Transcript PPT Template

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AV-09
Leveraging RCM Techniques to
Address Today’s Challenges
Presented at Avantis User Group 2012
Jason Vick
Manager, Mobility Technical Sales Consultants
© 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.
Introduction
• Reliability based initiatives are nothing new to our industry.
Traditionally these initiatives have focused on:
– Condition Directed Activities
• Tasks target preventing failures at the component level.
– Time Directed Activities
• Tasks target preventing failures at the component level.
– Failure Finding Activities
• Tasks target identification of failed components before a plant consequence.
• To achieve the goals of the Reliability Initiative it will take help from
everyone at the plant.
• Success will also depend on your ability to enforce Procedures and
create visibility to the data collected.
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Agenda
• RCM Overview
• The IntelaTrac Solution
• Operations
• Maintenance
• Engineering
• Bad Actor Identification
• KPIs & ROIs
Slide 4
1
RCM Overview
Slide 5
Reliability Centered Maintenance (RCM)
The RCM process was adapted from a program developed by the Airline
industry in the 1960’s when they found it too cost prohibitive to
upkeep the new larger planes that were being developed. The objective
of the program is to develop a proactive maintenance plan to maintain
continuous operation and maximize Plant throughput by maintaining
target rates in a safe and environmentally responsible manner.
To achieve this, a reliability-based maintenance, monitoring and
testing program, and RCM process training for personnel responsible
for implementing the recommendations needed to be implemented.
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RCM Principles
The initial RCM process begins with a three-step process that is
performed in the Initial System Analysis (ISA). This process is a joint
venture involving several groups including representatives from
Operations, Instrument technicians, Inspection (Rotating and Pressure
vessel groups) Electrical, and Machinery Maintenance.
• Identify the units objectives and specific operational functions
required to achieve those objectives
• Evaluate the equipment, determine the dominate failure cause and
the effect of that failure
• Identify the optimal task list to prevent that failure
– Failure Finding
– Failure Prevention/Postponement
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Task Definition Workflow Example
IntelaTrac Can Directly Impact These Areas
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Organizational Challenges
While RCM and other like initiatives offer huge benefits to many
organizations, there are a host of challenges that prevent most
people from achieving the highest levels of reliability.
1. Top down organizational support.
2. Employee Ownership.
3. Task Selection/Frequency.
4. Many PMs exist outside of CMMS (Data Visibility).
5. Deficient training (initial and ongoing).
6. Lack of Procedural Enforcement.
7. Misaligned Roles or lack of expertise.
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Industry Challenges
Example of Challenges in Process Industries:
● Over 50% of maintenance cost are directly related to improper operation of
equipment.
● 89% of all components fail randomly. These failures are most often caused
by neglecting the basic care of equipment.
● Secondary equipment failures and production slowdowns are 8-10 times
more costly than primary equipment failures. These failures are often
caused by Reassembly Errors, Part Defects, Installation Errors, and
Improper Operation.
The front line workforce has the opportunity to radically improve
plant reliability and operational profitability. Relying just on
Maintenance does not allow us to drastically reduce failures.
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2
The IntelaTrac Mobile Solution
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IntelaTrac’s Mobile Platform Addresses Industry Challenges
Field Worker Training
Field Worker Rounds
Process Data
Logbook
Product Changeover
Alarms & Events
Manual Maintenance
Lock Out / Tag Out
Startup/Shutdown Procedures
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Compliance
IntelaTrac Product Suite
Procedure Builder– advanced
procedure configuration
Schedule Manager– advanced
scheduling & workload balancing
Auditor Plus– work process and
procedure review
Web Reports – configurable
reports, emailing
Mobile / Workstation
IntelaTrac– procedure
execution
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Procedure Builder
Drag & Drop Configuration
• Procedure Items -basic
building blocks
• Integrations to External
Systems
• Peripheral Integration
• Conditions define followup Actions
• Single and Multiple
Actions
• Decisions for Advanced
Workflow
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Leveraging Decisions
Decisions allow a procedure to be configured in a way that enables
the end user to execute Tasks in a true dynamic fashion. Examples of
how Decisions can be used are:
• Scheduling Tasks either time based or condition based within a Procedure
that will have its own schedule.
• Changing Tasks, Limits, and Actions based upon variable conditions
• Triggering of Rechecks or Revalidations
For tasks that would trigger based on a single variable we typically
just assign the “Conditional” Task to an actual Condition.
PM Task Frequency must be as efficient and effective as possible.
Thus PM Tasks must have the capability to be dynamic.
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Integrations
Integrations allows for data to be pushed/pulled to 3rd party systems.
Additionally, new integrations can be added to IntelaTrac to accomplish
custom functions or communicate to 3rd party software that is not
currently supported. Some examples of Integrations are:
Supported
Custom
• OSI PI
• Schedule Modifier
• Honeywell PHD
• Tietonator EC
• AspenTech IP21
• Bentley System One
• Wonderware Historian
• IntelaTrac Tag
• Wonderware Galaxy
Just like an organization working together is critical for
success of a Reliability Program, the different software
used for the program must also easily work together.
