Sustain.Ability.
2012 Honeywell Users Group EMEA
1
Gary Peacock
Global Solution Marketing Manager, Asset Management
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Agenda
1. Industry drivers
2. Time for a paradigm shift
3. Asset Management
4. RAMP solution
5. Product overview:
Asset Manager & Field Advisor
6. Next steps
3
Industry Concerns and Drivers
Common Asset Management concerns heard within Industry
Aging assets and infrastructure
Shrinking pool of experienced people
Robustness of Reliability System
Data and information overload
Market volatility and competition
4
The Data and information Problem
Reliability Maintenance Operations
EAM/CMMS (SAP, Maximo,
etc.)
Process Data (DCS, Historian,
etc.)
Control Loop Performance Monitoring Visual
Inspections
Smart Instruments (HART, FF, etc.)
Corrosion Monitoring
Condition Monitoring
Users try to determine asset status from disparate data sources
no common understanding of true status
5
Sensor
Fu
sio
n f
rom
Wik
ipedia
art
icle
Data and information: Sensor Fusion
combining data derived from disparate sources so that the resulting information is better
than when these sources are used individually.
DATA
INFORMATION
KNOWLEDGE
WISDOM
SENSE MAKING
7
Robustness of Reliability System
100% Maximum relevant utilization
One calendar year
Visualization of OEE and TEEP
TEEP
Not
scheduled to
run
Excess
capacity
Net % of Max Potential Rate (MPR) (@ best consecutive period production rate)
Rate
Loss
Lack
of
sales
de-
rate
Net % UPTIME Unplanned
Downtime
Lack
of
Sales
Down-
time
Planned
Down-
time
Net % of First Time Prime Quality Recycle or
Scrap
all TEEP Gaps are
considered, including
Scheduled Outages
OEE = 100% Maximum Scheduled utilization
TEEP = 100% Maximum Potential utilization
Total Effective Equipment Productivity
Overall Equipment Effectiveness
OEE
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Overall Equipment
Effectiveness (OEE) Best-in-Class Middle 50% Bottom
Asset Management with
Predictive Failure Analysis 28% 17% 6%
Standardized KPIs
across enterprise 53% 40% 18%
Asset Downtime 3% 13% 34%
Plant Floor Automation 61% 45% 23%
Integrated EAM/CMMS 79% 56% 48%
Benchmarking
Table sources: 2010 Solarsoft Manufacturing Benchmark Study and Aberdeen Group, Enterprise Asset Management
Join STAN GRABILL for OEE Seminar on FRIDAY morning
OEE: Industrial Processes 90% 56% 42%
OEE: Food & Beverage 78% 62% 42%
OEE: Pharmaceuticals 45% 31% 23%
OEE = 100% Maximum
Scheduled utilization
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To
Proactive / Predictive
Real time data
Reliability Centric
Online & Automated
Integrated RCM, CBM &
CMMS Solution
Proactive & Predictive
Asset Management with Predictive Failure Analysis
Real-Time Decision Making: A new paradigm
From
Reactive / Run-to-failure
Historical data
Inspection Centric
Paper Operator Rounds
CBM as a Point Solution
Fire fighting
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Enterprise Asset Management Work-stream & Relationships
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)
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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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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)
Enterprise Asset Management Work-stream & Relationships
Reliability: GP Allied
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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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CMMS / ERP
Integration
Corrosion Monitoring
Smart Instruments
Visual Inspections
DCS & Historian
Process and Alarm Data
Downtime Reporting
Control Loop Monitoring
Equipment Condition
Monitoring
Asset Performance & Health Assessment
Rotating
Machinery
Monitoring
Management
Reporting & KPIs
Maintenance &
Reliability Users
Integrating Real-time Asset Management
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Single view of Asset Performance and Health
Data Management Applications
Very Clear & Easy to Understand
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Key Performance Information
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Abnormal Condition Assessment
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Downtime Dashboard
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Asset Manager
info used in
Reliability programs
Asset Manager
Notifications sent to EAM/CMMS
Reliable Asset Management Performance
RAMP
DATA SOURCES
Condition Monitoring
DCS & Historian
Smart Instruments
Operator Rounds
Corrosion Data
Simulation (UniSim)
Oil Analysis
Vibration Monitoring
OUTPUTS
Alerts & Notifications
Management Reporting & KPIs
Maintenance & Reliability
Scorecards
Downtime Reporting
Health Assessment
Automatic Work Order Generation
Honeywell
Asset Manager
EAM/CMMS
Work Execution Mgmt
