Tango Strategic Equipment Management Software Package

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1 Tango Strategic Equipment Management Software Package The Tango software package and the resulting Strategic Equipment Management program implementation provides a high value in increased plant profitability and a rapid payback typically far exceeding cost even in the first year of implementation. Tango s benefits fall into three categories: Reduce the Cost of Unreliability Tango identifies unreliable equipment and locations, links the cause of failure, cost of failure, and age to failure together; and focus the plant s reliability attention on needed improvements. Manages Plant Equipment Strategically for Lowest Life Cycle Cost Provides the basic foundation for tracking assets and their movement through operating locations, stores, and repair/overhaul facilities. Tango provides the ability to know where a piece of equipment is located, find similar equipment, and manage the repair and overhaul of equipment. Increase the Effectiveness of Predictive Condition Information and Repair Planning Tango integrates all of the repair and condition information known about unreliable equipment and locations. Tango then communicates this information to plant maintenance and management such that countermeasures and repair/replacement decisions can be made. Integrated Condition Manager - Condition Entry - Assignment of severity - Attached backup documents - Web based reporting - Decision support Integrated Condition Report Technology Status Report TANGO Functions Equipment Inventory - Receive new or overhauled equipment - Install at a location or in spares inventory - Search for spares in plant or at motor shop - Track equipment sent out for repair - Searched documents - Nameplate design and data Asset Database Equipment Manager - Asset History - Location History - Root Cause Patterns Asset Repair and Problem Entry

2 Tango Equipment Inventory Module Tango Does the Basics Well... The basic foundation for performing equipment and condition management requires the development of an inventory of the plant s critical locations and equipment. It is important to track both locations and equipment as problems can be specific to a machine, a class of machines, a location, or a group of locations. Also locations and equipment must be tracked independently because equipment often moves in and out of locations. Features of the Tango Inventory Module Include: Find a component in it s installed location or in spares. View the nameplate and design data. Send machines for repair. Track machines that are out for repair. Find a replacement machine. Attach machine information such as drawings, procedures, and reports. Search for machines with a specified set of design properties.

3 Tango Equipment Management Tango Benefits Tango identifies unreliable equipment and locations. Tango also provides a detailed record of both equipment and location history. Links critical reliability information: o Cause of failure. o Cost of failure. o Age of failure. Utilizes equipment overhaul shops to input failure and repair information. The Tango equipment management package allows the reliability engineer along with plant maintenance management to identify unreliable locations and equipment. Tango helps the reliability engineer prioritize which reliability problems will return the most profit benefit to the plant which helps measure the resulting savings from reliability improvement. Tango works in conjunction with the plant s CMMS system and your equipment overhaul shops to make information entry easy or automated. This allows valuable reliability information to be obtained with very little additional work by plant personnel. Tango warns the user of failures under warranty, failures with low service life, and locations with rapid or repetitive failures with each machine removed from service. In addition, Tango provides an analysis of reliability by plant, building, function, asset, and component such that areas of high repair cost lead the list and the user can drill down to specific location and equipment failure details. Provides management of out for repair equipment. Provides design data for each equipment type. Allows the attachment of supplemental documents, drawings, and photographs for designs, equipment locations, and repairs. Search capability allows you to find a similar group of equipment or very specific equipment, depending upon the extent of the search parameters. 3

4 Tango Equipment History Report Click paper clip icon to view design attachments. Drawings Service bulletins Manuals Click on the line to unfold equipment design data. Click to view repair shop rep ort. Click on the line to unfold location and cause of failure information. Click to provide purchase and design warranty details.

5 Tango Location History Report Click to unfold equipment design information

6 Tango Equipment Manager Functions Attachments The paperclip icon means there are attachments available for the item selected. Attachments are typically items such as photographs, drawings, manuals, reports, data tables, etc. Tango allows attachments to be linked to designs, specific equipment, locations, repairs, and condition entries. Send For Repairs Search With Tango, users may search the entire plant inventory for any machine in the database. In the example below; a search is being conducted for an AC Motor with a 365T frame size. The search will return every AC motor in the database that has 365T and related frames. Users may further narrow their search by entering additional search criteria such as manufacturer names, model number designations, horsepower, RPM, and voltage. If you are searching for a specific machine, you may enter the plant tag and/or serial numbers of the machine you seek. The send for repairs function allows the users to send a failed machine out for repairs, set up the reason for repair, and provide all the purchase information for the repair. Tango facilitates the partnership relation with repair shops, allowing them to enter failure findings, repair actions, cost, and reports through a remote file transaction feature. Out For Repairs Management The out-for-repair list gives you a complete list of the machines that have been sent to repair shops, their status, and when they are expected back from repair. This provides users with the ability to plan ahead and plan maintenance actions around expected machine delivery.

