t80 - asset intelligence - rockwell automation · pdf fileassessment critical spares/ support...

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

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T80 - Asset IntelligenceTransforming the value of Maintenance and Storeroom

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Why Are We Here…

What’s your healthy and balanced approach for success?

Leveraging asset intelligence, you too can improve plant productivity;

by using smart devices, reliability professionals and asset strategies!


Manufacturing Operational Challenges

• Pressure on efficiency and reliability

• Shrinking expertise in workforce

• Aging assets

• New assets increasing in complexity

• Increasing regulatory pressures

Manufacturers spend 40% of their time on reactive

maintenance vs. their 12% ideal (Maintenance Technology)


Asset Management Transformation Need

Industry Drivers Business Values

Improved Asset UtilizationAsset and Plant Optimization

Best-in-Class are performing with 3.5% unscheduled asset downtime


Asset Management Foundation

Integration of Lifecycle and Reliability data

Execute evolving Proactive Asset strategies

Advanced Analytics and Intelligence

Asset Optimization

Maintenance Strategy

Storeroom Processes

Warranty Tracking

Asset Change Mgmt.

Reliability- Risk/ Criticality

Asset Diagnostics

Obsolescence Mgmt.Good Baseline Data Managed Programs

Cross functional teams

Dynamic Data Platform Best in Class results!

Journey toward Asset and Plant Optimization

Operational Excellence

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Asset Management & Reliability Services

6

Understanding the

Asset Baselines

Operational

Continuous

Improvement

Diagnostic Reliability

Data Intelligence

Reliability

Professional and

Program Mgmt. Asset Tracking and

Repair Management

Storeroom

Management/

Operations

Stores and

Plant Floor

Assessment

Critical Spares/

Support Analysis

Equipment

Reliability

Analysis

KPI / Metric

Driven

Performance

Greater Plant Productivity = Asset Performance + Reducing Risks


Busin

ess V

alu

es

Industr

y D

rivers

Faster Time to Market

Lower Total Cost of Ownership

Improved Asset Utilization

Enterprise Risk Management

People and Asset Safety

Speed andInnovation

Asset and Plant Optimization

The SkillsGap Challenge

IT/OTConvergence

Services & Support Mission

7

Maximize Productivity,

Minimize Risks

In a Sustainable Environment.


Asset Management & Reliability Services

8

Understanding the

Asset Baselines

Operational

Continuous

Improvement

Diagnostic Reliability

Data Intelligence

Reliability

Professional and

Program Mgmt. Asset Tracking and

Repair Management

Storeroom

Management/

Operations

Stores and

Plant Floor

Assessment

Critical Spares/

Support Analysis

Equipment

Reliability

Analysis

KPI / Metric

Driven

Performance

Greater Plant Productivity = Asset Performance + Reducing Risks


Specific Services and Programs

Reliability & Maintenance

ServicesDiagnostic Reliability

Service

Reliability Consulting & Engineering

Services meet our end-user

customer demand for Asset Uptime

improvements.

• Assessments,

• Reliability solutions,

• Embedded reliability engineers

and program management.

Diagnostic Reliability ‘DR’ Service

provides our clients an improved

risk mitigation and control system

compliance on their most critical

production assets.

• Asset Knowledge

• Risk Reduction

• Asset Performance


Reliability Consulting & Engineering Service

Reliability Consulting & Engineering Services

meet our end-user customer demand for

Asset Uptime improvements

Mitigating production risks with proactive maintenance

Reducing MRO expenses, updated equipment strategies

Improvement of productivity KPIs (OEE, MTTR, MTBF)

Fostering a culture of continuous improvement

Reliability services available: Assessments: Equipment Reliability,

Maintenance Program

Reliability Solutions, Improvement Projects

Embedded Reliability Engineers, Program

Management.

