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AV-17Risk and PM Analysis: How effectiveis my current PM program?

AssetInsight™www.PatternDiscovery.com/products/assetinsight

By: Stan ShantzMeirSTSwww.MeirSTS.com

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

AssetInsight™www.PatternDiscovery.com/products/assetinsight

By: Stan ShantzMeirSTSwww.MeirSTS.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. MhyarInternational Consulting, Pattern Discovery Technologies Inc.

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• 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. MhyarInternational Consulting, Pattern Discovery Technologies Inc.

Sample MeirSTS Client Experiences

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MonitoringEquipment Health

Remaining UsefulLife (RUL)

MaintenanceEffectiveness

EquipmentHealth

ProductionDrivers

TurnaroundMaintenance

Failures Predictions

Accuracy

CMMS

ERP

MarketplaceDrivers

CM

11

44

33

EquipmentHealth

SessionAv-17

SessionAv-26

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FailurePrediction

High ResolutionDetection andTroubleshooting

Operational Data(Wonderware)

Patterns Diagnostics

SensorsHistorian

22SessionAv-24

SessionAv-20

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 “Meaningless UnrelatedData (MUD)”1 from variousmanufacturing unrelateddatabases, to continuously drivelower maintenance costs, increasesustainable reliability and, lower theexposure to corporate risk

The Causes:A. Expense pressures on

maintenance dept’sB. Proactive maintenance programs

are rarely monitored foreffectiveness.

C. Aging infrastructureD. Engineering and maintenance

planning pool stretched thinE. No connectivity between large

software databases

Concern Maintenance Effectiveness

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 “Meaningless UnrelatedData (MUD)”1 from variousmanufacturing unrelateddatabases, to continuously drivelower maintenance costs, increasesustainable reliability and, lower theexposure to corporate risk

The Causes:A. Expense pressures on

maintenance dept’sB. Proactive maintenance programs

are rarely monitored foreffectiveness.

C. Aging infrastructureD. Engineering and maintenance

planning pool stretched thinE. No connectivity between large

software databases

“1/3 of the cost is waste”… due to “Improper or Unnecessarymaintenance”(Topic- maintenance budget)

2009 Study of maintenance practices and results for 217 North Americancompanies - : Improving Cost of Ownership: Integrated Predictive Maintenance LaineMears, Ph.D., P.E. Clemson University presentation

“1/3 of the cost is waste”… due to “Improper or Unnecessarymaintenance”(Topic- maintenance budget)

2009 Study of maintenance practices and results for 217 North Americancompanies - : Improving Cost of Ownership: Integrated Predictive Maintenance LaineMears, Ph.D., P.E. Clemson University presentation

“Every year, companies in the United Statesspend over $700 billion on equipmentmaintenance within plants and facilities, withupwards of 40% wasted on ineffectivepreventive and predictive maintenanceactivities.”www.peopleandprocess.com

“Every year, companies in the United Statesspend over $700 billion on equipmentmaintenance within plants and facilities, withupwards of 40% wasted on ineffectivepreventive and predictive maintenanceactivities.”www.peopleandprocess.com

1 - Ken Bannister, Engtech Industries Inc.

How effective is my current PM program?

PreventativeMaintenance

(Frequency)

Operator EquipmentWellness – 5S, Visualmanagement

(Frequency)

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PredictiveMaintenance

(Frequency)

ConditionManagement

(Real Time)


PreventativeMaintenance

(Frequency)

Operator EquipmentWellness – 5S, Visualmanagement

(Frequency)

MultipleInspect /OverhaulPM Job’s

MultipleInspections nowork order

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PredictiveMaintenance

(Frequency)

ConditionManagement

(Real Time)

MultipleInspect /OverhaulPM Job’s

MultiplePM Job’s

MultipleInspections nowork order

Multiple ConditionManagement Points

PM Program toRisk Analysis Identify Corrective

WorkExecutionManpowerRestraints

ReliabilityExpectations

BudgetRestraints

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Example: PM Program for Single EntityInspection 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” maximumdeflection)

Check all bearing for noise

Replace wear bar on entity 445632

Etc.

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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” maximumdeflection)

Check all bearing for noise

Replace wear bar on entity 445632

Etc.

