2012 Honeywell Users Group EMEA. Sustain.Ability. Gary Peacock Global Solution Marketing Manager, Asset Management

Transcription

1 2012 Honeywell Users Group EMEA Sustain.Ability. Gary Peacock Global Solution Marketing Manager, Asset Management 1

2 Agenda 1. Industry drivers 2. Time for a paradigm shift 3. Asset Management 4. RAMP solution 5. Product overview: Asset Manager & Field Advisor 6. Next steps 2

3 Industry Concerns and Drivers Aging assets and infrastructure Shrinking pool of experienced people Robustness of Reliability System Data and information overload Market volatility and competition 3 Common Asset Management concerns heard within Industry

4 The Data and information Problem Visual Inspections Control Loop Performance Monitoring Process Data (DCS, Historian, etc.) Smart Instruments (HART, FF, etc.) Condition Monitoring EAM/CMMS (SAP, Maximo, etc.) Corrosion Monitoring Reliability Maintenance Operations no common understanding of true status 4 Users try to determine asset status from disparate data sources

5 Sensor Fusion from Wikipedia article Data and information: Sensor Fusion combining data derived from disparate sources so that the resulting information is better than when these sources are used individually. WISDOM KNOWLEDGE SENSE MAKING INFORMATION DATA 5

6 Robustness of Reliability System One calendar year 100% Maximum relevant utilization Not scheduled to run Net % UPTIME Unplanned Downtime Planned Downtime Lack of Sales Downtime Net % of Max Potential Rate (MPR) (@ best consecutive period production rate) Rate Loss Lack of sales derate Net % of First Time Prime Quality Recycle or Scrap all TEEP Gaps are considered, including Scheduled Outages 7 Overall Equipment Effectiveness OEE TEEP OEE = 100% Maximum Scheduled utilization TEEP = 100% Maximum Potential utilization Visualization of OEE and TEEP Excess capacity Total Effective Equipment Productivity

7 Benchmarking Overall Equipment Effectiveness (OEE) Best-in-Class Middle 50% Bottom OEE: Food & Beverage 78% 62% 42% OEE: Pharmaceuticals 45% 31% 23% OEE: Industrial Processes 90% 56% 42% Asset Downtime 3% 13% 34% Plant Floor Automation 61% 45% 23% Integrated EAM/CMMS 79% 56% 48% Standardized KPIs across enterprise 53% 40% 18% Asset Management with Predictive Failure Analysis 28% 17% 6% OEE = 100% Maximum Scheduled utilization Table sources: 2010 Solarsoft Manufacturing Benchmark Study and Aberdeen Group, Enterprise Asset Management 8 Join STAN GRABILL for OEE Seminar on FRIDAY morning

8 Real-Time Decision Making: A new paradigm From Reactive / Run-to-failure Historical data Inspection Centric Paper Operator Rounds CBM as a Point Solution Fire fighting To Proactive / Predictive Real time data Reliability Centric Online & Automated Integrated RCM, CBM & CMMS Solution Proactive & Predictive 9 Asset Management with Predictive Failure Analysis

9 Think of Asset Management as 3 Distinct Areas Many Data Sources Condition Based Maintenance (CBM) Real-Time & Off-Line Data Field Inspection and rounds Wired & Wireless Reliability Centric Maintenance (RCM) Enterprise Asset Management (EAM) Computerised Maintenance Management Systems (CMMS) 10 Enterprise Asset Management Work-stream & Relationships

10 Maintenance Management: EAM and CMMS Maintenance Management Work Execution Management Work Order Generation Document Management Financial Management Purchasing Management Inventory/MRO Management Planning & Scheduling Integration with EAM and CMMS such as SAP and IBM Maximo 11 Enterprise Asset Management Work-stream & Relationships

11 Reliability: GP Allied Alliance Partner (GP Allied) 400 Consultants Globally Excellent Industry Reputation Experience in all Industrial sectors ireliability Suite of tools Reliability Programs & Strategies RCM / RCA Asset Health Matrix Equipment Maintenance Plan KPI/Benchmarking Change Management Training (including craft skills) 12 Enterprise Asset Management Work-stream & Relationships

12 Condition Based Monitoring Real-Time Condition Monitoring Real-Time Corrosion monitoring DCS & Historian Simulation (UniSim) Real-time Vibration Monitoring Smart Instruments (FDM) Operator Rounds (Field Advisor) Oil Analysis Other Condition Monitoring 13 Enterprise Asset Management Work-stream & Relationships