7 Tango Condition Manager Program Integrate, Organize, and Communicate Predictive Maintenance Results Oil Thermogr aphy Vibration Electrical Ultrasonic The Tango Condition Manager package allows each predictive maintenance technologist to input their knowledge and recommendations about a degraded machine. Tango then integrates all of the technology condition information and presents the status to the plant through the plant intranet. Electrical Process Plant maintenance personnel will receive through the plant intranet a status report of all degraded machines within their area and trigger the repair work order. Tango also allows reliability engineers to examine the past failure cycles of the machine or location to identify unreliability and possible root causes of the problem. WEB

8 Tango Condition Manager Specialized Reports Maintenance supervisors, planners, reliability engineers, production, engineering, and plant management need to know the condition of machinery in order to properly operate and manage the plant. Tango Condition Manager compiles and presents this information through the plant intranet making current machinery condition information available in reports tailored to each type of user. The Measurement Overview report allows the user to examine the complete condition analysis for the machines in a selected region. The report provides all the measured machines and the status of all the condition technologies presented in a spreadsheet format that will show whether a fault trend is developing for a piece of equipment. By clicking on a technology the user can review details of any problems that is reported. Trend data is shown in the following manner: Represents a downward trend. Represents a flat trend, or a history that does not show any change. Represents an upward trend. Shows that no trend has developed yet for that piece of equipment. For most plants, the maintenance planners prioritize the maintenance work, write the work orders, and assure work order closure. The maintenance planner s report provides to the planner the information they need to write the work orders and provides a mechanism for them to alert the condition analyst that work has been completed and that condition validation should be performed.

9 Tango Integrated Condition Report Pie chart provides an analysis of the number of each machine s severity in the user s area. Index to rank the severity of the problem and the number of technologies in red condition. Click the severity index to view the condition technology details supporting the Integrated Condition Report. Color-coded severity indicators (red, yellow, blue, green). Listing of equipment that is down and unavailable for production. When this button is activated it indicates that plant maintenance has completed it s work and the equipment needs condition validation from the technology analyst.

10 Tango Location Technology Status Report Click to find attachments for technical support such as trend plots. Status check-off allows plant maintenance to enter corrective actions. Location and equipment condition histories provide all previous closed condition information. Corrective action taken. Two technologies are reporting condition problems on the component location.

11 Tango Send for Repair Tracking Functions to out-of-plant shops. Tango Repair shop form When a defective component is removed from service it must be scrapped or sent for repair. The above send for repair function allows the plant to note the reason for removal and where the equipment was sent for repair. Out For Repairs list Return to operations or stores

12 Tango Why Tango? 1. Making Informed Repair Decisions How long has the machine been in operation? How many overhaul cycles has is been through? What is the life of each overhaul cycle? What is the cost of a new component vs. a rebuild of the old? What is the cost of new vs. rebuilt components amortized over the expected life? Does the machine show accelerated failure patterns typical of a design problem? A full presentation of the above machine data allows the maintenance planner to make the correct repair decision. 2. Convenience and Time Savings Even if the above data is available in other plant information systems, it usually requires hours to retrieve and analyze the needed information. TANGO provides this information with a concise analysis in a matter of seconds. 3. Condition Presentation to all Plant Personnel TANGO allows a daily assessment of degraded plant equipment to be posted and viewed from any plant computer via a web browser. Plant area maintenance, operations, and management can be kept aware of potential machine problems which can affect productions. This allows a better team resolution problem avoidance. 4. Warranty Repairs In order to collect on a manufacturer s warranty the plant must know the purchase date and the install date of the machine. TANGO tracks this information and alerts you to a warranty claim. A Testimonial: A large continuous production plant changed their motor management procedure away from each operating area responsible for motor repair/replacement decisions to a single motor management function for the entire plant. Three years after the change in procedure was implemented, the plant s motor repair and replacement costs were reduces by 40%. These savings were gained from better repair costs realized by using a single motor repair vendor, a stronger new motor purchasing position, and a far more improved ability to make the proper repair or replacement decisions.