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AV 04 Balancing Cost & Risk Management for Reliability Gains

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Presentation By:

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Stanley Shantz

Stan Shantz is Principal and Managing Partner of Meir Soft Tissue Solutions. Over the last 21 years, Stan has been assisting International Fortune 1000 companies to develop and implement cost effective and sustainable maintenance strategies - without major capital investment - based on

our clients

Goals, Directives, and Objectives. The focus of his work has centered on the realization of the need to

create a culture that empowers managers to efficiently manage their people.

Stan has developed various methodologies and software tools for: International apprenticeship programs, Troubleshooting approaches to improve equipment reliability (MTTR & MTBF), The implementation and effective use of Condition Management (CM) programs, The implementation and effective use of Equipment Reliability strategies, The determination of the effectiveness of your PM program, and How to use historical information to continuously and cost effectively improve maintenance departments. These methodologies and software tools have all been designed to lower the cost of implementation thus achieving or exceeding the Return-On-Investment, while at the same time, achieving sustainable world-class results. Direct

+1-519-503-4201

email:

[email protected]

Or Contact Your Invensys Sales Representative

www.Preventative-Maintenance.ca

CURRENT SITUATION

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© 2012 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.

CURRENT SITUATION

Over the last 10 – 15 years companies have spent millions of dollars on Asset Management tools based on the promise that these tools would continuously lower maintenance costs and sustainably improve equipment reliability. During the last 4 years companies have had to stream line their operations and curb spending to survive. Risk Management concerns have also increased.

(Environmental, Legal, Image, Safety, etc.)

.

Based on these drivers, companies are looking at ways to improve profitability while lowering risk. Most companies are looking at ways to utilize existing capital investments more efficiently without additional major capital expenditure.

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REALITY

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Reality

HIGH Large Asset Inventory

(Fixed)

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Slide 7 B2B PROCUREMENT WORK FLOW BUSINESS PROCESSES EQUIPMENT WELLNESS Existing Tools MRO INVENTORY HISTORIAN AVANTIS.PRO

PREDICTIVE TECHNOLOGIE S R I S K Limited Budget

(Fixed)

Limited Resources

(Fixed) (Variable)

MAINTENANCE COST CENTER

SAME TOOLS DIFFERENT RESULTS

HIGH B2B PROCUREMENT EQUIPMENT WELLNESS WORK FLOW BUSINESS PROCESSES Existing Tools MRO INVENTORY HISTORIAN PREDICTIVE TECHNOLOGIE S AVANTIS.PRO

R I S K MAINTENANCE PROFIT CENTER Large Asset Inventory

(Fixed)

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Slide 8 Limited Budget

(Fixed)

Limited Resources

(Fixed)

UTILIZE HISTORY Holistically Analyze All Data & Examine For Statistical Patterns and Trends

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Step 1

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Find The Answer To These Questions: 1) Are Your Preventive Maintenance, and Predictive Maintenance Programs Effective and Adding Value?

2) Is your current Proactive Maintenance Program aligned with your corporate Risk Management concerns?

Reality On-going Support

Planned Work Proactive Maintenance Program & Corrective work Valuable Information Found in the

“Free Text Fields”

Trades People Fill In Supervisor Planner Reactive Work Emergency & Urgent 1 All Photo Images From FreeDigitalPhotos.net

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Natural Language Selection Categorizing ALL Historical Reactive and Planned Work Orders

3- 5 Years of History Analyze All “Free Text Fields” Using Natural Language Selection Categorize Free Text Fields + Unlimited number of Categories + Can be customized 1 Slide 12 Natural Language Selection is the same approach Twitter, YouTube, Facebook and Google use to monitor

“free text field”

data, enabling them to track trends.

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Step 1

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1) Are Your Preventive Maintenance, and Predictive Maintenance Programs Effective and Adding Value?

2) Is your current Proactive Maintenance Program aligned with your corporate Risk Management concerns?

Match the result from the action oriented Meir PM Tree report to your goals, objectives & directives. What Is Working? •Can additional value be added?

•Can it be accomplished cheaper or faster with better results? What is Not Working?

Slide 14 EAM / ERP System (3-5 Years History) Categorized Through Natural Language Selection

Reactive Proactive Emergency WO

Cost Labor MRO Inventory EAM / ERP Outage Duration Immediate Failure

+

Urgent WO

Cost Labor MRO Inventory EAM / ERP Outage Duration MRO Inventory Immediate Failure

Entity

True Cost Of PM Program 1 Reliability Vs Value Reliability Vs Risk

PM (Job) WO

Cost Labor MRO Inventory +

Deficiency WO

Cost Labor MRO Inventory Meir PM Tree +

Routine Repair WO

Labor Cost MRO Inventory PM Program Opportunities Training Opportunities MRO Inventory Opportunities

© Meir Soft Tissue Solutions 2009

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Step 2

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For each failure you want to improve …

Do you fully understand the Immediate Failure?

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Meir Immediate Failure Analysis

2 Analyze all Additional Historical EAM data NLS categories Inventory Design Failure Trends Failure Patterns Failure Frequency Estimated End Of Life Component Trends Etc.

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Step 3

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For each failure you want to improve…

Do you fully understand the Fundamental Failure?

MEIR Fundamental Failure

Troubleshooting Window (HMI / PLC / PC / SCADA) Historian Wonderware Historian Same Failure Pattern Over Past 25 Years

F E D C B

Pattern Discovery Event Detection Software

A Slide 18 © Meir Soft Tissue Solutions 2009

Suggested Failure Pattern

Pattern Discovery Event Detection Software will work with all brands of historian software.

3

Step 4

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Make Adjustments to the following:

Proactive Maintenance Program Troubleshooting Processes MRO Inventory & Procurement HR Trades / Technician Training Program (s) HR Hiring Standards Reliability Standards Workflow Business Processes

Questions

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