Report for PS PdM-RxM Survey 2020 - Plant Services...Maintenance manager 15.5% Maintenance engineer...
Transcript of Report for PS PdM-RxM Survey 2020 - Plant Services...Maintenance manager 15.5% Maintenance engineer...
Report for PS PdM-RxM Survey 2020
1. What is your primary job function?
12% Plant manager12% Plant manager
16% Maintenance manager16% Maintenance manager
8% Maintenance engineer8% Maintenance engineer
13% Maintenance technician13% Maintenance technician19% Reliability engineer19% Reliability engineer
8% Reliability technician8% Reliability technician
2% Controls engineer2% Controls engineer
5% Plant engineer5% Plant engineer
8% Sales/marketing8% Sales/marketing
2% Applications engineer2% Applications engineer
1% IT1% IT
5% Corporate executive5% Corporate executive
Value Percent
Plant manag er 12.4%
Maintenance manag er 15.5%
Maintenance eng ineer 8.2%
Maintenance technician 13.4%
Reliability eng ineer 18.6%
Reliability technician 8.2%
Controls eng ineer 2.1%
Plant eng ineer 5.2%
Sales/marketing 8.2%
Applications eng ineer 2.1%
IT 1.0 %
Corporate executive 5.2%
2. How big is the maintenance/reliability staff at your plant?
7% Just me (the MRO isoutsourced)7% Just me (the MRO isoutsourced)
19% 2-4 people19% 2-4 people
20% 5-1020% 5-10
26% 11-5026% 11-50
10% 51-10010% 51-100
19% More than 10019% More than 100
Value Percent
Just me (the MRO is outsourced) 7.2%
2-4 people 18.6%
5-10 19.6%
11-50 25.8%
51-10 0 10 .3%
More than 10 0 18.6%
3. What is the annual revenue of your organization?
22% Less than $50 million22% Less than $50 million
23% $50-500 million23% $50-500 million
18% $500 million-$5 billion18% $500 million-$5 billion
11% $5 billion-$100 billion11% $5 billion-$100 billion
9% More than $100 billion9% More than $100 billion
18% Not sure18% Not sure
Value Percent
Less than $50 million 21.6%
$50 -50 0 million 22.7%
$50 0 million-$5 billion 17.5%
$5 billion-$10 0 billion 11.3%
More than $10 0 billion 9.3%
Not sure 17.5%
4. How many total plants does your organization manage?
21% 1 plant21% 1 plant
31% 2-5 plants31% 2-5 plants
12% 6-15 plants12% 6-15 plants
36% More than 15 plants36% More than 15 plants
Value Percent
1 plant 20 .6%
2-5 plants 30 .9%
6-15 plants 12.4%
More than 15 plants 36.1%
5. What vertical does your plant most closely align with? (Please check all thatapply.)
Per
cent
Food and to
bacco
Pulp and p
aper
Oil and g
as
Automotiv
e
Chemical/p
harmace
utical m
anufactu
ring
Utility/
power genera
tion
Metals
and mining
Lumber, wood a
nd furn
iture
Metals
fabric
ation
Electronics
and in
struments
Commercial m
achinery
Transp
ortatio
n
Other (
please sp
ecify)
