Transcript US Steel Implementation Tango Motor Management
Tango Motor Management Implementation
Forrest Pardue Jan 2006 © 24/7 Systems, Inc. - 2006
Current State of Motor Management
• Many separate pieces of motor information in reports, databases, computer folders, spreadsheets • No Standardization • No Integration • Poor Communication • No warranty tracking • No Ability to Analyze Performance © 24/7 Systems, Inc. - 2006
RELIABILITY ADVANTAGES ARE WELL KNOWN World Class Average
Average life of electric motors
Mean time between repairs for pumps
Average vibration levels
Overtime, percent of total hours worked
Emergency work > 15 yrs > 6 yrs < 10 yrs < 3 yrs < 0.1 in/sec > 0.3
< 3 % > 10 % < 5% > 15 %
Total maintenance cost as percent of RAV < 2% > 3%
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Reliability impacts safety,environmental,quality,service,cost,and CTO”
Source: Bob Taylor SMRP 2003
Why do Motor Management?
• Prevent Failures in Service • Extend Motor Life • Manage Stores and Surplus Inventory • Manage Warranty Claims • Understand and Measure Reliability • Mine population for patterns • Manage repair vendors © 24/7 Systems, Inc. - 2006
Payback of Motor Management
• More production – Elimination of Failures in service • Less Maintenance – Longer MTBF • Inventory Control/ Reduction • Warranty Management – 3% motor cost?
• Repair Vendor Mgt – Quality/ MTBF © 24/7 Systems, Inc. - 2006
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Motor Management is Information Management
Identification and Design data Design documentation Purchase Stores Install and location Condition Test and Results Failure, Repair, and Warranty Collective analysis © 24/7 Systems, Inc. - 2006
Motor Management Outline
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Get Started – Goals and Success metrics Build a Motor database - Import any existing motor design data Failure/Repair Tracking - Set up repair tracker for all repair vendors Identify and enter stores inventory: Train stores person to keep current Import Motor functional locations from CMMS © 24/7 Systems, Inc. - 2006
Motor Management Outline
6. Functional location tracking by Production Area 7. Condition Tracking 8. CMMS Interface 9. Analysis © 24/7 Systems, Inc. - 2006
Step 1 – Get Started
• Turn on Tango Database for Plant • Establish Motor Management Program Goals • Establish how success will be measured • Assign a Motor Manager and train on Tango © 24/7 Systems, Inc. - 2006
Required for Reliability Information Management
• Standardize • Integrate • Communicate • Accountability • Analyze © 24/7 Systems, Inc. - 2006
TANGO
User Interface Options Desktop Application This is the workhorse program that provides administration, correction, entry of any information, reports and analysis.
TANGO Web Service Completely web based interface provides all TANGO reports and some analysis features along with very limited information entry.
Condition Assessment Task Management This application allows plant groups and contractors to enter Condition Assessment Results.
TANGO
Repair Tracker
™ Interface specifically designed for repair shops to enter design, failure and overhaul information.
Maintenance & Process Inspections Allows the setup and loading into a PDA of visual, inspection and gauge readings, with alarm and out of bounds warnings. Also allows creation of condition entry.
© 24/7 Systems, Inc. - 2006
Example Motor Management Goals
1. Gain a high quality and standardized root cause of failure analysis from all motor repair shops 2.
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2. Standardize repair reporting among all motor repair vendors 3. Integrate information from all vendors into a single database which would allow the creation of a long term history and analysis of failure patterns 4.
4. Expand repair tracking program to all repairable assets 5.
5.Completely eliminate repair vendor written documentation transmitted by mail or email 6.
6. Track equipment installed at functional locations 7 Associate multiple equipment condition results (vibration, MCA, IR) with plant equipment to highlight equipment that may require repair soon © 24/7 Systems, Inc. - 2006
How do you measure reliability?
How do you know its improving?
