Enterprise Asset Management - Wonderware California€¦ · IMPROVE PROFITABILITY Strategize...
Transcript of Enterprise Asset Management - Wonderware California€¦ · IMPROVE PROFITABILITY Strategize...
Presented By:
Maury Beck/Mike Llapitan WWCA 2019
Enterprise Asset Management
© 2018 AVEVA Group plc and its subsidiaries. All rights reserved.
ASSET PERFORMANCE MANAGEMENT
Solutions for Maximum Return on Industrial Assets
ASSET
PERFORMANCE
Increase longevity and
performance of assets while
ensuring safe, reliable
environment for the workforce
ASSET LIFE CYCLEIMPROVE RETURN ON CAPITAL
OPERATIONS
LIFE CYCLEIMPROVE PROFITABILITY
Strategize Analyze Maintain
APM Assessment
Risk-based
Maintenance
RCM
Business
Intelligence
Predictive/
Prescriptive
Optimization
Operator Rounds/
Digitized Work
Industrial Workflow
Enterprise Asset
Management
Asset Strategy
Asset Information
Asset Analysis
Asset Maintenance
Asset Information Management
Materials
• Inventory Catalog
• Storeroom Management
• Cycle Count
• Issues and Returns
• Receiving
• JIT Replenishment
• Mobile Solutions
• Asset Registry \ Entity Hierarchy
• Maintenance Inspections
• Work Management
• Scheduling and Assignment
• Time Entry
• Mobile Operator Rounds
• Contractor Management
• Maintenance Map
• Workflow
• Purchase Catalog
• Vendors
• Requests
• Purchase Orders
• Contract Management
• RFQs
• Invoice
• B2B Solutions
Enterprise Asset Management
Maintenance Procurement
• Collect asset condition data
• Create rules to monitor asset
• Define actions to maintain asset
Asset Condition Management
• Collect asset condition data
• Create rules to monitor asset
• Define actions to maintain asset
Financials / ERP
• KPI dashboard and reporting tool
• Decision support system
• MTBF, Bad Actors, inventory analysis
Dashboards
• Display locations of work requests, work
orders, preventative maintenance work
(PM), and assets on a map.
• Logically group and dispatch
maintenance activities.
GIS
Integrated Business Processes and Planning
ASSETS ARE THE HEART OF THE BUSINESS
© 2018 AVEVA Solutions Limited and its subsidiaries. All rights reserved.
▲ Insight into risks - Balance between financial
operational and safety risks
▲ Ever-changing legislation - Complying with
environmental and social requirements
▲ Sharing knowledge - Implement best practices
globally
▲ Continuous improvement – to drive maximum
return on industrial assets
RISK-BASED OVER-MAINTAINED
Goal
Cost of non-availability
(production loss + break
down)
Preventive
maintenance
cost
Total cost
Comfort mode
UNDER-
MAINTAINED
Fire fight mode
Optimum Too muchNot enough effort
WHY DOES EQUIPMENT FAIL?
AND CAN WE PREVENT IT?
Source HPI 2011:- 91% of bearings do not reach their conservative design life.
Machines don’t die, we kill them.
▲ 25% are preventable but not prevented because of an arbitrary decision that is simply not rooted in
knowledge or experience
▲ 15% are predictable but not predicted
▲ 20% are predicted but not stopped to undertake repair
▲ 25% are predicted and equipment is shut down
▲ 14% are other (consequential to an external activity)
▲ 1% are neither preventable nor predictable
CHARTING ASSET FAILURE
What causes a Bad Actor?
▲ Deficient Maintenance Strategy
▲ Task Frequency Incorrect
▲ Activity Not Performed As Scheduled
▲ Procedural Enforcement
▲ Parts Availability
▲ Design Change Needed
APPLY THE ANALYTICS TO IMPROVE MAINTENANCE AND OPERATIONS OF THE ASSETS
© 2018 AVEVA Solutions Limited and its subsidiaries. All rights reserved.
What’s Happening
Real-Time
• Processing of real-time
operational data
• Rule based inference for
causal analysis
Real-Time Domain
What Happened
Historical
• Assessment and exploration
of historical operational data
• Trends, KPIs, Dashboards to
present abstracted views
Historical Domain
What If
Predictive
• Comprehensive model based
assessment of operational
data ranges to determine
potential outcomes.
• Deterministic or non-
deterministic models
• Open-loop simulations
Science Domain
What to do
Prescriptive
• Systems that synthesize,
predict and provide scenario-
based guidance
• Deterministic or non-
deterministic models or
learning elements
• Closed-loop algorithms
Artificial Intelligence Domain
Age-related failure Random failure
EVOLVING BEYOND TRADITIONAL MAINTENANCE PRACTICES TO BECOME PREDICTIVE
© 2018 AVEVA Solutions Limited and its subsidiaries. All rights reserved.