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Schedule Manager
Calendar view of scheduled procedures.
Ideal for PM Tasks that are outside of CMMS.
Look Ahead (Current
or Future Scheduled)
Look Behind
(Completed, Overdue
or Missed)
Drag & Drop
Scheduling
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Mobilizing Third-Party Systems
Examples of Third Party Systems
Database
Server
Web Server
Synchronization
Server
IntelaTrac SDK
• Configuration
• Scheduling
• Execution
• Storage
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IntelaTrac
Mobile – Rounds & Procedures
• Operator is presented
with a list of Tasks
– Using Defined Pick Lists
– Device / Virtual Keyboard
– Peripheral Devices
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Mobile – Free Text Notes & Logbook
• Free Text notes may be
added at any time
• Or…triggered by an
Action
• Enter free text or select
a default note
• Default Notes can be
edited
• Note is also available as
a Log Entry
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Mobile – Historical Readings
• History
– Includes Notes
– History Details
– Historical Trends
– Pan & Zoom
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Mobile Trend Graphs
• OPC-HDA Trends are
transferred to the
computer automatically
• Zoom In / Zoom Out
• Select one or more tags
to view
• Some trends are always
available
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Mobile-Focused Advice and Escalations
Take
Action!
Message Text can be
calculated .
Could be delivered from an
external system at run time.
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Mobile- Attached Documents
Attached Documents provide a method to include additional
information (usually reference material), in the form of a PDF,
graphic, or spreadsheet, with a Procedure.
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Images on the Mobile
• Mobile IntelaTrac users can
attach images to Task Notes
• The Note and Image are
stored together
• The user can add additional
Notes and Images
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Mobile – Procedure Sign-off
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Auditor Plus
• Desktop application for
Supervision
• Pre Configured Reports
– Business Process Compliance
– Exception
– Administrative
• Drill down to the specific
Procedure instance
– Details
– Graphing
Slide 27
Web Reports
Creating Data Visibility through Scheduled
and Ad Hoc Web-based Reporting.
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3
Defect Identification
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Defect Identification
• Defect Identification is the key to
identifying and understanding the
Root Cause of your Bad Actors?
• What causes a Bad Actor?
– Deficient PMs
– PM Task Frequency Incorrect
– PM Not Performed As Scheduled
– Procedural Enforcement
– Parts Availability
– Design Change Needed
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Defect Identification: Seal Issues
As found during Operator Routine Duty Tasks
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Defect Identification: ENV Issues
As found during Operator Commitment Tasks
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Defect Identification: Vibration Issues
Found as a result of extending current CM program with
Operator collected vibration data via IntelaTrac
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4
KPIs & ROI
Slide 34
KPIs & ROI
• Identifying Key Performance Indicators
(KPIs) and ensuring your Return On
Investment (ROI) are critical for any
project executed at your plant. Now the
questions are:
– What do I track?
– How do I track it?
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KPIs
• Daily KPIs
– Daily KPIs should be tracked for round completion percentages, approval
percentages, and exceedences reported.
• ROI KPIs
– Equipment Failure saves.
– Work Orders written based off of IntelaTrac findings
– Work order cost reductions Post-IntelaTrac versus Pre-IntelaTrac.
– ENV Compliance
– F&S Compliance
• Reliability Based KPIs
– Unit Utilization Pre/Post IntelaTrac
– PM Schedule Attainment
– Equipment MTBF
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Pump Reliability and Average Repair
Cost – Refining Customer
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% of Pumps Worked vs. AvailabilityEnergy Customer
Power Plant Pump Availability
105.0
Percentage Available
100.0
95.0
90.0
85.0
80.0
% Available
GOAL
Trendline
75.0
Jun-06 Jul-06 Aug-06 Sep-06 Oct-06 Nov-06 Dec-06 Jan-07 Feb-07 Mar-07 Apr-07 May-07 Jun-07 Jul-07 Aug-07 Sep-07 Oct-07 Nov-07 Dec-07 Jan-08
Months
Your Plant is Running At 98%...Is it Reliable?
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ODR Driven Rotating Equipment Repair
Cost Reduction - Valero Ardmore
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Summary
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•
IntelaTrac manages the processes and
procedures used to ensure that organizations
consistently execute all field tasks required to
achieve reliable operations
•
IntelaTrac provides an extensible Task
Management and Performance Monitoring System
that fosters stewardship and accountability.
•
IntelaTrac mobile applications provide contextual
information and user guidance to help drive
reliability and improve performance
•
IntelaTrac tightly couples enterprise applications
with field workers and actionable tools to
implement and sustain reliable operations in a
wide range of industries
Questions & Answers
Contact Information:
Jason Vick
(m) +1 (302) 584-5196
[email protected]
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