0
10
20
30
Value Percent
Food and tobacco 20 .6%
Pulp and paper 12.4%
Oil and g as 24.7%
Automotive 13.4%
Chemical/pharmaceutical manufacturing 18.6%
Utility/power g eneration 19.6%
Metals and mining 12.4%
Lumber, wood and furniture 4.1%
Metals fabrication 11.3%
Electronics and instruments 10 .3%
Commercial machinery 6.2%
T ransportation 10 .3%
Other (please specify) 16.5%
6. Who in your plant makes decisions on asset monitoring tools and configurations?(Please check all that apply.)
Per
cent
Plant manager
Maintenance
manager
Maintenance
engineer
Maintenance
tech
nician
Reliabilit
y engineer
Reliabilit
y tech
nician
Controls
engineer (se
nsors
are e
mbedded in m
achinery)
Plant engineer
Sales/marke
ting
Applicatio
ns engineer IT
Corpora
te e
xecu
tive
0
50
25
75
Value Percent
Plant manag er 44.8%
Maintenance manag er 56.3%
Maintenance eng ineer 18.4%
Maintenance technician 14.9%
Reliability eng ineer 28.7%
Reliability technician 8.0 %
Controls eng ineer (sensors are embedded in machinery) 18.4%
Plant eng ineer 13.8%
Sales/marketing 3.4%
Applications eng ineer 5.7%
IT 6.9%
Corporate executive 20 .7%
7. Which of these technologies are you using to monitor assets?
Usingnow
In2020budget
Within3years
Noplans
Controls equipment (controllers, networks, software)
Row % 77.9% 3.5% 5.8% 12.8%
Self-diag nostic (smart) instrumentation and final control elements
(drives, valves)
Row %
46.5% 7.0 % 16.3% 30 .2%
Specialized system control systems (combustion controls, steam
trap monitors, water/wastewater, cooling systems, compressed
air)
Row %
52.3% 9.3% 8.1% 30 .2%
Predictive maintenance (PdM) technolog ies for condition-
monitoring (thermog raphy, oil analysis, vibration, ultrasound,
motor testing )
Row %
66.7% 10 .3% 12.6% 10 .3%
Instrumentation (valve analysis, sig nal processing and alarm
manag ement software)
Row %
60 .0 % 8.2% 12.9% 18.8%
Automation, data archiving , and reporting software
Row % 54.7% 17.4% 15.1% 12.8%
Automation of work order g eneration (including repair history,
diag nostics, procedure and parts information)
Row %
48.8% 14.0 % 17.4% 19.8%
Embedded remote monitoring devices
Row % 35.3% 11.8% 24.7% 28.2%
Energ y monitoring and control devices (drives, valve actuators)
Row % 42.4% 11.8% 18.8% 27.1%
8. Which types of maintenance approaches are currently deployed by your plant?(Please check all that apply.)
Per
cent
Reactive (i.e., runto fail)
Preventive (i.e.,periodic and/orroute-based)
Condition-based(i.e., inspections)
Predictive (i.e.,diagnostics ahead
of failure)
Prescriptive (i.e.,both diagnosticsand guidance for
repair)