• MTBF by equipment type, location… • Faults by fault type, equipment type • Root cause of failure by equipment, location • Cost of failure by equipment, location © 24/7 Systems, Inc. - 2006
Step 2 – Motor Inventory
• How are we going to build the motor database • Import from other systems • Survey • Incremental as sent for repair © 24/7 Systems, Inc. - 2006
• Brass Tag • Serial No • Barcode • ID chip
Identification
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Motor ID Tag and Nameplate
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Design data for tag# 17100
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Design Data by Motor Type
• AC Induction Motor • AC Synchronous • AC Wound Rotor • Permanent Magnet • DC Shunt • DC Series • DC Compount • DC Stabilized • Gear Motor – AC Induction • Servo • Stepper • DC (All Types) © 24/7 Systems, Inc. - 2006
Name Plate Data is not enough
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Plant Tag * Serial Number * Frame Size * Materials Master Number * Model Number * Motor Mfg * Power * Speed * Voltage - Stator *
Air Gap Bars - Rotor (cnt) Bearing ID Number - DE Bearing ID Number - NDE Comments Connection Config (Stator) Current - Full Load (Stator) Current(Secondary) - Full Load (Stator) Duty Efficiency Formed Coil Insulation Class Key Value For MCE Lubrication ID Maximum Install Interval (Days) - Current Maximum Install Interval (Days) - Specified Maximum Storage Interval (Days)
Design Details
17100 01man66439-g001-ab 449hp 1184080 ?
Reliance 200 HP 1190 RPM 460 V 223 A Solid Coupling. Adaptor Base.
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Search Ability
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Installed Accessories
• Break Wheel • Coupling haves • Filters • Blowers • Tach • Modifications © 24/7 Systems, Inc. - 2006
Design Documents
• Manual • Wiring diagram • Service Bulletins • Lubrication Specification • Photos • Baseline test © 24/7 Systems, Inc. - 2006
Purchase Information
• Vendor • Cost • PO # • Warranty • Specifications © 24/7 Systems, Inc. - 2006
Step 3 - Repair Tracker
• Tango web portal for repair shops • Repair vendors do information entry • No plant data entry • Results in history of failures and repairs • No plant location information needed at this point © 24/7 Systems, Inc. - 2006
Repair and Failure Tracking
Motor Shop Input
• Design details • Failure mode confirmation • Repair actions & cost • Warranty information • Linked documents – damage photos, load tests, balance reports
Plant User’s Tools
• View a list of what’s out for repair • Search inventory by design details • Retrieve complete equipment lifecycle history • Analyze dominant failure modes • Report cumulative repair costs • See linked documents – damage photos, load tests, balance reports
Tango ™ Web-service
Secure access via user name login No plant firewalls to cross when entering information Users retrieve information via browser – no software to install © 24/7 Systems, Inc. - 2006
Repair Documentation
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Repair Documentation
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© 24/7 Systems, Inc. - 2006
Steps 4-6 Begin Tracking Motor life cycle History
• Stores • Installed locations • Out for repair • Scrap © 24/7 Systems, Inc. - 2006
Tango
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Equipment Management Functions
Tango Equipment Inventory CMMS
• Cost of Repair • New Purchase Equipment • In place Maintenance
OLAP Database Data Mining
INSTALLED SPARE OUT FOR REPAIR PURCHASE SCRAP • In Place Maintenance • Test & Inspection • Store Room • Scheduled Replacement • Condition Findings/History Task • Trend Data & Observed History • Location Documents • Repair Shops Root Causes • Cost • Design Information • Repaired Documents • New Equipment Vendors • Design Information • Cost © 24/7 Systems, Inc. - 2006
Tango
™
Equipment Lifecycle Flow
MTBF
Equipment Installed In Service Location
Ongoing Events
Condition Assessment Operator Observations Operator Data Logging Inspection Tasks In-place Maintenance
Overhaul Due, Problem Detected, Equipment Fails
Repair Cost
True Causes of Failure
No Yes Quote Approved?
Remove Equipment From Service Location
No Yes Repairable?
© 24/7 Systems, Inc. - 2006
Repair Shop Step 4 - Stores Management Plant Receiving & Stores Production Area Rack/Bin Functional Location © 24/7 Systems, Inc. - 2006
Stores Motor Management Functions
• Receive Motor from repair shop • Incoming inspection / test • Are accessories Installed?