Maintenance Mgmt
Workflow
Document Mgmt
Financial Mgmt
Purchasing Mgmt
Inventory/MRO Mgmt
Scheduling
Programs & Strategies RCM/RCA Asset Health Matrix Equipment Maintenance Plan KPI/Benchmarking Change Management Training
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Asset Manager offers a single view of performance and health
Integrating Real-time Asset Management
Equipment
Condition
Monitoring
Downtime
Reporting
Visual
Inspections
Corrosion
Monitoring
Smart
Instruments
DCS &
Historian
Asset
Manager
Downtime
Reporter
Corrosion
Field
Advisor
Vibration
Products
Smart
Instruments
UniSim
Wireless Asset Health
Management
Process
Reliability
KPI /
Benchmarking
Trending
RCM
Rotating
Machinery
Monitoring
RCM
Partners
and tools
Integration
with CMMS Integration
with EAM
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Asset Manager
Real-Time Condition Based
Maintenance (CBM)
Reliability Centred
Maintenance (RCM)
Total Effective Equipment
Productivity (TEEP)
Overall Equipment
Effectiveness (OEE)
Computerized Maintenance
Management Sys. (CMMS)
Enterprise Asset
Management (EAM)
Real-Time Data Acquisition
STRATEGIC
TACTICAL
BENCHMARKING
TECHNOLOGY
INFRASTRUCTURE
Abnormal Situation
Management (ASM)
Operator Driven Reliability
(ODR)
Asset Health Monitoring
(AHM)
Risk Based Inspection
(RBI)
Reliability Centred Design
(RCD)
Work Execution Management
(WEM)
Reliability & Maintenance
Engineering (RME)
Operational Performance
Monitoring (OPM)
Scalable Solutions integrated through Asset Manager
Applying RAMP
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Abnormal Situation
Management (ASM)
Operator Driven Reliability
(ODR)
Asset Health Monitoring
(AHM)
Risk Based Inspection
(RBI)
Reliability Centred Design
(RCD)
Work Execution Management
(WEM)
Reliability & Maintenance
Engineering (RME)
Operational Performance
Monitoring (OPM)
Scalable Solutions integrated through Asset Manager
Applying RAMP: Tactical AHM
accurate view of asset health Field Advisor SKF Vibration Corrosion Monitoring Field Device Manager OneWireless Mobile Equipment Monitoring ..
STRATEGIC
TACTICAL
BENCHMARKING
TECHNOLOGY
INFRASTRUCTURE
Real-Time Condition Based
Maintenance (CBM)
Reliability Centred
Maintenance (RCM)
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Abnormal Situation
Management (ASM)
Operator Driven Reliability
(ODR)
Asset Health Monitoring
(AHM)
Risk Based Inspection
(RBI)
Reliability Centred Design
(RCD)
Work Execution Management
(WEM)
Reliability & Maintenance
Engineering (RME)
Operational Performance
Monitoring (OPM)
Scalable Solutions integrated through Asset Manager
Applying RAMP: Tactical OPM
one view of the truth UniSim Design Downtime Reporter Corrosion Monitoring Well Performance Monitoring
OMPro .
STRATEGIC
TACTICAL
BENCHMARKING
TECHNOLOGY
INFRASTRUCTURE
Real-Time Condition Based
Maintenance (CBM)
Reliability Centred
Maintenance (RCM)
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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
RAMP Underlying Principles
Integration of People, Processes and Technology
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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)
See these in the
demo room!!
Integrate information
Multiple sources
Future proof
Fault Models
Based on integrated information
Alerts
Based on the fault model execution
Alert-based Automatic Actions
Operator notifications
E-mail notification
Problem Solving
Collaboration between teams
Historical information
Link to relevant documentation
Another bridge between Operations and Maintenance
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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
Execute Tasks
Enter comments
Review Consequences
When limits are exceeded
Review History
Corrective Actions
Execute reconditioning tasks
Upload Work
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Tremendous Benefits Received
Reduce incidents by up to 40% Increase operator competency Support continuous improvement
Improve Safety
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 %
Improve Efficiency
Improve plant availability 3-8% Preserve and extend asset life Reduce maintenance costs 3-5% Improve customer service 5-15%
Improve Reliability
Green house gas emissions
reduced by 25%
Ensure compliance standards Reduced total cost of ownership Reduce energy consumption
Improve Sustainability
Typical Return on Investments are 3 Months to 1 Year
>$5B US in measurable benefits has been
added to our customers bottom-line *Results based on past customer experience
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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
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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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