CITECTIIM DOWNTIME MONITORING WHITEPAPER

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1 CITECTIIM DOWNTIME MONITORING WHITEPAPER Abstract: A business paper which considers how Downtime Monitoring provides major services revenue opportunities for Systems Integration work involving productivity data collection and web-based reporting. 1 CitectIIM Downtime Monitoring Whitepaper

2 About the Authors This document was written by Tony Watkins, Applications Manager, Industrial Information Management, and Peter Long, General Manager, Applications Engineering, Citect Pty Ltd. About Citect Celebrating its 30th anniversary this year, Citect is a global business solutions provider and leader in industrial automation and information management. Its CitectHMI/SCADA and Plant2Business software and industrial information management (IIM), analysis modules are complemented by professional services, customer support and training. These solutions are enhanced by strong partner programs and are sold in numerous industries, including food and beverage, pharmaceuticals, mining, water and waste water, facilities monitoring, gas pipelines and power distribution. Citect is headquartered in Sydney Australia, has 17 offices in Australia, USA, Europe, China and Africa, and its products are distributed in more than 50 countries worldwide. For further information, visit Citect Pty Ltd. All rights reserved. The information contained in this document represents the current view of Citect on the issues discussed as of the date of publication. Because Citect must respond to changing market conditions, it should not be interpreted to be a commitment on the part of Citect, and Citect cannot guarantee the accuracy of any information presented after the date of publication. This white paper is for informational purposes only. CITECT MAKES NO WARRANTIES, EXPRESS OR IMPLIED, IN THIS DOCUMENT. Complying with all applicable copyright laws is the responsibility of the user. Without limiting the rights under copyright, no part of this document may be reproduced, stored in, or introduced into a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) or for any purpose, without the express written permission of Citect Pty Ltd. Citect may have patents, patent applications, trademarks, copyrights or other intellectual property rights covering subject matter in this document. Except as expressly provided in any written license agreement from Citect, the furnishing of this document does not give you any license to these patents, trademarks, copyrights or other intellectual property. Citect, CitectSCADA, CitectHMI, Citect Plant2Business and Citect Plant2NET are either registered trademarks or trademarks of Citect Group Corporation in Australia and/or other countries. The names of actual companies and products mentioned herein may be the trademarks of their respective owners. 2 CitectIIM Downtime Monitoring Whitepaper

3 Contents About the Authors... 2 About Citect... 2 Contents... 3 Introduction... 4 Using Downtime to Drive Productivity Improvement... 4 Productivity or Efficiency Improvement Methodology... 5 Features & Benefits... 6 Presentation... 7 Analysis... 8 Moving Forward with Downtime Driven Benefits CitectIIM Downtime Monitoring Whitepaper

4 Introduction More than ever before, owners, executives and managers of production facilities are searching for ways to maximize the performance of their operations. However, it doesn t stop there. Once genuine performance gains have been realized it is imperative to maintain, or enhance those results. For many years improvement gains in production processes have been asset focused where bigger, better, faster has been the goal. Major investment in production assets produced the gains, however it often came at a significant cost to the business. At a time when capital funds are tight and return on investment expectations are so demanding, business owners are looking towards production efficiencies and effectiveness to extract performance gains and realize the full potential of their existing assets. Manufacturing Improvements Many organizations find it hard to pay enough attention to one of the key elements of success: Equipment Uptime. By paying attention to equipment and the reasons why it stops we gain an understanding of downtime and therefore what can be done to increase uptime. This understanding can lead to operator training, equipment functionality improvements and better preventive maintenance, thereby improving manufacturing processes and the organization's financial performance. The only way to achieve this understanding is to develop an information system that can help you track each downtime event. Tracking each downtime event allows managers or supervisors to graph equipment performance and evaluate total downtime per shift, product number and operator. Finally, you can start a continuous improvement process involving your machine operators, production supervisors, shift managers, mechanics and engineers. Using Downtime to Drive Productivity Improvement The Basic Concepts Analysis of a facility s downtime provides a window into what changes can be made to work practices, maintenance practices and equipment configurations to increase the length of time for which the equipment is producing at its optimal rate. Over the last decade, improvement to information and automation systems has dramatically improved the efficiency of production/manufacturing facilities. These information systems have been able to get most of their Production and Quality data automatically. However, downtime data has been hard to manage and is generally very dependent on manual entry and prone to inconsistent data. For those companies that have attempted to implement automatic IT systems to do these tasks, most have had mixed results, ending up with systems that are not practical to maintain as business needs mature. The experience of those that have achieved success is worth taking a look at. The methodology widely accepted is that of continuous improvement. Start with a simple model that identifies the key downtimes and then extend the system. The top 10 or 15 downtimes are normally addressed and generally provide the most significant improvement over a short time frame, for a relatively low cost and effort. 4 CitectIIM Downtime Monitoring Whitepaper

