advanced analysis capabilities including problem identification and
root cause analysis
• Extremely easy to use – workflow process
• Model building
• Model tuning
• Playback
• Alarm/alert workflow
• Fault diagnostics
PRiSM Predictive Asset Analytics Software
Air Liquide uses PRiSM
to compressor problems
& avoid forced outages
Client:
Air Liquide
Location:
Global
Closing the Loop:
Schneider Electric helped Air Liquide use
a scheduled opportunity outage to repair
a damaged turbine engine. Prior to the
scheduled outage, the plant notified the
M&D center indicating a vibration sensor
anomaly Air Liquide was able to use a
planned outage to investigate the
compressor and found a cracked
impeller.
Results:
We’re Closing the Loop to help Air
Liquide:
‣ Detect equipment failures before they
occur
‣ Prevent unscheduled system
downtime
‣ Harness real-time information that
brings plant operators and
engineering experts together to
collaborate
Predicting a
CompressorFailure
Using
Real-time DataTo detect unforeseen events
Saving
+500K Preventing reactive maintenance
and unplanned downtime
$
Achieve the Next Level of Digital Maintenance MaturityWith Comprehensive Enterprise APM
Pre
scri
pti
ve
Condition
Preventive
Predictive
Risk-based
Risk-based approach to APM
Strategy Effectiveness
Criticality
Assessment
Asset Library
Templates
RCM Risk
Analysis
MRO Spare
Optimization
Asset life Cycle
Costing
Root Cause
Analysis
Prioritize Assets
Highly critical
assets receive
priority and more
rigorous analysis
Leverage
Experience
Apply asset
library templates.
Covers 70-90%
of the asset
portfolio
Create
Feedback Loop
Critical assets,
more rigorous
RCM studies can
be applied for
higher detail level
Investigate
incidents and
failures, mitigate
actions taken,
tracked and
assigned
Quantify the
effect of spare
parts to optimize
levels
Strategy/What if
simulation
Achieve the Next Level of Digital Maintenance MaturityWith Comprehensive Enterprise APM
Pre
scri
pti
ve
Risk-based
Condition
Preventive
Predictive
Digital Training and Simulation
Confidential Property of Schneider Electric
Augmented Experience
Empowering the Workforce with Digital Transformation
Operator and Maintenance
Work Execution
Improve operator safety, reliability of assets and operational profitability
Digitally Transform Operator TasksClosing the Business Loop to Improve Workforce Efficiency
Knowledge
Transfer
Product
Changeover
Alarm and
Events
Regulatory
Compliance
Lock Out /
Tag Out
Process
Inspections
Operator
Rounds
Collect
Stranded Data
BASF Partners with
Schneider Electric for
Industrie 4.0 Initiative
Client:
BASF
Location:
Global
Closing the Loop:
BASF started an Industrie 4.0 initiative to
cover their entire value chain with
multiple work streams including
predictive maintenance and augmented
reality. For the first initiative, BASF
selected SE’s Predictive Asset Analytics
software and for the second initiative
they selected SE’s Operator Rounds
software with integrated workflow for
mobile and augmented reality.
Results:
We’re Closing the Loop to help BASF:
• Enable predictive maintenance to
reduce unscheduled downtime,
improve asset reliability, availability
and performance
• Achieve mobile operator driven
reliability with increased access to
information
World’s Leading Chemical Company
More than
112,000 Employees globally
Augmented Reality Rollout on
400+ PlantsWith 1,000+ End Users
Questions?
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Interoperability Visualization
Asset Model Analytics
Operations and Optimization
Manage Asset Operation
Optimize Asset Operation
Planning and Scheduling
Plan Asset Operation
Schedule Asset Operation
Monitoring and Control
Monitor and Visualize
Asset Operation
Control Asset Operation
Asset Performance
Maintain Asset
Analyze Asset Performance
Engineering
Design Asset
Design Operating
Process
Build and
Commission
Asset
Operations
Lifecycle
Improve Profitability
Asset
Lifecycle
Maximize Return on Capital
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Industrial Software PlatformPortfolio across operations and asset lifecycle
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• Create a real time operational control loop that accurately and
efficiently manages the enterprise based on information and analytics
• Reduce waste
• Increase overall equipment effectiveness (OEE)
• Enhance situational awareness throughout the enterprise
• Integrate supply chain logistics with customer operations
• Optimize maintenance strategies
• Reduce unscheduled downtime
• Improve regulatory compliance and safety
Digital TransformationKey Objectives
We are the market leader in APMWhat the analyst community is saying
“The announcement of a partnership with MaxGrip to provide asset risk assessment and strategy definition rounds out the portfolio of APM solutions to put Schneider Electric in the top quartile of providers from a functionalityperspective.”
Dan Miklovic, LNS Research
Page 28Confidential Property of Schneider Electric |
Why Does Equipment Fail?And can we prevent it?
Source HPI 2011:- 91% of bearings do not reach their conservative design life.
Machines don’t die, we kill them.
• 25% are preventable but not prevented because of an arbitrary decision that is simply not rooted in
knowledge or experience
• 15% are predictable but not predicted
• 20% are predicted but not stopped to undertake repair
• 25% are predicted and equipment is shut down
• 14% are other (consequential to an external activity)
• 1% are neither preventable nor predictable
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Charting Asset FailureToo many variables
What causes a Bad Actor?
• Deficient Maintenance Strategy
• Task Frequency Incorrect
• Activity Not Performed As Scheduled
• Procedural Enforcement
• Parts Availability
• Design Change Needed
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