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Slide 1
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.
Slide 3
• 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
Slide 4
MonitoringEquipment Health
Remaining UsefulLife (RUL)
MaintenanceEffectiveness
EquipmentHealth
ProductionDrivers
TurnaroundMaintenance
Failures Predictions
Accuracy
CMMS
ERP
MarketplaceDrivers
CM
11
44
33
EquipmentHealth
SessionAv-17
SessionAv-26
Slide 5
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)
Slide 7
PredictiveMaintenance
(Frequency)
ConditionManagement
(Real Time)
How effective is my current PM program?
PreventativeMaintenance
(Frequency)
Operator EquipmentWellness – 5S, Visualmanagement
(Frequency)
MultipleInspect /OverhaulPM Job’s
MultipleInspections nowork order
Slide 8
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
Slide 9
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.
Slide 10
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
Slide 11
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
Coolant Alarm Level 2
Tag 32 (<510f) & Tag 54 (>450psi) & Tag 87(>35cfm & <39.9cfm) =Generate Urgent work order
Coolant Alarm Level 3
Tag 32 (<520f) & Tag 54 (>5000psi) & Tag 87(<34.9cfm) = Shutdownmachine and generate Emergency work order
Slide 12
Condition Based Real Time Monitoring
Coolant Alarm Level 1
Tag 32 (<500f) & Tag 54 (>400psi) & Tag 87(>40cfm & <45cfm) =Generate Inspect work order
Coolant Alarm Level 2
Tag 32 (<510f) & Tag 54 (>450psi) & Tag 87(>35cfm & <39.9cfm) =Generate Urgent work order
Coolant Alarm Level 3
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
Slide 13
Time
PM Job # 33425 PM Job # 33425 PM Job # 33425PM Job # 33425 PM Job # 33425PM Job # 33425
PdM
CM /CbM
How effective is my current PM program?
WO # 366787 WO # 368002
WO # 368556
Urgent Urgent
Emergency
PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221
PM
Example: PM Program for single entity
Slide 14
TimeWO # 366889 WO # 367034 WO # 368917
WO # 366291
WO # 369103
Inspect Corrective EmergencyWO # 365714
Emergency
Urgent
Emergency
PM Job # 33425 PM Job # 33425 PM Job # 33425PM Job # 33425 PM Job # 33425PM Job # 33425
CM /CbM
PdM
How effective is my current PM program?
WO # 366787 WO # 368002
WO # 368556
Urgent Urgent
Emergency
PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221 PM Job # 221
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?
Slide 15
TimeWO # 366889 WO # 367034 WO # 368917
WO # 366291
WO # 369103
Inspect Corrective EmergencyWO # 365714
Emergency
Urgent
Emergency
PM Job # 33425 PM Job # 33425 PM Job # 33425PM Job # 33425 PM Job # 33425PM Job # 33425
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
Slide 16
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
Slide 18
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
Slide 19
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
Slide 20
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
Slide 21
Remaining UsefulLife (RUL)
MaintenanceEffectiveness
EquipmentHealth
ProductionDrivers
TurnaroundMaintenance
Failures Predictions
Accuracy
CMMS
ERP
MarketplaceDrivers
CM
11
44
33
PDT Pattern Hub
SessionAv-17
SessionAv-26
Slide 22
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]
Slide 24