2012 Honeywell Users Group EMEA
Sustain.Ability. Gary Peacock Global Solution Marketing Manager, Asset Management 1
Agenda 1. 2. 3. 4. 5.
Industry drivers Time for a paradigm shift Asset Management RAMP solution Product overview: •
Asset Manager & Field Advisor
6. Next steps
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Industry Concerns and Drivers Aging assets and infrastructure Shrinking pool of experienced people Robustness of Reliability System Data and information overload
Market volatility and competition 3
Common Asset Management concerns heard within Industry
The Data and information Problem
Visual Inspections
Control Loop Performance Monitoring
Process Data (DCS, Historian, etc.)
Smart Instruments (HART, FF, etc.)
Condition Monitoring
EAM/CMMS
Corrosion Monitoring
(SAP, Maximo, etc.)
Reliability
Maintenance
Operations
no common understanding of true status 4
Users try to determine asset status from disparate data sources
“…combining data derived from disparate sources so that the resulting information is better than when these sources are used individually.” WISDOM KNOWLEDGE SENSE MAKING
DATA 5
INFORMATION
Sensor Fusion from Wikipedia article
Data and information: Sensor Fusion
Robustness of Reliability System One calendar year
Not scheduled to run
100% Maximum “relevant” utilization Unplanned Downtime
Net % UPTIME Net % of Max Potential Rate (MPR) (@ best consecutive period production rate)
Net % of First Time Prime Quality
Rate Loss
Recycle or Scrap
OEE TEEP
Overall Equipment Effectiveness 7
OEE = 100% Maximum Scheduled utilization TEEP = 100% Maximum Potential utilization
Visualization of OEE and TEEP
Planned Downtime
Lack of Sales Downtime
Lack of sales derate
all TEEP Gaps are considered, including Scheduled Outages
Excess capacity
Total Effective Equipment Productivity
Benchmarking Overall Equipment Effectiveness (OEE) OEE: Food & Beverage
Best-in-Class
Middle 50%
Bottom
78%
62%
42%
OEE: Pharmaceuticals
45%
31%
23%
OEE: Industrial Processes Asset Downtime Plant Floor Automation Integrated EAM/CMMS Standardized KPIs across enterprise Asset Management with Predictive Failure Analysis
90% 3% 61% 79%
56% 13% 45% 56%
42% 34% 23% 48%
53%
40%
18%
28%
17%
6%
OEE = 100% Maximum Scheduled utilization
Table sources: 2010 Solarsoft Manufacturing Benchmark Study and Aberdeen Group, Enterprise Asset Management
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Join STAN GRABILL for OEE Seminar on FRIDAY morning
Real-Time Decision Making: A new paradigm
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From
To
Reactive / Run-to-failure
Proactive / Predictive
Historical data
Real time data
Inspection Centric
Reliability Centric
Paper Operator Rounds
Online & Automated
CBM as a Point Solution
Integrated RCM, CBM & CMMS Solution
Fire fighting
Proactive & Predictive
Asset Management with Predictive Failure Analysis
Think of Asset Management as 3 Distinct Areas Many Data Sources • Condition Based Maintenance (CBM) • Real-Time & Off-Line Data • Field Inspection and rounds • Wired & Wireless • Reliability Centric Maintenance (RCM) • Enterprise Asset Management (EAM) • Computerised Maintenance Management Systems (CMMS) 10
Enterprise Asset Management Work-stream & Relationships
Maintenance Management: EAM and CMMS Maintenance Management • Work Execution Management • Work Order Generation • Document Management • Financial Management • Purchasing Management • Inventory/MRO Management • Planning & Scheduling
• Integration with EAM and CMMS such as SAP and IBM Maximo
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Enterprise Asset Management Work-stream & Relationships
Reliability: GP Allied Alliance Partner (GP Allied) • ≈ 400 Consultants Globally • Excellent Industry Reputation • Experience in all Industrial sectors • iReliability Suite of tools Reliability Programs & Strategies • RCM / RCA • Asset Health Matrix • Equipment Maintenance Plan • KPI/Benchmarking • Change Management • Training (including craft skills) 12