0
20
40
60
80
Value Percent
Reactive (i.e ., run to fail) 75.3%
Preventive (i.e ., periodic and/or route-based) 76.6%
Condition-based (i.e ., inspections) 63.6%
Predictive (i.e ., diag nostics ahead of failure) 51.9%
Prescriptive (i.e ., both diag nostics and g uidance for repair) 22.1%
9. T o what degree does your team or organization currently engage inRxM prescriptive maintenance?
31% Using now31% Using now
7% In 2020 plans/budget7% In 2020 plans/budget
25% Within 3 years25% Within 3 years
38% No plans38% No plans
Value Percent
Using now 31.2%
In 20 20 plans/budg et 6.5%
Within 3 years 24.7%
No plans 37.7%
10. Which mature predictive maintenance (PdM) technologies have you deployed orare you planning to deploy?
Using now In 2020 budget Within 3 years No plans
Vibration
Row % 70 .1% 5.2% 10 .4% 14.3%
Ultrasonic
Row % 44.7% 7.9% 21.1% 26.3%
Acoustic
Row % 21.1% 10 .5% 18.4% 50 .0 %
Corrosion
Row % 39.5% 14.5% 9.2% 36.8%
Infrared
Row % 56.6% 19.7% 7.9% 15.8%
Oil analysis
Row % 63.6% 13.0 % 5.2% 18.2%
Predictive modeling software
Row % 15.6% 13.0 % 22.1% 49.4%
Electric motor testing
Row % 44.2% 15.6% 13.0 % 27.3%
11. What percent of assets are on each technology?
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Vibration
Row % 22.1% 10 .4% 5.2% 7.8% 6.5% 11.7% 7.8% 13.0 % 10 .4% 0 .0 % 5.2%
Ultrasonic
Row % 34.2% 15.8% 9.2% 6.6% 5.3% 7.9% 5.3% 2.6% 6.6% 2.6% 3.9%
Acoustic
Row % 57.9% 6.6% 7.9% 6.6% 2.6% 1.3% 3.9% 3.9% 3.9% 3.9% 1.3%
Corrosion
Row % 42.1% 10 .5% 6.6% 2.6% 1.3% 3.9% 2.6% 11.8% 10 .5% 5.3% 2.6%
Infrared
Row % 23.7% 9.2% 11.8% 14.5% 2.6% 5.3% 3.9% 3.9% 15.8% 6.6% 2.6%
Oil
analysis
Row %
23.7% 13.2% 1.3% 13.2% 5.3% 5.3% 10 .5% 6.6% 10 .5% 7.9% 2.6%
Predictive
modeling
software
Row %
68.8% 2.6% 6.5% 0 .0 % 0 .0 % 3.9% 1.3% 6.5% 3.9% 3.9% 2.6%
Electric
motor
testing
Row %
33.8% 14.3% 6.5% 2.6% 5.2% 10 .4% 5.2% 6.5% 10 .4% 2.6% 2.6%
12. Which advanced PdM features have you deployed?
Usingnow
In 2020budget
Within 3years
Noplans
Internet-enabled / IIoT technolog ies
Row % 26.3% 11.8% 26.3% 35.5%
T roubleshooting decision tree
Row % 43.4% 9.2% 18.4% 28.9%
HMI with color-coded alerts
Row % 42.1% 10 .5% 14.5% 32.9%
Optimized PdM work processes
Row % 43.4% 11.8% 19.7% 25.0 %
Route optimization for mechanics and
operators
Row %
44.7% 11.8% 19.7% 23.7%
Energ y consumption of assets
Row % 31.6% 17.1% 21.1% 30 .3%
13. Please rate the drivers for deploying your PdM solutions.
Not a factor Low Medium High
Reduce maintenance costs
Row % 10 .4% 9.1% 37.7% 42.9%
Reduce operational costs
Row % 10 .4% 9.1% 33.8% 46.8%
Improve uptime
Row % 10 .4% 5.2% 24.7% 59.7%
Knowledg e capture
Row % 13.0 % 28.6% 41.6% 16.9%
Increase visibility into troubled assets
Row % 14.3% 16.9% 41.6% 27.3%
Environmental, health, and safety issues
Row % 13.0 % 14.3% 35.1% 37.7%
Reg ulatory compliance
Row % 13.0 % 22.1% 28.6% 36.4%
Energ y manag ement
Row % 18.2% 26.0 % 36.4% 19.5%
Reduce risk
Row % 10 .4% 10 .4% 37.7% 41.6%
14. Who uses the information provided by your PdM systems and with whatfrequency?
Never Weekly Monthly Quarterly
In-house maintenance
Row % 13.0 % 54.5% 22.1% 10 .4%
In-house operations
Row % 23.7% 40 .8% 30 .3% 5.3%
In-house reliability eng ineers
Row % 23.7% 47.4% 23.7% 5.3%
T otally outsourced to third-party maintenance and
repair
Row %
53.9% 5.3% 21.1% 19.7%
T hird-party remote monitoring
Row % 69.7% 9.2% 15.8% 5.3%
OEM supplier
Row % 61.8% 5.3% 22.4% 10 .5%
15. Please rate the performance of your PdM program over the past 12 months.
17% Not effective17% Not effective
33% Needs some improvement33% Needs some improvement
21% Satisfactory21% Satisfactory
23% Effective23% Effective
7% Very effective7% Very effective
Value Percent
Not effective 16.9%
Needs some improvement 32.5%
Satisfactory 20 .8%
Effective 23.4%
Very effective 6.5%
Usingnow
In 2020budget
Within 3years
Noplans
Asset type notinstalled
Automation assets (field devices,
control valves)
Row %
45.3% 4.7% 10 .9% 25.0 % 14.1%
Control system assets (DCS, I/O,
controllers, networks)
Row %
40 .6% 7.8% 15.6% 21.9% 14.1%
Production assets (rotating
equipment, mechanical pumps)
