Communication Methods for Successfully Executing a PdM Program with a Geographically Diverse Team. Ken Piety MARCON February 2013

Transcription

1 Communication Methods for Successfully Executing a PdM Program with a Geographically Diverse Team Ken Piety MARCON February 2013

2 Traditional Models: In-House & Outsourced Traditional in-house and outsourced programs bring people to machines for data collection and analysis. In-House Buy your own equipment Train your personnel Small team in shared or neighboring offices Information exchange is often verbal Outsourced Depend on supplier to provide equipment Contracted personnel setup program and make periodic visits to the plant to collect for analysis Contracted personnel has other customers and his own boss Information is exchanged both verbally and in written reports 2

3 Problems Faced by Traditional Models In-House Program Costs: Fixed staff and expenses Sustainability: Vulnerable to loss of expertise Variability in available expertise Limited information visibility Outsourced Program Costs: Travel is expensive and non-productive Variability in available expertise Limited coverage between visits All program data may reside on one person s laptop 3

4 A Better Way? Can we reduce costs and improve accuracy, effectiveness, and sustainability? Key Features Needed: Assign necessary program functions to those who can execute the tasks at lowest cost and with greatest effectiveness. Bring data to the people who need it, when they need it. Reduce vulnerability from loss of critical talent. Improve communications within the plant and across your corporation. Start up programs faster at a lower cost, with little or no capital expenditure. Enable scalability to grow or shrink the program as needed. 4

5 Distributed Model Separates data collection and diagnostics to reduce onsite time and enable comprehensive coverage via geographically diverse teams. Visiting personnel set up the program and train onsite staff. Onsite personnel collect data. Onsite personnel plan and perform maintenance. Offsite personnel monitor and analyze machine conditions and recommend corrective actions. This model could be executed entirely by your own staff or with the help of an outside service company or some combination of the two! 5

6 Communication: Key Stakeholders & Activities Can stakeholders and activities function separately, yet ensure information does NOT fall through the cracks? Data Collection Data Analysis and Machine Health Reporting Maintenance Planning and Performance Program Management Plant and Corporate Management 8

7 Information paths must be bi-directional and insure delivery to the point of use Data Collection Analysis Management Maintenance Planning and Execution

8 Virtual Diagnostic Center Virtual Diagnostic Center + Team of Experts + State-of-the-Art Communication Key Features Needed: A physical data center accessible anywhere in the world via the Web. Hardware and software with advanced data communication abilities. Deep bench of analysts with diverse expertise. Advanced Tools: Database Replication Diagnostics Presentation of information via a secure Web Portal Operational infrastructure linking pieces together. No information is lost at distant locations Closed-loop communication connects all team members 10

9 Virtual Diagnostic Center 11

10 Data Center Benefits Centralization: All PdM data accessible to multiple users. Collaboration: Collaboration between analysts results in better diagnostic accuracy. Integration: PdM is accessible to other business systems, thus supporting data exchange. Transparency: The more people who see PdM information, the more valuable it becomes. Communication: alerts, text messages, and/or automated phone calls notify individuals of specific events. Participation: Others can gather data, contribute knowledge, and record observations. Optimization: The right people perform each function at the lowest cost. 12

11 What Does the Data Center Bring to the Equation? High Availability of IT Infrastructure Maintenance and upgrades with zero downtime Redundant systems with automatic failover Power and data backup systems Easy Access Anywhere, Anytime Data and applications are hosted and just a login away Access from mobile devices Especially advantageous when traveling Secure Data Latest Releases of Software Applications Reduced, Predictable Costs No Capital costs Reduced Startup time and costs Reduced operating costs due to shared resources 13

12 Why Organization are Moving to the Distributed Model Declining population of machinery analysis experts. Analysis and diagnostics are the most technically challenging activity in a vibration PdM program. Analysis is labor intensive for both portable and online systems. Difficulty retaining analysts. Takes at least two years to train a new analyst. Limited number of analysts are experts on all types of machines and faults. The ROI for any PdM program is directly related to accurate and timely assessments of equipment health. 14

13 Communication is Key Barriers to movement of data and information have been overcome. PdM applications no longer need to be isolated on laptops and desktops with limited connectivity to other plant or corporate systems. Communications infrastructure and mobile devices have shrunk the world, and radically changed both our personal and business lives. Virtual operations can thrive if the right tools and methods are available to prevent information loss between distant participants. 15

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18 Database Replication Replication allows data to be shared between separate copies of the same database. Many physical connection topologies are supported: Two standalone computers. These computers do NOT access the same network. They require a direct cable connection or removable media device (such as USB thumb drive) to communicate. Across a Local Area Network (LAN). Both computers have access to the same LAN. Across a Wide Area Network (WAN). Both computers have access to a File Transfer Protocol (FTP) site. Across LAN and WAN. This configuration is used primarily when there are multiple remote databases, some with LAN and some with WAN access. The master database must have access to both to be able to communicate with each of the remove databases. 20

19 Replication Synchs Remote & Master Databases Replication Initiated from the Master Database MASTER MESSAGES Folder Replication Initiated from a Subscription Database MESSAGES Folder SUBSCRIPTION 21

20 Data Exchange Methods: File/FTP/Both Replication can use a File-based and/or FTP-based data exchange method. Method used depends on whether the Master and Subscription databases are on the same Local Area Network (LAN) or whether they need to communicate via an external FTP site. File: Use when the Master and Subscription databases are on the same LAN. FTP: Use when the Master and Subscription databases need to communicate via an external FTP site. Both: Use when there are multiple subscription databases and some are on the LAN and others require communication via FTP. 22

21 Replication Cycle Results Replicated portions of the database are identical at all remote database locations. Selectable by database, plant, or area. All information is synchronized to the latest changes. Database Setup Measured Data Automated Expert System Results Reviewed Report by Analyst 23

22 New two component analyzer design uses rugged commercial tablets or smart phones Where do we go with Trio analyzers? Win 7 Ultimate PC Tablet Computers

23 Analyzer Desktop 25

24 Analyzer: Navigation Layout 26

25 Analyzer: Expert System Results 27

26 Analyzer: Data Collection Options 28

27 Analyzer: Expert System Results 29

28 Detailed field notes can be constructed to document the state of the machine under test 30

29 The note can clearly identify the physical location of concern 31

30 Observations can be documented by typing in free form notes 32

31 Maybe a sound recording or voice note would better communicate the concern 33

32 Perhaps a picture or video recording would be more helpful for the analyst 34

33 Routine data may need to be supplemented with special test measurements 35

34 Any special test measurement taken will automatically generate a note 36

35 Analysts can communicate with the field tech by attaching Requested Action to a machine 37

36 Requested Actions must be reviewed and acknowledged by the field tech 38

37 Analysis Software: Diagnostic Report 39

38 Analysis Software: Data Review 40

39 Analysis Software: Report Editor 41

40 Analysis Software: Event Tracker 42

41 Portal: Dashboard 43

42 Portal: Plant Summary View 44

43 Portal: Recent Reports 45

44 Portal: Machines by Severity 46

45 Portal: Machine Status View 47

46 Portal: Event Tracker 48

47 Portal: Recommended Action Event Case History 49

48 Accepting Change: Moving to a New PdM Model I prefer to stay with the traditional approach I have been using. That is OK, until Your analyst leaves or retires. You need to expand your program. Your program funding is cut. You need to buy new tools. Your corporation wants consistency at all sites. Innovations in PdM program design and communication tools will change how we do our jobs for the better! 50

49 Thank You! Kenneth Piety VP of Technology Azima DLI Phone: