Enterprise Asset Performance Management

Transcription

1 Enterprise Asset Performance Management Fayez Kharbat Process & Control Systems Department Engineering Specialist, September 23 rd, North American Plant-to-Enterprise Conference September 21-23, Orlando, FL

2 The following Strategic Initiatives of MESA International are associated with this presentation: Asset Performance Management (APM) Real-Time Enterprise (RTE)

3 Agenda Enterprise Asset Performance Management (EAPM) basics Asset Lifecycle Management Architecture & Solutions Drivers & Strategy Execution Methodology Expected Benefits & ROI Summary

4 EAPM Mission EAPM provides means to share information regarding the right time to do maintenance based on the health of equipment, coupled with the best time to bring an asset down given operational demands APM goes beyond maintenance: It cuts across many boundaries. The bottom line is return-on-assets [ROA] ARC Advisory Group

5 Basics on EAPM Operations and maintenance drive plant performance. Operations is measured on maximum asset utilization while maintenance is measured on availability Enterprise Asset Performance Management is about striking an optimal balance between asset utilization and availability and sustainability Since the bottom line in the hydrocarbon industries is Return on Assets (ROA), improving the bottom line is a function of how much utilization is achieved from assets and how well assets are utilized when on line

6 Asset Definition Asset-Centric Operations Process Engr Maintenance Reliability Human Program-Centric Project Mgmt Engr/Design Procurement Construction Primary Facilities & Equip Automation Remote Support IT HW/SW Mobile MRO Material Physical Virtual Reference Data Functional Design Procedural Activity Records Commercial Status History Asset = Plant Asset Machinery, Equipment, People and Information - with the purpose of providing an economic and/or social benefit

7 EAPM Measurements Asset Performance The degree to which an asset performs its intended function measured against agreed targets and standards. These measurements include: Uptime Total Effective Equipment Performance (TEEP) Overall Equipment Effectiveness (OEE) Delivery Performance

8 EAPM Measurements Asset Management The actions required to ensure that the asset is: Safe for operators, user and public Environmentally safe and sustainable Operating at Maximum level of service efficiently Achieving all the above with lowest asset lifecycle cost Asset Effectiveness The degree to which an asset fulfils its purpose Sustaining economic value Financial terms measurement e.g. Net Present Value (NPV), Return on Capital Employed (ROCE)

9 EAPM maximize Asset Effectiveness EAPM Ensures that the asset safely performs its planned function over defined time horizon in terms of: The operational performance of plant assets is assured The risk involved in operating those assets are controlled Energy, Emissions, and other Sustainable Manufacturing targets are achieved

10 Strategies for Operation Outside operator detects an abnormal situation (e.g. visual inspection, noise, etc.) Field data readings are wirelessly transmitted and combined with real time process sensor data and suggest impending failure maintenance wants to? operations wants to? How is the work process handled? Should we deal with this in a logical consistent way?

11 Architecture Enterprise Asset Management Work management Materials Management Plant Maintenance Supply Chain Management Schedules Enterprise Asset Performance Management Performance Analytics Capability Assessment Strategy Management Targets & Schedules Performance & Constraints Engineering and Design Change Management Regulatory Documents Engineering Data Tag Master Production Management/Monitoring Production Data Incident Data Quality Data Cycle Times Maintenance Management Condition Monitoring Asset Management Condition Monitoring Vibration Monitoring Online Device Monitoring

12 Asset Management Landscape Enterprise Asset Management (EAM) Work management Materials Management Purchasing and Stores Maintenance Strategy Maintenance History Enterprise Asset Performance Management (EAPM) Strategy Development (RCM, RBI,etc.) Strategy Management (Asset) Condition Assessment (Calibration, Inspection, etc.) Performance Management (KPIs, RCA, Analysis, etc.) Conditional Alerts Monitoring Strategy Engineering Characteristics Re-Design Recommendations Process Historians/Condition Monitoring Predictive Technologies Online Monitoring Anomaly Detection Engineering and Design Tag Master Engineering Data Regulatory Documents Management of Change

13 Asset Lifecycle Traditional Model Project Management Asset Management Plan FEED Detailed Design Source & Build Commission & Handover Operate & Maintain Retire OPEX Revenue Capital Costs (CAPEX) ROA Net Income

14 Plant Assets Lifecycle n io at pt im iz O, Oper P i l o t al i d at i o n V Prod C Ha omm n d is s-o sio n T n, ra in in Sour g ce/ Buil d Stead yi in Fac ncrease i l it y U se Time Obs ll/ S e ve o m Re ARC Advisory Group. Retire Fr o Opera m tion fy Identi y rtunit Oppo P Bu relim dg E et ng & r, Sc Pr he oj du Anal le ysis & of Al C o st terna tives ing n gr, l ed E P l an i a t e D ec s, Ex BOM r/ Wea ence olesc

15 Asset Lifecycle Management Processes Optimization Steady Increase in Facility Use Pilot Oper, Prod Validation Wear/ Obsolescence Commission, Hands-on Training Source/ Build Retire From Operation Detailed Engr, BOMs, Exec Plan Design & Build Operate & Optimize Maintain & Improve Prelim Engr, Proj Budget & Schedule Sell/ Remove Identify Opportunity Analysis & Costing of Alternatives ARC Advisory Group.