• Check Info in Tango and release to pay Invoice • Place in stores rack, track in Tango • Periodic inspection/ test/ rotate • Ship to production area and designate action in Tango © 24/7 Systems, Inc. - 2006
Stores Structure
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Equipment Traveler
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Anonymous Locations
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Step 5 Location Structure
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Step 6 Location Tracking
• Typically performed by reliability engineer in each production area • Move from Anonymous to specific functional location • Specify in Tango when sent for repair © 24/7 Systems, Inc. - 2006
Click a paper clip icon to view linked documents Click a red row to see repair, failure mode, and shop documents Click a green row to unfold location information
Tango
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Equipment History Report
Get Design, Life Cycle Movement, & Repair Details
Click this row to unfold equipment design data Click a yellow row to see purchase and warranty details © 24/7 Systems, Inc. - 2006
© 24/7 Systems, Inc. - 2006
© 24/7 Systems, Inc. - 2006
See all different equipment ID’s that have been in the service location
Tango
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Location History Report
Retrieve history of all equipment that’s been in service
Click any row to access the equipment history report © 24/7 Systems, Inc. - 2006
Step 7 Know Condition of Motors and prevent failure in service
• Predictive Monitoring • Maintenance/ Production Inspections • Integration of results • Work scheduling • Validation of repairs © 24/7 Systems, Inc. - 2006
Present asset-centered health status
• • Results from all technologies being applied to a piece of equipment are posted under a common location name Problems are prioritized with color coding; equipment with most serious ‘red’ conditions show up at top of the list © 24/7 Systems, Inc. - 2006
Allow information users to drill down for as much detail as they want
• Details are available from each technology reporting on a piece of equipment © 24/7 Systems, Inc. - 2006
© 24/7 Systems, Inc. - 2006
Including the technical detail if they want it...
Tango
™
Condition Manager Program
Integrate, Organize, and Communicate Condition Monitoring Results
Oil Thermography Vibration Electrical Ultrasonics Process © 24/7 Systems, Inc. - 2006
Pie chart quickly shows how many assets in a user’s area are in states of problem severity Color coded list prioritizes problems according to severity
Tango
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Integrated Condition Status Report
Quickly View All Known Health Issues on Critical Equipment
Findings from multiple condition monitoring technologies are shown for each asset component Work Order Status shows if work has been initiated for each Condition Entry Case Closure shows that work has been completed and is ready for condition confirmation © 24/7 Systems, Inc. - 2006
Rounds Logging of Parameters & Observations
• Measurements • Gauge Readings • Observations • Barcode Point ID © 24/7 Systems, Inc. - 2006
© 24/7 Systems, Inc. - 2006
Step 8 – CMMS Interface
• Often custom based on customer needs © 24/7 Systems, Inc. - 2006
Step 9 - Analysis
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How do you increase reliability?
How do you make equipment last longer?
• Know condition of critical equipment and prevent failure in service • Know equipment lifecycle history • Know root causes of failure • Eliminate causes of failure • Make operations and maintenance accountable for Improvement • Analyze information for patterns and adjust to improve © 24/7 Systems, Inc. - 2006
Analyze information for patterns and adjust to improve
• Need for training or tools • Operations or design problems • Quality © 24/7 Systems, Inc. - 2006
Eastman Chemical customized report: Response to condition generated work requests
• Eastman Chemicals in 2004: 91% of vibration reported problems were resolved through August • Management expects resolution within 120 days of reporting
“When people know that the bosses know & care, prompt response happens”
© 24/7 Systems, Inc. - 2006
Using condition history to spot reliability gaps
© 24/7 Systems, Inc. - 2006
Eliminate causes of failure
• Training • Tools • Design • Quality • Operations © 24/7 Systems, Inc. - 2006
Analysis
• Root Causes of Failure by equipment and location • MTBF by equipment and location • Cost By Equipment and location © 24/7 Systems, Inc. - 2006
Data Mining Using Tango
Tango has several predefined data mining reports which allow you to determine what equipment or locations are the least reliable.
© 24/7 Systems, Inc. - 2006
Data Mining Report Listing
• You can use standard mining reports • You can add your own custom mining report • You can serve the reports via the web © 24/7 Systems, Inc. - 2006
How do the Equipment Measures Look?
• Data mining reports are “drill down” reports. You start at the top of a hierarchy and drill down to the levels which seem interesting.
© 24/7 Systems, Inc. - 2006
Pick Out the Interesting Items
• From this level its easy to see that AC Induction motors have an MTBF of less than 3 years based on a population of over 1000 installations – much less than what is considered the industry standard.
© 24/7 Systems, Inc. - 2006
You Can Look at Premature Failures
• According to the data, 65 motors were installed less than 2 weeks –that’s over 6% of installed motors © 24/7 Systems, Inc. - 2006
Do We Have a Lemon?
• We can see that the piece of equipment with Plant Tag 55 was installed twice for just a single day. At this point we would want to look at the equipment history report for this motor to understand why this motor failed twice so quickly.
© 24/7 Systems, Inc. - 2006