Enterprise Asset Management Work-stream & Relationships
Condition Based Monitoring Real-Time Condition Monitoring • Real-Time Corrosion monitoring • DCS & Historian • Simulation (UniSim) • Real-time Vibration Monitoring • Smart Instruments (FDM) • Operator Rounds (Field Advisor) • Oil Analysis • Other Condition Monitoring
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Enterprise Asset Management Work-stream & Relationships
Integrating Real-time Asset Management CMMS / ERP Integration
Management Reporting & KPI’s
Maintenance & Reliability Users
Rotating Machinery Monitoring
Asset Performance & Health Assessment DCS & Historian
Process and Alarm Data
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Control Loop Monitoring
Visual Inspections
Smart Instruments
Corrosion Monitoring
Equipment Condition Monitoring
Downtime Reporting
Data Management Applications Very Clear & Easy to Understand
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Single view of Asset Performance and Health
Key Performance Information
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Abnormal Condition Assessment
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Downtime Dashboard
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RAMP Asset Manager Notifications sent to EAM/CMMS
• • • • • • • •
EAM/CMMS • Work Execution Mgmt • Maintenance Mgmt • Workflow • Document Mgmt • Financial Mgmt • Purchasing Mgmt • Inventory/MRO Mgmt • Scheduling
DATA SOURCES Condition Monitoring DCS & Historian Smart Instruments Operator Rounds Corrosion Data Simulation (UniSim) Oil Analysis Vibration Monitoring
• • •
Honeywell Asset Manager
Programs & Strategies • • • • • •
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RCM/RCA Asset Health Matrix Equipment Maintenance Plan KPI/Benchmarking Change Management Training
Asset Manager info used in Reliability programs
Reliable Asset Management Performance
• • •
OUTPUTS Alerts & Notifications Management Reporting & KPI’s Maintenance & Reliability Scorecards Downtime Reporting Health Assessment Automatic Work Order Generation
Integrating Real-time Asset Management DCS & Historian
Vibration Products
Asset Health Management
Downtime Reporter
Equipment Condition Monitoring
Asset Manager Process Reliability
Corrosion
Integration with EAM
Field Advisor
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Downtime Reporting
RCM
UniSim Rotating Machinery Monitoring
Wireless
Smart Instruments
RCM Partners and tools
Corrosion Monitoring
Visual Inspections
KPI / Benchmarking Trending
Smart Instruments
Integration with CMMS
Asset Manager offers a single view of performance and health
Applying RAMP STRATEGIC
Reliability Centred Maintenance (RCM) Real-Time Condition Based Maintenance (CBM)
TACTICAL
Risk Based Inspection (RBI)
Operational Performance Monitoring (OPM)
Abnormal Situation Management (ASM)
Reliability Centred Design (RCD)
Operator Driven Reliability (ODR)
Work Execution Management (WEM)
Asset Health Monitoring Reliability & Maintenance (AHM) Engineering (RME) Asset Manager Enterprise Asset Management (EAM) TECHNOLOGY INFRASTRUCTURE
Computerized Maintenance Management Sys. (CMMS) Real-Time Data Acquisition
BENCHMARKING
Overall Equipment Effectiveness (OEE) Total Effective Equipment Productivity (TEEP)
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Scalable Solutions integrated through Asset Manager
Applying RAMP: Tactical AHM STRATEGIC
Reliability Centred Maintenance (RCM) Real-Time Condition Based Maintenance (CBM)
TACTICAL
TECHNOLOGY INFRASTRUCTURE
BENCHMARKING
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Risk Based Inspection (RBI)
Operational Performance Monitoring (OPM)
Abnormal Situation Management (ASM)
Reliability Centred Design (RCD)
Operator Driven Reliability (ODR)
Work Execution Management (WEM)
Asset Health Monitoring (AHM)
Reliability & Maintenance Engineering (RME)
“accurate view of asset health” •Field Advisor •SKF Vibration •Corrosion Monitoring •Field Device Manager •OneWireless •Mobile Equipment Monitoring …………..
