delivering high value condition caterpillar -...

© Copyr i gh t 2014 O SIs o f t , LLC .

Presented by

Delivering High

Value Condition

Monitoring at

Caterpillar

Dick Douglas, Caterpillar

Chris Wiseman, Casne Engineering


A Global Reach

• Global reach and presence is unmatched

in the industry

• Serve customers in more than 180

countries around the globe

• More than half of our sales are outside the

United States

• Manufacturing, marketing, logistics,

service, R&D and related facilities along

with our dealer locations total more than

500 locations worldwide

Dealers • 188 worldwide with more than 126,000

employees

• Independent, locally owned

• Key competitive advantage

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A Broad Range of Products and Industries

Cat equipment – more

than 3 million pieces

globally – is at work for

our customers on

highways, rail lines,

oceans and rivers, in

forests, quarries, mine

sites and oil fields.

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• Advanced Engineering and Integration Services

• Power Systems, Instrumentation & Controls, Software Solutions

• 34 years of professional practice

• OSIsoft Solution Partners since 2001

• CAT Solution Providers since 2009

Field services: site assessments and PI integration for CAT Global Petroleum, Global Mining,

and Global Power

CAT Equipment Care Advisor development, PI data integration, custom tools development

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Turning Equipment Data into Actionable Information

Creating notifications that are valid and actionable. Its about the end user’s trust of the

system and its proven history.

Condition Monitoring

© Copyr i gh t 2014 O SIs o f t , LLC .6

From information overload……. ……To actionable intelligence

• Engage End User

• Visualize Analytics in a Way That’s Easily Understood

• Help the End User Understand the Problem to Make More Intelligent Repair Decisions

Business Challenge


Condition Monitoring - Challenges

• Getting data back consistently from mobile assets is a huge challenge

• Assimilating the data and building an analytic structure to process it.

• Turning the data into actionable information that the end user (repair planner) can fully understand and trust to help him make more efficient, accurate repair decisions

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Failure

Machine AlarmReactive Extensive Damage

High Cost

Most Downtime

PlannedSome Damage

Moderate Cost

Moderate Downtime

PredictiveMinimum Damage

Minimum Cost

Planned Downtime

Pe

rfo

rma

nce

Physical Indicator

Wear material

Operational

Change

Prognostic deviation

Time

Leveraging Early Warning


Pe

rfo

rma

nce

Unscheduled

Functional

Failure

Engine derated –

low power reported

by operator

Alert about the Erratic (mostly high)

behavior of the exhaust split

Time to Failure

Problem emergence

(Small spikes in the exhaust split noticed)

Low

Dealer/Customer Product

Problem Management

Predictive

Monitoring

High

May 16thMarch 3rd

74 days early warning

Early Warning Opportunities

Approach

Why Focus on a Sensor/Harness Issue?

Estimated Thermal Cycle Damage


Solution

• Implemented PI Asset Framework-Based Customized

Analytics

• Implemented Salesforce Front-End

10

Solution and Results


Architecture

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AF Information

Repository

ACE

PI

SS

AnalyticsAsset


Equipment Hierarchy in AF

• Single Point of Data Aggregation

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Referenced Templates in AF

• Table References Within

All Attributes

• Attributes Referenced to

Allow Changes at a

Single Source

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Meaningful Analytics

• Customized Simple Analytics

– Trend Violation, Statistical Methods, Alarms

• Advanced Analytics

– Anomaly Detection from Normal, Custom Alarm

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Models Mapped Within AF

15


Operating Modes

• Different Operating Modes Require Different Limits

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Limits on Demand

17


Asset Based Scorecards

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SmartSignal Integration

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Results

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Dealer Asset Overview:• Actively monitored

– 4 customer mining sites

– ~ 125 machines (793C, 793D, 793F and 994F)

Results:

• 275+ sensor/harness issues

• 450+ system problems

• 6+ catastrophic engine failure preventions from air leak, premature bearing wear, broken valve stem guide and

broken piston rings

• 75+ injector failures

• 15+ cases of coolant entry into engine oil

• 10+ boost/exhaust leaks

• Value – $3.9M+ savings in dealer repair costs and improved efficiencies

CM Analytics Results – Study Done for 18 Month Period 2010 / 2011

CM Services Delivered to Dealer:• Uninterrupted service - 78 consecutive weeks

• Delivered 312 reports

• Communicated over 800 issues with recommended action to dealers

• Action – taken on over 90% of recommendations


Cat CM Analytics Dealer Repair Planner Feedback

• “We have had some good wins to date specifically relating to

exhaust leaks, sensor issues, voltage drops and engine filter DP.”

• “In short the system is operating as an early warning system, we

can detect and track issues before they reach level 1 or 2 in the

VIMS on board module.”

• Greatest fear is that the direct interaction and help from

the Cat service team will go away in the future in favor of

automated downloads

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• [email protected]

• Subject Matter Expert

• Caterpillar

• [email protected]

• Senior Analytics Engineer

• Casne Engineering

24

mailto:[email protected]

mailto:[email protected]


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