Common delivery outcomes include:

Strategic roadmap with improvement priorities,

ROI justification and best practices

Solving chronic / acute problems on critical

equipment with optimal maintenance plans

Lead TPM / RCM program and projects


Reliability Assessment Maintenance - Detailed Checklist 3.2

Reliability Topic Component Score

System Type 5

Data Storage 4

Preventive Maintenance 5

Corrective Maintenance 3

Alerts 2

Metrics 2

MRO 3

Management 4

Maintenance Personnel 3

Operators 1

Coverage 5

Adequacy 4

Execution 4

Review / Maintenance 3

Coverage 5

Training (General) 3

Training (TPM) 1

System 1

Personnel 2

Execution 3

Standards 4

Condition 2

TPM Events, Blitzes Frequency 3 3.0Self-Auditing Process 2 2.0Capital Planning Process 4 4.0

Policies 4

Equipment 5

Maintenance Resources 3.0

Safety 4.5

Equipment Assessment 3.0

Autonomous Maintenance 2.0

Level 1

Impaired

Maintenance Procedures

2.7

4.0

Maintenance Management

System

Culture

3.4

Level 2

Poor

Level 3

Adequate

Level 4

Advanced

Level 5

Expert

Reliability & Maintenance Assessments

Equipment Reliability Assessment

Selected group of equipment (8-10 machines),

Performing reliability analysis, risk profiling,

Failure mitigation strategies, defining areas of

improvement and

Roadmap development with ROI and project plans

Maintenance Program

Assess maintenance program effectiveness, vision,

Performing equipment strategies (CM, PM, PdM),

CMMS utilization analysis, MRO functions/ costs, and

Roadmap development with ROI and project plans


Reliability Solutions Improvement Projects

Our domain experts use equipment knowledge, proven processes and user requirements

leveraging appropriate reliability techniques* to drive an outcome with sustainable results.

*Common reliability techniques used: criticality analysis, Failure Modes Effect Analysis (FMEA), root cause analysis, Five Whys, spare parts analysis, fault tree analysis, fault code development, training needs analysis,

condition based monitoring, maintenance process gap analysis, maintenance strategy development, work order improvements, standard operating procedures/ process mapping, corrective actions plans, MAAR (monitor,

analyze, act and review) chart development, CMMS utilization analysis, CMMS Data Cleansing, program management and Reliability-Centered Maintenance (RCM)/ Total Productive Maintenance (TPM) program training.

Mitigate equipment risks across

production lines, machines and

control systems.

Build execution plans for modern

maintenance strategies and help

with corrective action plans.

Develop process visuals for data

driven KPIs, MAAR charts and

lead reliability trailered training


Reliability Resource based Contract

Our Service Experts are available to augment your team’s effectiveness through a dedicated

resource contract; applying the right skillset, experience, process training and support tools,

to help ensure sustainable program results.

Dedicated Reliability Engineer, Program

Manager for a term: 6, 9 or 12 months w/

rolling project list driving results:

Mitigating production risks with proactive

maintenance

Reducing MRO expenses, updated

equipment strategies

Improvement of productivity KPIs (OEE,

MTTR, MTBF)

Fostering a culture of continuous

improvement

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 14

RE

SU

LT

S Risk / Criticality Analysis – 43 Systems

• Prioritized Resource Utilization

• Mitigated Risk / Unplanned Downtime

• Identification of Reactive, Preventative, Predictive Maintenance Strategies

Failure Mode Effects Analysis (FMEA) – 59 Systems

• Preventative Maintenance Plans – Strategy, Tactics, Frequencies, Spares

High volume manufacturing with high downtime costs

Regulatory concerns for lost production Combination of new and old equipment Undefined and unmitigated equipment risks Limited engineering and maintenance resources;

minimal reliability expertise Compliance and Validation requirements

CHALLENGES SOLUTION

Develop PM Strategies for Automation Devices

• Failure Mode Effects Analysis (FMEA)

• Develop risk mitigation strategy and appropriate preventative

maintenance strategy

Prioritize Activities via Risk / Criticality Analysis

• Quantify risk – safety, environmental, and production

• Production downtime and maintenance labor costs are also

assigned to produce a consequence value ($)

Life Sciences – Medicine ProducerReal Results: Risk & FMEA Solution


Diagnostic Reliability Service

Diagnostic Reliability Service is a

strategic Asset Management Solution

providing asset intelligence-based

outcomes, to optimize the total lifecycle

value of your electrical control platforms!