Row %
70 .3% 3.1% 14.1% 6.3% 6.3%
Distribution pipelines
Row % 31.3% 7.8% 15.6% 23.4% 21.9%
Electrical systems
Row % 56.3% 6.3% 17.2% 17.2% 3.1%
Fleet vehicles
Row % 21.9% 6.3% 14.1% 35.9% 21.9%
HVAC/R system
Row % 37.5% 7.8% 12.5% 35.9% 6.3%
16. What types of assets are managed by your PdM solutions?
17. Please rate the importance of PdM in relation to other investments?
1- LeastImportant 2
3 - ModeratelyImportant 4
5 - MostImportant
PdM technolog ies
Row % 17.2% 9.4% 29.7% 29.7% 14.1%
Reliability solutions
Row % 14.1% 10 .9% 21.9% 31.3% 21.9%
EAM/CMMS
Row % 14.1% 10 .9% 29.7% 25.0 % 20 .3%
Safety systems
Row % 9.4% 10 .9% 17.2% 20 .3% 42.2%
DCS
Row % 15.6% 18.8% 25.0 % 18.8% 21.9%
Field devices
Row % 20 .3% 15.6% 29.7% 21.9% 12.5%
Plant process networks
Row % 17.2% 15.6% 21.9% 28.1% 17.2%
EH&S solutions
Row % 14.1% 14.1% 31.3% 17.2% 23.4%
Sustainable & energ y
manag ement
Row %
9.4% 15.6% 26.6% 32.8% 15.6%
18. Please rate the obstacles limiting the success of your PdM initiatives.
Not a factor Low Medium High
No improvements needed
Row % 42.2% 18.8% 20 .3% 18.8%
Budg et constraints
Row % 4.7% 7.8% 35.9% 51.6%
Undefined financial benefits
Row % 6.3% 23.4% 32.8% 37.5%
Limited IT resources
Row % 10 .9% 29.7% 29.7% 29.7%
Lack of executive support
Row % 9.4% 23.4% 32.8% 34.4%
Limited eng ineering resources
Row % 9.4% 29.7% 35.9% 25.0 %
Undefined operational benefit
Row % 7.8% 29.7% 37.5% 25.0 %
Lack of EAM integ ration
Row % 15.6% 23.4% 35.9% 25.0 %
Poor prog ram execution
Row % 7.8% 39.1% 29.7% 23.4%
Level of employee eng ag ement
Row % 9.4% 23.4% 40 .6% 26.6%
19. What data collection methods do you use with your PdM system?
Usingnow
In 2020budget
Within 3years
Noplans
Paper-based system
Row % 62.5% 6.3% 3.1% 28.1%
Handheld data collector
Row % 60 .9% 9.4% 14.1% 15.6%
Embedded sensors/monitoring
devices
Row %
54.7% 10 .9% 18.8% 15.6%
Wireless sensors/transmitters
Row % 42.2% 14.1% 18.8% 25.0 %
Internet-enabled sensors
Row % 26.6% 9.4% 18.8% 45.3%
Industrial-g rade smartphone
Row % 10 .9% 6.3% 18.8% 64.1%
Consumer-g rade smartphone
Row % 21.9% 7.8% 6.3% 64.1%
Industrial-g rade tablet
Row % 29.7% 6.3% 28.1% 35.9%
Consumer-g rade tablet
Row % 18.8% 6.3% 12.5% 62.5%
Industrial-g rade PC
Row % 37.5% 9.4% 17.2% 35.9%
Consumer-g rade PC
Row % 40 .6% 14.1% 6.3% 39.1%
20. Is your PdM system integrated with any of the following higher-level systems?
Using now In 2020 budget Within 3 years No plans
Reliability solutions
Row % 36.7% 5.0 % 16.7% 41.7%
Historian
Row % 41.7% 6.7% 8.3% 43.3%
EAM/CMMS system
Row % 48.3% 13.3% 10 .0 % 28.3%
EH+S solution
Row % 13.3% 13.3% 13.3% 60 .0 %
ERP system
Row % 26.7% 11.7% 16.7% 45.0 %
Cloud-based analytics
Row % 15.0 % 11.7% 23.3% 50 .0 %
21. Are you using OEM-enabled remote monitoring technologies and/or services?
38% Using now38% Using now
