Presented by Reliabilityweb.com

Transcription

1 Presented by Reliabilityweb.com

2 Upcoming CRL Workshops Jan 30 Feb 3 Mar Apr May Reliability Leadership Institute Fort Myers, Florida More information:

3 Providers

4

5 Sponsors

6 WIRAM Series Next Generation Maintenance: The Journey from Calendar-Based Maintenance to Prescriptive Analytics by Rendela Wenzel, Associate Senior Consultant Engineer, Eli Lilly

7 Agenda Approach to Maintenance Redesign Next Generation Improvement Scope Improvement Opportunities Move from Time Based to Condition Based Maintenance Results Less maintenance can be the answer, smart maintenance is the answer

8 Next Generation Maintenance 2 Prong Approach Improvements Change equipment PM paradigm PM Intervals Equipment Usage Optimized Maintenance Job Plan Calibrations Spare Parts Evaluate shutdown and scheduling PdM Expansion Move from time based PMs to CBM by leveraging: PdM Technologies Historical/Process Control Data External Data Reliability to drive smart maintenance

9 Next Generation Maintenance Strategy: Scope: Targeted mechanical maintenance PM intervals for HEPA filters, valve elastomer, pressure safety valves, HVAC inspections, rupture disks, diaphragms, heat exchanger inspections Calibration PM intervals for pressure, flow, temperature, DP, level, humidity PM Reliability Process Expansion Move from time based PMs to CBM by leveraging: PdM technologies Historical/process control data External data Drive to smart maintenance Optimized PM frequencies for process instrumentation Develop optimized strategy with integrated planning and scheduling Rollout strategy and modify processes to support it Manage Maintenance CMMS Scheduler (planning and scheduling activities) New obsolete spare part process Job plan improvements Anywhere (mobile technology) Work flow management

10 Increase PdM Capability Leverage current technologies and expertise to increase overall PdM, determine current usage and determine new baseline Determine best CBM technology Minimize intrusive PMs and move toward less intrusive smart PMs PdM technologies evaluated for global needs and capabilities Vibration, IR, Oil Analysis, Ultrasonic Develop global implementation strategies and action plans

11 PdM Progression Reactive Maintenance

12 PdM Progression Preventive Maintenance

13 PdM Progression Predictive Maintenance with Established Limits Next Generation Maintenance

14 Next Generation Maintenance In the current absence of sophisticated algorithms or mechanistic models for equipment, an emerging approach uses Advanced Pattern Recognition Many tools are occupying this space. Here are some examples (to review capabilities)*: Emerson AMS Suite Mtell Previse

15 Global CBM Capability - Diagnostics & Analysis Vibration Analysis Oil Analysis Lubricants Chemical Properties Contamination Wear particles Infrared Thermography Fault Types Misalignment Imbalance Bearing Defects Gear Defects Looseness Belt Drive Problems Electrical Problems Cavitation Motor Current Analysis Current Signature Rotor bar health (induction motors) Stator faults Thermal Maps Electrical Shorts Wiring Faults Insulation breakdown Heat Buildup Mechanical Wear

16 CBM Model

17 PM Quadrant Update Site monthly meetings Data analysis, site implementation strategy, resource requirements, site concerns Data analysis on each equipment type Gather global data from sites Job Plan optimization, global roll-out Global library for equipment types developed for Global Delivery

18 Reliability CBM Expansion Quadrant Update Leverage current technologies and expertise to increase overall PdM usage from current 2% baseline to 11-15% Determine best CBM technology (Mtell, SCHAD, AMS) Minimize intrusive PMs and move toward less intrusive smart PMs Global PdM technology capability analysis Assessed needs and capabilities to include personnel and equipment All PdM technologies included (Vibration, IR, Oil Analysis, Ultrasonic) Communication of user requirements and site pilot development Pilot to begin in March 2017

19 Next Generation Maintenance Status and Next Steps Discovery Phase Site initial meetings Development of global equipment lists Analyze Phase Analyze site data Group data into subsets to analyze

20 Communication Forums Weekly Data analysis and project update Monthly: Corporate meetings to communicate with sites Quarterly Corporate Reliability Forums Ad Hoc Network meetings and site meetings as requested

21 Metrics SMRP Benchmark Stocked MRO Inventory Value per RAV% [Stocked MRO Value($) x 100]\RAV($) World Class Benchmark.3% to 1.5% Total Maintenance Spend % RAV World Class Benchmark < 3% RAV to craft wage headcount ($) RAV ($) / Craft wage headcount World Class Benchmark $8,000,000 to $9,000,000

22 Site Progress, Effort, and Benefit

23 Results Developed global calibration and mechanical inspection strategies Calibration frequencies optimized by an average of 70% Mechanical frequencies currently being optimized by an average of 50% Mechanical job plans currently being optimized by an average 40% Spare parts reduction currently being optimized by 25% Less damage to equipment Less overall deviations Improved safety due to less LOTO and maintenance activities More uptime/capacity Decreased labor, increased PdM and non-intrusive maintenance