Scalable Solutions integrated through Asset Manager
Applying RAMP: Tactical OPM STRATEGIC
Reliability Centred Maintenance (RCM) Real-Time Condition Based Maintenance (CBM)
TACTICAL
TECHNOLOGY INFRASTRUCTURE
BENCHMARKING
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Risk Based Inspection (RBI)
Operational Performance Monitoring (OPM)
Abnormal Situation Management (ASM)
Reliability Centred Design (RCD)
Operator Driven Reliability (ODR)
Work Execution Management (WEM)
Asset Health Monitoring (AHM)
Reliability & Maintenance Engineering (RME)
“one view of the truth” •UniSim Design •Downtime Reporter •Corrosion Monitoring •Well Performance Monitoring •OMPro •………….
Scalable Solutions integrated through Asset Manager
RAMP Underlying Principles 1. Relentless integration of all aspects of people, processes, and technology 2. Applied across the entire asset life cycle:
Capital Delivery (CapX) Operations (OpX) Maintenance (MaintX)
3. Includes the management of all assets
mechanical, electrical, stationary, process automation and control assets
4. Modular and scalable 5. Change Management is woven into the deployment 24
Integration of People, Processes and Technology
Asset Manager R410 • Built on the Intuition Platform • Single Location for Asset Management – Wired & Wireless Vibration Monitoring – Real-time Corrosion management – Control System & Instrumentation Monitoring – Inputs from OPC, PHD, any Experion site, ………..
• Integration with Honeywell and 3rd Party Products & Solutions – Aptitude Analyst & DMx (SKF Corp) – iReliability Suite; including a fault model library (GP Applied) Integrate information
Fault Models
• Multiple sources • Future proof
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• Based on integrated information
Alerts • Based on the fault model execution
Alert-based Automatic Actions • Operator notifications • E-mail notification
See these in the demo room!! Problem Solving • Collaboration between teams • Historical information • Link to relevant documentation
Another bridge between Operations and Maintenance
Field Advisor R200 and R201 (2012 releases) • Technology Refresh – Honeywell Intuition framework and modernized handheld user interface – Microsoft SQL Server Standard edition
• • • •
Updated configuration tools with graphical configuration New rounds scheduling, tracking and reporting calendar Efficient Installation/Migration and Integrated Security Automatically trigger and track operator tasks
Select Work
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Execute Tasks • Enter comments
Review Consequences • When limits are exceeded
Review History
Corrective Actions • Execute reconditioning tasks
Upload Work
Tremendous Benefits Received Improve Safety –Reduce incidents by up to 40% –Increase operator competency –Support continuous improvement
Improve Efficiency – Reduce
off-spec material up to 50% –Reduce transition material up to 30% –Catalyst consumption down by 1% –Improve throughput 2-8% –Reduce energy use 5-10% –Improve forecast accuracy 4-20% –Reduce inventory 15-30 %
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Improve Reliability –Improve plant availability 3-8% –Preserve and extend asset life –Reduce maintenance costs 3-5% –Improve customer service 5-15%
Improve Sustainability – Green house gas emissions
reduced by 25% – Ensure compliance standards – Reduced total cost of ownership – Reduce energy consumption >$5B US in measurable benefits has been added to our customers’ bottom-line *Results based on past customer experience
Typical Return on Investments are 3 Months to 1 Year
Recommended Next Steps (At HUG) • Visit the demo room – Honeywell • • • •
Asset Management and RAMP Asset Manager R410 Field Advisor Corrosion
– SKF • Vibration
– GPAllied • iReliability • RCM
• Attend the OEE Seminar – Friday 16th November, 09:00 – 12:00 – Presenter: Stan Grabill 28
Recommended Next Steps (When you get back) • Ask for an assessment at your site • Start small if needed – Solutions are scalable
• Be a champion for your company • Must get operations and management involved • Do something…
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Questions?
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