ARC STUDIES SHOW ONLY 18% OF ASSET FAILURE IS AGE-RELATED. BASED ON THESE DATA, PREVENTIVE MAINTENANCE PROVIDES A BENEFIT FOR JUST 18 PERCENT OF ASSETS, AND MONITORING FOR
PREDICTIVE MAINTENANCE IS A RECOMMENDED OPTION FOR THE REST.WWW.ARCWEB.COM/LISTS/POSTS/POST.ASPX?ID=260
Reactive and
Preventive Programs
Predictive Technology
for Early Warnings
It’s a JourneyFailure Patterns
Requires a comprehensive
maintenance infrastructure
APR and diagnostics to
predict impending failure
Rules-based logic using
sensor data
Planned based on time or
usage statistics
Run to failure
Strategic,
Proactive,
Optimized
Risk-Based
Maintenance
Predictive Maintenance
Condition-Based Maintenance
Preventive Maintenance
Reactive Maintenance
18%
82%
Power /Energy 35% Water & Waste WaterFood & Beverage
Facilities Pulp & Paper
Avantis By Industry
Various Manufacturing
Achieved
89% planned
maintenance
Controls
> 65% of savory snack market
generating >$10b
in annual sales
Avoided
$4M in costs due
to Inventory
transfer
Frito Lay Increases Asset
Availability and Improves
Maintenance Planning
LOCATION
Plano, TX
SOLUTION
Frito-Lay is PepsiCo’s largest North American
division, representing 33% of PepsiCo’s revenues
and 38% of PepsiCo’s profits. Frito Lay selected our
EAM software to improve reliability, performance and
environmental and safety compliance. We enabled
Frito to standardize work processes and data
collection for improved labor efficiency. We’re
enabling Frito Lay to:
▲ Increase equipment availability and reduce
unscheduled downtime
▲ Improve workforce collaboration and labor
productivity
▲ Continuously improve plant performance,
safety and reliability
“Operating plants with the highest levels of productivity
requires closed loop orchestration of the complete asset
management life cycle”
LOCATION
New York City, NY
SOLUTION
DSNY, the world’s largest sanitation department,
leverages Avantis.PRO Enterprise Asset Management
(EAM) to operate 59 district garages, a fleet of more than
2,000 rear-loading collection trucks, 450 mechanical
brooms and 500 salt/sand spreaders.
▲ Deployed full EAM capability with mobile
maintenance which provides access to thousands
of employees to enable efficient execution of work
across the city.
▲ Maintenance scheduling and tracking
▲ Closed loop monitoring of the maintenance process
▲ Optimizing the work execution process
and improving asset reliability
NYC Department of
Sanitation Deploys EAM
to Achieve Strategic Goals> 3.2M tons
of refuse
per year
Recycling
> 600,000 tons
of material
Clearing
> 10,000 employees and an
annual budget of
$1.4 billion
Keep NYC healthy, safe and clean by collecting, recycling
and disposing of waste, cleaning streets and vacant lots,
and clearing snow and ice.
WEB INTERFACE
▲ Modern and easy-to-use user interface
▲ Support for multiple browsers and form
factors
▲ Internet Explorer, Edge, Google Chrome
- most recent versions
▲ Simplified user experience
▲ Customers can create a user experience
to meet the needs of their various
maintenance personas
FLEXIBLE USER EXPERIENCE
Cabinet and Designer
▲ Design cabinets for user specific needs
▲ On the fly sorting, filtering and manipulating of data allows users to
view work in a manner that is more meaningful
▲ Cabinet layouts can be saved for future use
Forms Designer
▲ Flexible way to design the user interface forms to be fit for purpose
▲ Security profiles can limit forms available to users (short form for
general users, long form for planners)
▲ Field level security
Flexible Management Dashboards
▲ Design dashboards for snapshots of your equipment
▲ Highly flexible tool which enables all levels of the organization to view
summary and detailed information in an intuitive, visual manner
▲ Dashboards are accessible inside or outside your firewall
KEY BENEFITS OF EAM
Reduce unplanned outages
▲ What is the cost of one hour of downtime?
▲ 5% average production loss per annum due to unscheduled downtime
Reduce downtime
▲ More timely and effective responses to issues
▲ More effective shutdown/turnaround
Reduce unnecessary preventive maintenance
▲ 30 to 50% of preventive maintenance is unnecessary
▲ Can represent 10 to 20% of total maintenance cost
▲ Source: ARC