5 A simple model is one that starts at the highest level of the facility with relatively few business rules just one for each production line or surge feeding area. This will allow for the system to collect data on each production downtime, classify it, (by type of downtime) then categorize it, (by cause of downtime). This information can then been used to rectify the biggest issues in the facility, getting maximum benefit in the shortest timeframe. As these issues are rectified the system can be fine tuned to drill down into the lower areas. Two of the major benefits that organizations have cited of this approach have been: - The fully automatic collection of when delays started and finished The removal of the need for operators or other staff to categorize the alarms to work out causes; (Alarms are considered to be symptoms whereas Downtime analysis examines the causes) A continuous improvement process is essential for organizational change. Every continuous improvement process needs an efficient way to assess the improvements and track performance. Without performance tracking, any initiative for change will lose strength and the people involved will lose the motivation to continue with it. CitectIIM and in particular, the CitectIIM Downtime analysis module successfully assists with this issue, by providing you with the tool needed to track performance and improve your operation. The Approaches Improving equipment effectiveness is a science that has many complex aspects. Over recent years extensive work has been carried out to establish ways of quantifying and reducing losses in production time. Some of these have been very complex, working better in certain industries, while others have been very impractical to introduce to plant floors. However, they have in common, the placement of a structured measurement method which can be applied to the gathered data. Available methodologies with some reference to the time equipment include: - Lean Manufacturing OEE (Overall Equipment Effectiveness) TEEP (Total Effective Equipment Productivity) TPM (Total Productive Maintenance) Continuous Improvement Asset Utilization Downtime Tracking CitectIIM is a suite of application modules that contribute to improving equipment performance. CitectIIM Downtime is a module that collects, aggregates and presents data relating to the time equipment that is not productive. Alone it can provide significant benefits, however, integrated with other modules, the Downtime data allows for one or more of the above methodologies to be adopted to get maximum improvement of a facility. Productivity or Efficiency Improvement Methodology The most significant activity in setting up a Downtime system is the establishment of the key information about the way in which the facility is presently operated. As a configurable system, CitectIIM Downtime has clearly defined the information needed. This information is most effectively acquired during a workshop on Downtime with input from representatives for all the stakeholders (operations and maintenance managers, operators, reliability engineer, maintenance planners, production managers and planners and the people that are going to maintain the system IT or engineering etc) and an experienced Downtime practitioner. The process of getting all stakeholders together to collect this information 5 CitectIIM Downtime Monitoring Whitepaper

6 practically guarantees the success of the project as each has an understanding of the needs and the outcome of the project. It allows for everyone to resolve issues and form a common understanding of any work practice change that may be needed. For most sites this takes 1-2 days with up to another week for the collection of other pieces of data that may be required. The information collected includes: - Definition of a time usage model (the types of downtimes and/or classifications) The cause codes and descriptions applicable for the site The plant hierarchy used on the site or in the site s ERP system Details of which key areas are best for initial commencement of monitoring The definition of which rules will determine that an area or line is not producing to capacity Details of which users will/should be enabled to see/modify the information Plan of the related information flow in the organization This information is fed into the CitectIIM Downtime specification for use in the system configuration phase. Features & Benefits A Summary of the Features of CitectIIM Downtime: - Comprehensive ad-hoc and custom analysis presentation of downtime Downtimes automatically triggered from control system or manually triggered if required Virtual downtime (based on loss caused by low production rates rather than a 100% downtime) Downtime Classification/Category and Cause from auto-filtering Pick lists Fast, minimal effort for downtime details entry Free format Comment fields Ability to split records when causes may change during a downtime Integrate with HMI/SCADA system or stand alone Concept of Plant Hierarchy User privileges allow for distinct areas of control All Downtime terms configurable to suit site s existing practices Audit trail of edits to delay details after confirmation Recording of user ID at time of details entry The Benefits: - An automatic structured collection of the events that cause production losses A configurable application that allows the business rules to be adjusted without programmer intervention The automatic collection and consistent presentation provides more time for analysis and rectification than just data collection Empowers key personnel to make informed decisions to improve business performance 6 CitectIIM Downtime Monitoring Whitepaper

7 Presentation CitectIIM Downtime, as part of the CitectIIM suite of analysis modules provides a comprehensive presentation of Downtime data out-of-the-box, and the capacity to add to this through configuration or the development of custom reports. The Standard data views of Downtime allow for grouping and charting by classification, cause code, cause equipment, production loss location and any other field included at the time of configuration. 7 CitectIIM Downtime Monitoring Whitepaper

8 In addition, CitectIIM Downtime comes with standard reports and the capacity to build custom reports with access to all collected data and system Meta data. Analysis Experience with a variety of industries shows that two sorts of analysis takes place shortterm and longer-term. Short-term analysis of the data is very focused on day-to-day issues. Operations, production and maintenance managers look at the top 10 areas having delays and the top 10 causes. Their need is to keep the plant running as efficiently as possible today. This is the purpose of the presentation above. It provides a rapid view of the area of the plant s downtimes at the click of a button. Each view can be saved as a Favorite and reused on subsequent days. Longer-term analysis is for the determination of the systemic issues that indicate the need to change a working practice, maintenance practices or equipment configuration. This analysis would also be used to justify the purchase of additional equipment to improve productivity. Downtime analysis can aid by preparing data that quantifies the costs of downtime making cost justifications far more rational. Moving Forward with Downtime Driven Benefits CitectIIM Downtime is part of the performance improvement picture. Other aspects require collection of other data (Production, Quality, Cost, Maintenance) and preparing performance indicators that allow the performance to be seen and corrected. Application of CitectIIM Metrics (KPIs and Dashboards) is discussed further in a separate Whitepaper entitled Effective Measurement and Use of Key Performance Indicators. For further information on Citect products and services, visit 8 CitectIIM Downtime Monitoring Whitepaper