24 Contact: Rendela K. Wenzel, CMRP Consultant Engineer, Global Plant Engineering, Maintenance, and Reliability Eli Lilly and Company Lilly Technology Center - North, Indianapolis IN U.S.A (office) wenzelrk@lilly.com

25 Manufacturing Analytics

26 Missing Critical Data Lack of Factory Knowledge Disconnected Systems Point Solutions Lack of Connectivity

27 Complicates Lean & Reliability Projects Poor Customer Experience Slows Reaction Times & Ability to Correct Reduced Margins

28 The manufacturers we talk to have a BIG problem Inefficiency could be costing as much as 50% of the bottom line. Equipment data is not being captured Staff is not capable of collecting, interpreting, and using the data Current analytics solutions are too complex and too expensive They look at machines/work cells manually or one at a time

29 Sensors, Production Lines & Machines

30 Single Contextualized View OEE Root Cause Analysis Availability Utilization Capacity Etc..

31 Holistic View Device Sensor Line Plant Multi-Plant

32 Analyze By Date Facility Department Shift Team Cell Part Job Machine or Device

33 Time to Value ROI in Months 1 Week to Implement 30 Days to Value 30% Avg. Increase in Efficiency

34 Contact SensrTrx Bryan Sapot President

35 Learning Wireless Sensors for Predictive Maintenance Abhinav Khushraj Co-founder

36 Petasense company background Founded 3 years ago Backed by the same investors that backed Fitbit to IPO Traction in power generation, food processing, facilities and pharmaceuticals Abhinav Khushraj Technology & business leader at Nokia, Citrix. Founded 2 startups. Passionate about wireless and data science. MIT alum. Arun Santhebennur Serial entrepreneur in SaaS and speech recognition technology. Founded Resolvity and VoiceGain. Worked at Deloitte. Passionate about math based problems. IIT alum.

37 What is Petasense? A simple easy-to-deploy end-to-end wireless Predictive Maintenance system 1. Petasense Vibration Mote 2. Petasense Cloud 3. Machine Learning Based Analytics

38 How does it work? Petasense Motes WiFi Access Cloud Machine learning Web and Mobile

39 What kind of machines can we monitor? Motors Pumps Gearboxes Chillers Compressors

40 Petasense case studies Combined cycle power plant in California Petasense Motes monitoring water feed and condensate pumps. A single detected fan failure saved $500,000. University Central Energy Facility Over 100 motes monitoring 25 critical chillers. Problems incl. misalignment were detected. Tomato Processing Plant Petasense Motes monitoring over 30 evaporator pumps and pulper finishers.

41 Metrics of Petasense deployment > 400 Petasense Motes installed >1,000,000 Tri-axial vibration readings >510,000,000,000 Bytes of data analyzed by Petasense machine learning algorithms

42 Thank you! Abhinav Khushraj Co-founder

43 Educational Session Developing Your Business Case for Reliability & Maintenance Improvement Made Simple by Susan Lubell, Steppe Consulting Inc.

44 Agenda Framework approach for establishing your strategic asset management & reliability plan Establish a baseline: "know where you are Define where you re going Who needs to be involved Measuring progress and results Essential elements for success

45 Destination? Without a map, the only place that you ll be is lost..

46 Financial Strategy People Strategy Operations Strategy Asset Management Strategy Corporate Strategy Corporate Strategy

47 Maturity Assessment As Is

48 Maturity Assessment To Be

49 Low Value High Prioritizing Low High Effort

50 Asset Management, Reliability & Maintenance Integration Economic and SHE&R Risk and Value Assessments Asset Tactics & Integrity Management Plans Enterprise Asset Management System Repair, Replace, Retire, Revise, Upgrade, Maintain Scheduling & Work Order Management Material Transfers, MoC, SCM Processes Program Optimization Production and Asset Data

51 Stakeholders Maintenance Operations Engineering Major Projects Supply Chain Management Accounting & Finance EHS & Regulatory Asset Integrity

52 Measuring Progress Criteria Scalable Maximum 3-5 Controllable Examples Costs to implement and saved / avoided Regulatory schedule compliance Equipment availability, reliability, uptime Consistently applied criteria for maintenance work priorities

53 Critical Success Factors Cultural & Stakeholder Engagement Senior management commitment Local champions Appreciating timelines to implement and realize tangible results Short, medium, long Start small and build success Communication

54 Agenda Framework approach for establishing your strategic asset management & reliability plan Establish a baseline: "know where you are Define where you re going Who needs to be involved Measuring progress and results Essential elements for success

55 Questions Susan Lubell P.Eng MBA MMP Steppe Consulting Inc.

56 Questions & Answers

57 Thanks to Our Sponsors

58 Next Webinar Date: Wednesday, February 8

59 Keynote To Be Announced by Will Tudoroff, Service Delivery Product Manager, SEC of America

60 Educational Session Elements of a Successful Condition Monitoring Program by Chris Colson, Managing Principal, Allied Reliability Group

61 Introducing Soluciones 2.0!

62 Save the Date! April 24-28, 2017 Las Vegas, NV For more information, contact:

63 We d love to hear your feedback! your questions or comments to sean@reliabilityweb.com

64 Thank You for Joining Us!