The core service-based outcomes are: Evergreen spare parts and support plans

Mitigating control equipment reliability risks

Driving proactive maintenance strategies

This packaged service provides:

Automated central asset intelligence system

Reliability program improvement specialists


Common User Scenarios

Asks from engineering/maintenance team:

Locate/ Identify status of troubled devices

Obtain proactive notice of device change/ history

Track device service cycle/ utilization

Identify/ manage device and system firmware

Determine product safety/ service advisories impact

Mitigate high-risk equipment risks/ failures

Perform a critical/ spare parts gap analysis

Verify migration plans to reduce legacy obsolescence

Asks from leadership team:

Improve asset uptime/ utilization/ assurances on critical infrastructure (i.e. controls platform) through proactive maintenance, continually mitigating risks and acting on performance/ reliability opportunities

Develop a data-driven solution for managing control assets over their lifecycle, enabling us to optimize capex/ Opex budget allocations with business units and plants

Diagnostic Reliability Service streamlines manual activities previously performed in isolation, packaging it to drive Asset Intelligence!



Automated Central Asset Intelligence System



They are well trained on Rockwell Automation products,

processes and commonly used applications, as well as

products from other manufacturers, enabling them to provide

comprehensive support strategies

Our engineers and program managers

provide a critical role in the Diagnostic

Reliability Service, through proven

processes and resource tasks!

Reliability program improvement specialists

Our domain experts have

diverse industry and

applications backgrounds,

and are certified by the

Society for Maintenance

and Reliability

Professionals

Annual reliability strategy workshop

Quarterly reliability improvement

project working sessions

DR Service startup/ commissioning

Expertise availability to further

augment your team towards your

asset and plant optimization goals



The packaged service combines the right people,

processes and technology to maximize the total

lifecycle value of your electrical control platforms!

Connected Information Asset baseline review and solution feasibility

DRS system startup and commissioning

System infrastructure and support as a service

Monitoring & Improving Three year strategy roadmap with smart milestones

Configuration of analytical triggers/ event rules

Specialist working sessions; executing strategies

Sustaining & Optimizing Annual workshop prioritizing improvement projects

Reliability specialists leading optimization initiatives

Delivering a packaged service solution

Analyze Act ValidateIdentify

Power Devices

Control Systems Maint./ Prod.

Systems

Connected Information

Monitoring & Improving

Sustaining & Optimizing

Device changes

Faults, Limits

Failure rate/ modes Firmware Compl.

PSA impact Health

Evergreen

spare parts

and support

plans

Mitigate

control

equipment

reliability

risks

Drive

proactive

maintenance

strategies

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 20

Diagnostic Reliability Service implemented on 6 site locations

(~500 devices per site)• Online monitoring and auditing

• Ongoing equipment health trending within dashboards

• Proactive maintenance activities that are driven by analysis

• Asset Management improvement plan roadmap to drive operational and

maintenance efficienciesRESULTS

• Accurate management of control assets• Accuracy and completeness of control asset records

• Spares inventory correctly supports installed base

• Sustainability of enterprise system data records

• Verify asset lifecycle management

• Multiple sites within a region with many layers of

devices and systems

• Regulatory and Compliance requirements

CHALLENGES SOLUTION

Large Producer and Refiner of OilReal Results: Diagnostic Reliability Service

• Implement Rockwell Automation® Diagnostic

Reliability Service

• Including network assessment

• System implementation to IT requirements

• User training with specific dashboard design

• Ongoing service contract


DR Service – Benefits Summary

Benefits and Value Justification…

Reduce Inventory/ Device data collection time

and accuracy

Optimize controls critical spare parts inventory

Unscheduled downtime prevention with early

alerts/ notification

Shrink MTTR on Equipment using Asset

Information system

Reduction of engineering time due to

emergency downtime burden

Reduction in failure costs on legacy parts

through hyper-care & proactive replacement

As our clients are working toward executing their Total

Productive Maintenance, Reliability Centered Maintenance

and/ or Operational Excellence Initiatives, the DR Service is

ready to be an integrated into your program framework.

Uptime, Productivity

Mfg. Risk, MRO Costs

Proactive Maintenance using Asset Intelligence provided by DRS to Minimize Risk and drive greater Productivity!


Why Are We Here…

Accelerating High Performance Operations by Empowering people to make smarter, more informed decisions

Leveraging Asset Intelligence you too can improve plant productivity; utilizing smart devices,

reliability professionals and asset strategies!

t80 - asset intelligence - rockwell automation · pdf fileassessment critical spares/ support...

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