A New Approach that Improves Asset Utilization, Reliability and Plant Performance

Transcription

1 A New Approach that Improves Asset Utilization, Reliability and Plant Performance Leverage a Holistic Business Approach to Managing Assets Our Speaker: Kim Custeau, Director, Product Marketing With over 24 years of experience in the area of Asset Management products and services, Kim has had roles in sales, consulting and has worked for the last 10 years in various marketing positions. This has enabled her to always have a connection with the market and our customers across industries and around the world. Kim s focus today is in the area of product marketing for our Asset Management solutions.

2 Key Market Transitions and Drivers Affecting Your Profitability Replacing People Empowering People Process Mgmt Transactional Business Island Perspective Rigid/Fixed Operations Product Management Real Time Business Holistic Perspective Agile Operations Safety and Reliability Sustainability Geographic Balance

3 Sound Familiar? I m losing production time to unplanned downtime Trouble meeting production commitments Too much paperwork Work Orders Requests and Execution process on paper Continuous Improvement Initiatives are necessary (Six Sigma, etc.) Increasing maintenance cost, out of control Lack of key decision support information Not meeting daily schedule Unplanned downtime due to equipment failure High cost of expedited equipment ordering and delivery Premature failure of equipment

4 Can traditional maintenance software products truly contribute to the performance of the plant and ultimately to the performance of the business? A new holistic business approach to managing plant assets to drive business value.

5 The Key Areas of Focus Impacting Client Profitability Environmental Excellence Productivity Excellence Minimizing environmental impact while increasing profit Minimizing emissions from industrial assets Reducing waste from industrial assets Relieving environmental constraints on business value Maximizing profitability with existing resources Maximizing production value & agility Enabling worker productivity & collaboration efficiencies Minimizing variable cost impact of plant operations Asset Excellence Control /Safety Excellence Maximizing the profitability from industrial assets Maximizing reliability of critical plant assets Maximizing operational performance of critical plant assets Maximizing the profit contribution of critical plant assets Sustaining/improving plant safety while increasing profit Sustaining & improving plant safety Reducing impact from unsafe plant conditions Relieving control & safety constraints on business value

6 Asset Excellence Maximizing the profitability from industrial assets Increased demand to better manage all the assets in an organization Strong push to increase production capacity, at a reduced cost, and with a positive effect on safety and the environment.despite aging assets and shrinking workforce

7 Asset Excellence IOM s Definition of Asset Excellence Maximizing enterprise profitability by balancing effective availability and utilization of all assets. Physical, People, Process.

8 Asset Excellence Maximizing the profitability from industrial assets IOM strength is the ability to combine our experience and broad range of offerings to transform diverse sources of asset data into a single, real-time view of overall asset health to enable support of production goals Increase visibility of actionable information, not just data but contextualized information Improve timeliness of actionable information, Last month, last week not good enough

9 Asset Excellence Business Goals Create Production Value Reduce Energy Consumption Reduce the Cost of Materials Creating Economic Business Value Improve Safety Improve effects on the environment

10 Business Drivers Increase Equipment Availability Improve Equipment Utilization Increase maintenance productivity Lower overall materials costs & reduce MRO inventory

11 Solution Stack IOM strength is the ability to transform diverse sources of asset condition data into a single, real-time view of overall asset health to enable support of production goals. Getting the right information to the right people at the right time. EAM CM Mobility Visualization

12 Enterprise Asset Management coupled with Condition Management

13 Enterprise Asset Management The Avantis Enterprise Asset Management (EAM) solution and our extension offerings form the core of our Asset Performance Management (APM) solution set. This solution provides maintenance management, spares and inventory management and a complete procurement capability. When coupled with the powerful Condition Management, Invensys is uniquely positioned to offer customers real-time answers to help reduce costs while continuing to maximize asset reliability and performance. The overall APM solution set helps customers to realize outstanding return from all their assets people, processes and equipment, thereby enabling true Asset Excellence.

14 Avantis Enterprise Asset Management Proven World Class EAM Solution Over 25 years in the business Over 700 customer sites around the world Complete Asset Management Solution Set Software components Professional Services with proven InRIM Methodology Comprehensive Real-time Solutions Open integration standards Predictive and Condition Monitoring

15 Comprehensive Offering Fully functional competitive product consisting of; Maintenance MRO Inventory Control Procurement Approval Advanced Scheduling Mobile Applications Supply Chain Collaboration module GIS Integration Decision Support Condition Management

16 Inalum 600 Megawatt hydropower and aluminum smelter plant Power plant and smelter with 130 concurrent users of Avantis Using all modules with plan to integrate to Microsoft Dynamics Using KPI dashboard produced from Avantis to drive business processes and react in timely manner to variance from plan Invensys delivery methodology ensured coordinated efforts of Production, Maintenance, Procurement and Inventory towards meeting company objectives Reduced spares inventory from 36ml to 16ml and increased ability to provide parts when required Integrated spares cataloging software and bar-coding Slide 16 Invensys 00/00/00 Invensys proprietary & confidential

