A 'New Approach' to Manufacturing with Asset Excellence Technology

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1 A 'New Approach' to Manufacturing with Asset Excellence Technology IntelaTrac - The industry's leading Mobile Workforce and Decision Support System. Our Speaker: Don Frieden Vice President of Mobile Solutions Invensys Operations Management Has more than 18 years of experience in the process industries. Before joining Invensys Operations Management, he founded SAT Corporation in 1995 and developed IntelaTrac Holds two patents in Radio Frequency Identification (RFID) tag technology Co-inventor of the Universal Tag Formatting Schema

2 A 'New Approach' to Manufacturing with Asset Excellence Technology IntelaTrac - The industry's leading Mobile Workforce and Decision Support System. Don Frieden, Vice President of Mobile Solutions Invensys Operations Management 2009 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

3 Agenda Basics of Field Force Mobility The Mobile Approach Discussion Summary Slide IPS North America Client Conference

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

5 IntelaTrac Enables Operations Management Process-oriented organizations drive value by improving their business processes and asset performance...our OIMS (operational integrity management system) is a means to help ensure that every operating organization has the resources, skills, systems, procedures, and tools to perform safely, reliably, and with environmental care..operations Task Management (OTM) is a systematic approach to HSE management designed to ensure compliance with the law and to achieve continuous performance improvement..the Operations Management System (OMS) has two purposes: to further reduce HSE risks in our operations and to improve the quality of operations

6 Extending Collaboration and Decision Support to Operations Management The 1990 s Operator The 2000 s Production Worker Roles Operations Engineering Maintenance Reliability & Safety Plant Mgmt & IT HMI Displays Information / Collaboration HMI Mobile Devices Web Based Reports KPI Dashboards PLC s Data Sources PLCs Databases Planning Systems Lab Systems Maintenance Applications Machines Production Assets Rotating and Fixed Equipment Lines

7 Managing People, Assets and Processes IntelaTrac enables companies to manage their stranded assets People Plants Processes Field Workers and Service Technicians Equipment / Machinery What they Make and Do 7

8 Capturing Stranded Data Typically 40-60% of assets in a plant are non-instrumented IntelaTrac solution is a necessity even in newly built, fully instrumented manufacturing plants 8

9 What Industry Challenges are Customers Facing? Many plants struggle for lack of clear operating priorities business management must define an operating plan share the vision hold employees accountable to execute the plan Customers struggle with the human performance elements and cultural change issues new ways to work new technology deployment real-time enterprises aging workforces

10 Transforming Work Processes Low Performers High Performers Paper based work processes without historized data Automated work processes with accountability and stewardship Mobility is not about collecting data---it is all about using technology to transform and optimize stranded assets (e.g. non- instrumented equipment, remote workers, and work processes management)

11 Addressing Human Performance and Cultural Change Issues IntelaTrac serves as a catalyst for implementing field worker best practices New work practices change behavior New behavior changes the culture IntelaTrac Workforce Management & Decision Support System: Accelerates process improvements Helps sustain process improvements Provides rapid hard dollar paybacks IntelaTrac has been declared a Global Best Practice by major Oil, Chemical, and Power companies.

12 Improve Operational Reliability and Asset Availability Operations Maintenance IT & Infrastructure

13 More Effective Use of Maintenance Resources Operations Maintenance IT & Infrastructure

14 Consistent IT Environment with Standard Resources Operations Maintenance IT & Infrastructure

15 IntelaTrac Mobile Applications Plant Safety Operator Driven Reliability Condition Monitoring Remote Decision Support Stranded Asset Management Paperless Maintenance Workforce Scheduling and Collaboration Integrated Business Process and Task Management Extends Condition Monitoring Offerings - Mtelligence Wireless applications will see greater deployment because of the ability to enable new and better ways of operating manufacturing plants. ARC Advisory Group 15 Invensys proprietary & confidential Invensys 18 June, 2010

16 Wonderware IntelaTrac Defined IntelaTrac manages the processes and procedures used to ensure that organizations consistently execute all field tasks required to achieve reliable operations. IntelaTrac provides a Task Management and Performance Monitoring System providing stewardship and accountability. IntelaTrac mobile applications provide contextual information and user guidance to help drive reliability and improve performance IntelaTrac tightly couples enterprise applications with field workers and actionable tools to implement and sustain reliable operations

17 IntelaTrac Applications and Integrated Workflow Capabilities Mobile Workers System Administration SuperUsers User Administration Device Management System & Data Center Management Procedures Versioning Scheduling Operator Rounds Data Collection Work Requests Management Supervisors Enterprise Integration Exception Reports Process/Performance KPI s Notifications Round/Route Approval Performance Monitoring Exception Management Shift Handover/Logs CMMS / Reliability D7i, JDE, Maximo Process Historian PI, InSQL, etc.