16 EAPM Measures (KPIs) OEE = Utilization% * Rate% * Yield% Where: UTIL% = Utilization(Actual)/Utilization(Planned) RATE% = Production Rate(Actual)/Production Rate(Planned) Yield% = Prime Yield(Actual)/Prime Yield(Planned) ROCE% = PROFIT% * CAPEX% * DESIGN% * OEE% Where: ROCE% = ROCE(actual)/ROCE(Planned) PROFIT% = Per Unit Profit(Actual)/Per Unit Profit(Planned) CAPEX% = Invested Capital(Planned)/Invested Capital(Actual)3 DESIGN% = Availability(Actual)/Availability(Planned) Human Human Operate & Optimize Design & Build Virtual Virtual Maintain & Improve Operators and Maintenance personnel can focus their joint efforts toward major problems Physical

17 Business Processes Focus WO/EAPM With EAPM Plant Business Process Production Incident Tracking Maintenance Operations Inspection EH&S Failure Reduction Mechanical Integrity Maintenance Operations Inspection Financial Management EH&S Operational Silos Focus on Business Process

18 Operational Drivers Strategy & Programs People & Processes Disconnected Applications & Information Normally 5-7% Cost Avoidance is achieved when Asset Performance Management System is used effectively It has been shown that typically equipment reliability problems accounts for about 38 percent of all unplanned slowdowns or shutdowns Problems with Data Quality, Data Entry Completion, End users are not reliability oriented, No Standardization

19 Production Losses Provide Total Effective Equipment Performance (TEEP) Basis for EAPM The ratio of the good product produced to maximum possible production over a given calendar time period Overall Equipment Effectiveness (OEE) The ratio of the good product produced to planned production over a given calendar time period OEE = A/B TEEP = A/C (B) Planned Production (C) Maximum Production (A) Good Production

20 EAPM Added Value Strategy & Programs People & Processes Enterprise Asset Performance Management (EAPM) EAPM provides asset owners with a single point of access to a collaborative transactional workspace to manager their assets throughout their productive lifecycle Enterprise Asset performance management is the backbone to culture of reliability Applications & Information EAPM enables organizations to identify, contain, analyze and remove production losses and thus improve production performance

21 Requirements For a Successful Deployment Visible corporate leadership Baseline reliability performance expectations The establishment of clear, attainable goals The selection of metrics Measure reliability performance and a path to improvement Establishing a partnership with IT Services to develop and implement change Clearly defined roles and responsibilities Impacted Maintenance, Operations the entire organization

22 Prerequisites for a Successful Implementation Ensure Good Reliability and Maintenance Data Entry Establish Business KPI s and provide consistent methods of calculations Conduct risk-based criticality assessment of plant equipment (ABC indicator) Establish Root Cause Analysis Establish RCM, PMO, Reliability Engineering, Statistics, Six Sigma Work flow roles and responsibilities Inspection Module and Management Empowerment

23 Effective EAPM Implementation The following actions must be emphasized and accomplished: Management of Change (MOC): Support / Participation Culture Change: Change Toward APM Software / Tool: Cost of Suitable Integration Readiness: Measure / Gap Analysis APM Effective Implementation: Action Plan Training: APM Focused Training and Awareness Sessions Changing Agent: Empower & Support Implementation Team Implementation Method: Selective Sites at a time, Business Vertical, Corporate Business

24 EAPM Culture Requirements Companies are Facing a Challenge Shift from Reactive to Pro-active culture Why moving to reliability culture To ensure business success To provide a safe working environment To meet changing regulations The requirements to achieve cultural change Management commitment Reliability is everyone s responsibility (Operations, Maintenance, Engineering)

25 Assets Expected Return As large investments in assets and ongoing cost are made, owners are eager to see higher rates of return on their capital employed maximized lifecycle value. This gets fulfilled when: The operational performance of plant assets is assured The risk involved in operating those assets are controlled

26 EAPM ROI Prerequisites Clearly and consistently communicate the value of EAPM to the higher management Establish awareness program of the value of EAPM for the organization

27 EAPM Direct Savings Reduction of unplanned downtime Reduction of planned downtime (TA frequency can be extended) Reduction of maintenance inventory Avoidance of major maintenance work Reduced production losses Reduced safety and environmental losses Reduced Capital Costs (better life cycle costs management can be achieved leading to significant savings in total material costs) Improved quality performance (product quality can be improved and rework of produced parts can be decreased) Improved Energy Utilization (this improvement is achieved through early detection and resolutions of performance deficiencies) Maximize the effectiveness of your assets Optimize the productivity and reliability of your plant assets

28 Prevent Disasters

29 Summary Deploying EAPM provides: Integrated solution for reliability and maintenance Obtaining a satisfactory transformation change (cultural, data quality, and management) ARC Advisory Group.

30 Q&A Thank You