17 Invensys Approach Condition Management

18 Vectren Vectren Corporation (NYSE:VVC), is a progressive energy-holding company headquartered in Evansville, Indiana Delivers gas and/or electricity to more than one million utility customers in Indiana and Ohio Challenge Streamline Maintenance work and Equipment processes Drive down the cost of unplanned work

19 Condition Based Maintenance - BEFORE Over 15,000 separate equipment readings archived in Honeywell PHD data historians at two power plants. Vibrations Temperature Hours RPM s Gallons Temperature Data Historian

20 Condition Based Maintenance - AFTER Page Readings Work Request Work Order Data Historian Condition Manager

21 Vectren Today Continuous improvement of operations and services Better preventive maintenance and scheduling Planning work ahead not driven by emergencies Tracking metrics such as: Productivity of workforce, Reasons for downtime Reasons for delay Enables Reliability Centred Maintenance Slide 21 Invensys 00/00/00 Invensys proprietary & confidential

22 Invensys Approach - Operational Work Advisories Operator Visibility into Maintenance Operator sees work status, scheduled date, and priority in HMI screen Lets Operator know if Maintenance is already aware of important alarms If repair is W.I.P., Operator is aware Improves Productivity Less haggling between Ops & Maintenance Allows Ops to request escalation of priority or change of scheduled start date where necessary

23 Preventing Equipment Failure Detect Health Degradation in Equipment Equipment problems automatically detected from condition monitoring without manual inspections Detect primary failure indicators, avoid secondary failure Work Notification automatically created based on rules, template based Alarm details fed directly into EAM Work Order based on Rules Prevents Failure, Reduces Unnecessary Maintenance Reduce unplanned downtime Increase Equipment Life Maximize Equipment Performance

24 Mobile Workforce

25 The Traditional Approach Paper Based Too Late Failure!!! Hours Later Slide IPS North America Client Conference

26 Integrated Capabilities System Administration Super Users Mobile Workers User Administration, Device Management System & Data Center Management Procedures Versioning Scheduling Operator Rounds Data Collection Work Requests Minutes not hours, equipment saved Management Supervisors Enterprise Integration Exception Reports Process/Performance KPI s Notifications Round/Route Approval Performance Monitoring Exception Management Shift Handover/Logs Maintenance Management Solution Process Historian OSI PI, AspenTech

27 Improve Asset Availability through Operator Driven Reliability Manages the processes and procedures to ensure that organizations consistently execute all field tasks required to achieve reliable operations. provides a Task Management and Performance Monitoring System providing stewardship and accountability. provide contextual information and user guidance to help drive reliability and improve performance tightly couples enterprise applications with field workers and actionable tools to implement and sustain reliable operations

28 Improve Asset Availability through Operator Driven Reliability Display necessary procedures and inspection rounds for each operator Prioritize Equipment Maintenance activities Direct operator actions in the field Collect feedbacks from field operators Condition based actions

29 Mobile Workforce Operations Rounds Start-up and Shutdown Procedures Maintenance and I & E inspections & data collection HSE safety and environmental rounds Security - Rounds Learning mobile learning on-the-job QA time stamped lab samples

30 Transform Your Work Processes Low Performers High Performers Paper based Work Processes Automated Work Processes with Accountability & Stewardship

31 Visualization with Context

32 Connecting Plant Floor to Boardroom Enterprise Management Avantis.DSS Business Intelligence, Digital Dashboard Maintenance and Production Management Avantis.PRO Work Management, MRO Supply Chain Controls Real Time Plant Management Avantis.CM Multi Variable and Advanced Model Based Equipment, System and Process CM Avantis Adapter Set Standard Integration Modules and Comprehensive ToolSet Avantis.DATAPILOT Data Management - Data Extract, Load and Mass Change Engine

33 The Challenges Aggregation Management & Executive need higher level views All assets are not created equal Similar assets are used in different operations Health of assets groupings not easily defined Generates further needs for Asset Management context Hierarchy, Criticality Visualization to be both rich and intuitive Slide 33

34 The Challenges Scalability More and more assets are somehow instrumented Sites with 250,000+ assets are not uncommon Thousands of positioners, pumps, motors Real-time systems generate huge amounts of data for each asset Yes... more needs Capability to deploy many like assets - Template Asset Management context Prioritization & Criticality Asset Visualization needs to aid navigation & discovery Slide 34

35 IOM Asset Intelligence - Visualization Slide 35

36 EYESim Immersive Virtual Reality Plant IMMERSIVE VIRTUAL REALITY PLANT is a comprehensive solution linking Control Room Operators..... by means of high fedelity Process Simulation and a Virtual Walkthrough Plant Environment for a complete: PLANT CREW TRAINING...to Field Operators.....to Maintenance Operators.. Invensys proprietary & confidential

37 Value Delivered EAM & CM Consistent Best Practices execution and compliance Enhanced Asset Responsiveness Drive changes to Operator Actions Based on Regulatory/Market Conditions. Mobility Operator Driven Reliability Asset Availability Mobile Learning mitigate impact of workforce turnover Visualization Immersive Walkthrough Training and plant Simulation Continuous Improvement Eliminate Paper, Reduce Errors, Deploy Changes Quickly

38 Invensys Operations Management takes a unique open and holistic approach to help you achieve maximum profitability Real Collaboration. Real-Time Results TM