18 Enabling Intelligent Workflow Linear Procedures VS IntelaTrac Mobile Workflow Approach Task Specific Decision Tree Check Pump Oil Condition Good OR Bad YES? NO Predefined Decision Predefined Trees By Role, Decision Process, Predefined Trees TaskBy Role, Decision Process, Trees TaskBy Role, Process, Task Decisions IF OIL GOOD GO TO NEXT TASK ADD OIL THEN GO TO NEXT PUMP CHECK TEMP Good OR Bad SHUTDOWN THE PUMP

19 Advance Scheduling and Workforce Management Schedule Manager advanced scheduling and Calendar view of Procedure management Crew Setup support for scheduling to rotating shifts Auditor Plus Enhanced procedure audit and reporting Mobile IntelaTrac On- Demand procedure management including Workstation IntelaTrac

20 Work Process Review and Approval Rounds are Reviewed & Approved Daily by Appropriate Person Provides Supervisors with Easy Access to As-found and As-left Data Displays Equipment and Process Deviations Historical Reading are Displayed for Trending and / or Further Troubleshooting

21 Shift to Shift Communication & Relief Notes Log Book Entries Are Available to Field Operators Pick Lists are Provided for Field Operators to Improve Data Consistency and Ease of Data Entry Electronic Log Books Provide Shift Supervisors and Field Operators with Common View of Shift Relief Notes

22 IntelaTrac Value Proposition Ineffective Manufacturing Decisions Process Personnel IntelaTrac Operational Experience Effective asset management Data collection, integration, and analysis Management of SOP s and best practices Regulatory compliance and environmental monitoring Process efficiency Quality control and accountability Organization effectiveness Job performance Field force training and on the job training Field Force Enablement

23 Typical Benefits Case Key Performance Indicators % Improvement Key Factors Production Efficiency 0.5-1% Reduction in production downtime/slowdowns Reduced Maintenance costs on select list of assets** Increased Workforce Productivity Training, Knowledge Management, Permitting Production Arbitrage Energy Management & Real- Time Optimization 25-30% Predictive maintenance of rotating equipment and assets in harsh environments 5-10% Electronic paperwork, transfer of some PM to Operations 5% Improved training processes, improved best practices, reduced mean time to permit TBD Improved decision support with access to noninstrumented data and instant messaging to field ** 1-2 % on total maintenance budget for all assets in company budget

24 Case Study - ExxonMobil ExxonMobil declares IntelaTrac an enterprise-wide Best Practice IntelaTrac Applications Safety inspections Maintenance PM items Process inspection Work order request Process safety management Drum/tower level checks Environmental checks Equipment pressure drops Asian Refinery reports an 88% reduction in pump failures in the first year for a savings of $500,000 on this asset category California Refinery reports 66% reduction in costs of seal replacement U.K. refinery, saved over $175,000 in the first year on maintenance costs alone

25 Case Study - Chevron Using IntelaTrac to accelerate and sustain process improvements, Chevron has reduced maintenance costs, improved availability, and achieved cost effective regulatory compliance. Mike Brooks, Global Refining IT Adviser, Chevron The Challenges Chevron wanted to improve refinery performance and reliability, reduce maintenance costs, and simplify regulatory compliance. It was also eager to document the knowledge of workers approaching retirement. The Solutions Chevron is using Windows Mobile devices running Microsoft software and the Wonderware IntelaTrac field automation software to standardize refinery process steps and deliver decision support to field workers. The Results Yielded significant payback from improved refinery reliability, reduced maintenance costs, better knowledge retention, and improved environmental compliance. The company estimates cost reductions of $3 million to $5 million annually across eight refineries.

26 Case Study Valero Energy Initial Project in 2002 Focused on driving reliability process improvements Operational Excellence savings on over $2M / site Expanded to accelerate additional process improvements (HSE compliance and Energy Optimization Today IntelaTrac is Valero standard and deployed across 12 refineries IntelaTrac system is mission critical for regulatory compliance (OSHA PSM and EPA Title V) Significant increases in field workforce productivity (3X improvement documented at some sites) Site documentation (DCR) over past 4 years, the introduction of IntelaTrac has yielded 99.5% completion of scheduled rounds AVERAGE # OF ROUNDS COMPLETED MONTHLY # Rounds per 1- Danger Alarm MONTHLY AVERAGE YEAR # Rounds per 1- Danger Alarm Sources: -Valero; 2007 NPRA Q&A and Plant Automation and Decision Support Conference, Austin, Texas --Valero; 2006 ERTC Asset Maximization Conference, Vienna, Austria

27 Integration with System Platform

28 What Does Success Look Like? Institutionalized work processes Lifts performance of all workers Integrated messaging drives instant changes Integrated remote data Auditable regulatory compliance Model for progress

29 Bluetooth Support and Integration with Peripheral Devices Infrared Temperature Guns Pyrometers Vibration Probes Non-Destructive Test (NDT) RFID Adding: GPS Acoustical Monitoring

30 Global 1000 Client Base

31 Summary IntelaTrac supports best practices delivery and incorporates work flow and mobility IntelaTrac provides a common field user interface for tasks delivered from multiple Systems of Record IntelaTrac has an extensible integration framework IntelaTrac extends existing work processes Slide IPS North America Client Conference

32 Thank You! Question & Answer Thank you for your participation! If you have further questions, do us at Invensys and the Invensys logo are trade marks of Invensys plc

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