5% In 2020 budget5% In 2020 budget
13% Within 3 years13% Within 3 years
43% No plans43% No plans
Value Percent
Using now 38.3%
In 20 20 budg et 5.0 %
Within 3 years 13.3%
No plans 43.3%
DecliningNochange
Increase 0 -5%
Increase >5%
Control systems (DCS, PLC)
Row % 5.0 % 60 .0 % 25.0 % 10 .0 %
Production assets (rotating equipment,
compressors)
Row %
5.0 % 46.7% 35.0 % 13.3%
Instrumentation
Row % 3.3% 51.7% 31.7% 13.3%
EAM/CMMS
Row % 6.7% 61.7% 20 .0 % 11.7%
Data historian
Row % 11.7% 63.3% 20 .0 % 5.0 %
Predictive analytics software
Row % 8.3% 56.7% 31.7% 3.3%
22. What changes, if any, are planned in your PdM investments for the following?
23. What is your percent Reactive Maintenance (annual average)?
Per
cent
0% 4% 8%12%
16%20%
24%28%
32%36%
40%44%
48%52%
56%60%
64%68%
72%76%
80%84%
88%92%
96%100%
0
2.5
5
7.5
10
12.5
24. What is your annual Maintenance Cost / Replacement Asset Value?
Per
cent
0%
378566%
757132%
1135698%
1514264%
1892830%
2271396%
2649962%
3028528%
3407094%
3785660%
4164226%
4542792%
4921358%
5299924%
5678490%
6057056%
6435622%
6814188%
7192754%
7571320%
7949886%
8328452%
8707018%
9085584%
9464150%
9842716%
0
2
4
6
8
10
25. How much of your maintenance technology effort is predictive routes (PdM)versus condition based maintenance (CBM)?
18% All or mostly PdM18% All or mostly PdM
15% About 80% PdM and lessthan 20% CBM15% About 80% PdM and lessthan 20% CBM
5% About 60% PdM and less than40% CBM5% About 60% PdM and less than40% CBM
23% About 40% PdM and lessthan 60% CBM23% About 40% PdM and lessthan 60% CBM
17% About 20% PdM and lessthan 80% CBM17% About 20% PdM and lessthan 80% CBM
22% All or mostly CBM22% All or mostly CBM
Value Percent
All or mostly PdM 18.3%
About 80 % PdM and less than 20 % CBM 15.0 %
About 60 % PdM and less than 40 % CBM 5.0 %
About 40 % PdM and less than 60 % CBM 23.3%
About 20 % PdM and less than 80 % CBM 16.7%
All or mostly CBM 21.7%
26. How is your Reliability/Maintainability/PdM/CBM programorganized/supported? (check all that apply)
Per
cent
RCM initia
tive u
nder
Reliabilit
y Departm
ent
RCM initia
tive u
nder Mainte
nance D
epartment
RCM initia
tive u
nder Engineerin
g Departm
ent
As part
of a L
ean Manufa
cturin
g initia
tive o
r under O
peratio
ns
As part
of a T
otal P
roducti
ve M
aintenance
(TPM) in
itiativ
e
Industr
y 4.0
or s
imila
r initia
tive to
get m
ore in
terco
nnected
Other (
please sp
ecify)
0
10
20
30
40
50
Value Percent
RCM initiative under Reliability Department 33.3%
RCM initiative under Maintenance Department 50 .0 %
RCM initiative under Eng ineering Department 23.3%
As part of a Lean Manufacturing initiative or under Operations 21.7%
As part of a T otal Productive Maintenance (T PM) initiative 28.3%
Industry 4.0 or similar initiative to g et more interconnected 5.0 %
Other (please specify) 5.0 %