Example: PM Program for Single EntityPredictive 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 contactJane Doe at 765-765-7764 immediately

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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 contactJane Doe at 765-765-7764 immediately

Example: PM Program for Single Entity

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) = Shutdownmachine and generate Emergency work order

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Condition Based Real Time Monitoring


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) = Shutdownmachine and generate Emergency work order

How effective is my current PM program?Example: PM Program for single entity

PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221

PM

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Time

PM Job # 33425 PM Job # 33425 PM Job # 33425PM Job # 33425 PM Job # 33425PM Job # 33425

PdM

CM /CbM


WO # 366787 WO # 368002

WO # 368556

Urgent Urgent

Emergency


PM

Example: PM Program for single entity

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TimeWO # 366889 WO # 367034 WO # 368917

WO # 366291

WO # 369103

Inspect Corrective EmergencyWO # 365714

Emergency

Urgent

Emergency


CM /CbM

PdM


WO # 366787 WO # 368002

WO # 368556

Urgent Urgent

Emergency


PM

What componentfailed?

Why callback?Inventory problem?Trade problem?New problem?

Why ?What componentfailed?

What componentfailed?

PM FailureFrequency?

Example: PM Program for single entity

Why ?What componentfailed?

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TimeWO # 366889 WO # 367034 WO # 368917

WO # 366291

WO # 369103

Inspect Corrective EmergencyWO # 365714

Emergency

Urgent

Emergency


CM /CbM

PdM

Why was it notcaught in PdMWO ?

Glad wecaught thatone?

Why didwe miss itagain?

PM FailureFrequency?

AssetInsight – Multi-site input – Singleoutput

Site AAvantis.PRO

Site BSAP PM Site C

Maximo

Site DOracle

1 Extract, Transfer, Load

Work OrderHistory

Inventory &ProcurementHistory

Informationfrom EAM

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2 Natural Language ProcessFree Text Fields & PM Program

3 Star Schema

PDT Pattern Hub

Current PMProgram

Inventory &ProcurementHistory

Data Tables and Star Schema Pattern DiscoveryPattern Hub

PreprocessingPreprocessing

NaturalLanguageProcessing

Engine

NaturalLanguageProcessing

Engine

Verificationand

Validation

Verificationand

Validation

WO NumberType

Entity NameEntity Number

DateDate Work Complete

SKU#Part UsedCategory

TaskPriority

Trade NameTrade CategoryInventory CostTime WorkedPM activitiesPdM activities

PM JobEtc.

Sample ofProcess

PM FrequencyUnderstand how oftenthe equipment is failingand adjust frequency

PM InventoryUnderstand parts being

used by PM and how often

PM BottlenecksUnderstand top 10 worstentities based on cost,

labour hours andfrequency

PM OpportunitiesHighlight the amount of effort

being spent on Emergency andUrgent work on entities covered

by PM

PM TradesUnderstand quality of

workmanship, knowledge,skills and tasks

Custom Reports

WO NumberType

Entity NameEntity Number

DateDate Work Complete

SKU#Part UsedCategory

TaskPriority

Trade NameTrade CategoryInventory CostTime WorkedPM activitiesPdM activities

PM JobEtc.

AssetInsight

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PM OptimizationSample List of Standard Best Practice ReportsPM Health Index (Benchmarkable Index)

PM Financials – Understand True PM costs (Year To Date to Budget, Select time frame & Ratios)

PM Hours – Understand manpower utilization and efficiency (Year To Date to Budget, Select time frame & Ratios)

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 frequency

PM Inventory - Understand parts being used by PM and how often

PM Bottlenecks - Understand top 10 worst entities based on cost, labor 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, knowledge, skills and tasks

PM Custom Reports

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PM Health Index (Benchmarkable Index)

PM Financials – Understand True PM costs (Year To Date to Budget, Select time frame & Ratios)

PM Hours – Understand manpower utilization and efficiency (Year To Date to Budget, Select time frame & Ratios)

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 frequency

PM Inventory - Understand parts being used by PM and how often

PM Bottlenecks - Understand top 10 worst entities based on cost, labor 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, knowledge, skills and tasks

PM Custom Reports

Inventory OptimizationSample List of Standard Best Practice ReportsInventory 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 – Frequency of usage by SKU

Inventory Custom Reports

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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 – Frequency of usage by SKU

Inventory Custom Reports

Trade OptimizationSample List of Standard Best Practice Reports

Maintenance Manpower

Maintenance Human Resource

Trade Custom Reports

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Remaining UsefulLife (RUL)

MaintenanceEffectiveness

EquipmentHealth

ProductionDrivers

TurnaroundMaintenance

Failures Predictions

Accuracy

CMMS

ERP

MarketplaceDrivers

CM

11

44

33

PDT Pattern Hub

SessionAv-17

SessionAv-26

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FailurePrediction

High ResolutionDetection andTroubleshooting

Operational Data(Wonderware)

Patterns Diagnostics

SensorsHistorian

22SessionAv-24

SessionAV-20

Contact Information

Stan ShantzPrincipal and General [email protected]

Slide 23

Paul SheremetoPresident & CEO1-519-888-1001 [email protected]

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