13 Integrating Real-time Asset Management Management Reporting & KPI s CMMS / ERP Integration Maintenance & Reliability Users Rotating Machinery Monitoring Asset Performance & Health Assessment DCS & Historian Control Loop Monitoring Visual Inspections Smart Instruments Corrosion Monitoring Equipment Condition Monitoring Downtime Reporting Process and Alarm Data 14

14 Data Management Applications Very Clear & Easy to Understand 15 Single view of Asset Performance and Health

15 16 Key Performance Information

16 17 Abnormal Condition Assessment

17 18 Downtime Dashboard

18 RAMP Asset Manager Notifications sent to EAM/CMMS EAM/CMMS Work Execution Mgmt Maintenance Mgmt Workflow Document Mgmt Financial Mgmt Purchasing Mgmt Inventory/MRO Mgmt Scheduling DATA SOURCES Condition Monitoring DCS & Historian Smart Instruments Operator Rounds Corrosion Data Simulation (UniSim) Oil Analysis Vibration Monitoring Honeywell Asset Manager OUTPUTS Alerts & Notifications Management Reporting & KPI s Maintenance & Reliability Scorecards Downtime Reporting Health Assessment Automatic Work Order Generation Programs & Strategies RCM/RCA Asset Health Matrix Equipment Maintenance Plan KPI/Benchmarking Change Management Training Asset Manager info used in Reliability programs 19 Reliable Asset Management Performance

19 Integrating Real-time Asset Management DCS & Historian RCM Partners and tools Smart Instruments Vibration Products Wireless Asset Health Management Visual Inspections Downtime Reporting Corrosion Monitoring Rotating Machinery Monitoring Downtime Reporter UniSim Corrosion Asset Manager RCM Process Reliability Equipment Condition Monitoring Smart Instruments Integration with EAM Field Advisor KPI / Benchmarking Trending Integration with CMMS 20 Asset Manager offers a single view of performance and health

20 Applying RAMP STRATEGIC TACTICAL TECHNOLOGY INFRASTRUCTURE Risk Based Inspection (RBI) Abnormal Situation Management (ASM) Operator Driven Reliability (ODR) Reliability Centred Maintenance (RCM) Real-Time Condition Based Maintenance (CBM) Asset Health Monitoring Reliability & Maintenance (AHM) Engineering (RME) Asset Manager Enterprise Asset Management (EAM) Computerized Maintenance Management Sys. (CMMS) Operational Performance Monitoring (OPM) Reliability Centred Design (RCD) Work Execution Management (WEM) Real-Time Data Acquisition 21 BENCHMARKING Overall Equipment Effectiveness (OEE) Total Effective Equipment Productivity (TEEP) Scalable Solutions integrated through Asset Manager

21 Applying RAMP: Tactical AHM STRATEGIC Reliability Centred Maintenance (RCM) Real-Time Condition Based Maintenance (CBM) TACTICAL Risk Based Inspection (RBI) Abnormal Situation Management (ASM) Operator Driven Reliability (ODR) Asset Health Monitoring (AHM) Operational Performance Monitoring (OPM) Reliability Centred Design (RCD) Work Execution Management (WEM) Reliability & Maintenance Engineering (RME) TECHNOLOGY INFRASTRUCTURE BENCHMARKING accurate view of asset health Field Advisor SKF Vibration Corrosion Monitoring Field Device Manager OneWireless Mobile Equipment Monitoring.. 22 Scalable Solutions integrated through Asset Manager

22 Applying RAMP: Tactical OPM STRATEGIC Reliability Centred Maintenance (RCM) Real-Time Condition Based Maintenance (CBM) TACTICAL Risk Based Inspection (RBI) Abnormal Situation Management (ASM) Operator Driven Reliability (ODR) Asset Health Monitoring (AHM) Operational Performance Monitoring (OPM) Reliability Centred Design (RCD) Work Execution Management (WEM) Reliability & Maintenance Engineering (RME) TECHNOLOGY INFRASTRUCTURE BENCHMARKING one view of the truth UniSim Design Downtime Reporter Corrosion Monitoring Well Performance Monitoring OMPro. 23 Scalable Solutions integrated through Asset Manager

23 RAMP Underlying Principles 1. Relentless integration of all aspects of people, processes, and technology 2. Applied across the entire asset life cycle:- Capital Delivery (CapX) Operations (OpX) Maintenance (MaintX) 3. Includes the management of all assets mechanical, electrical, stationary, process automation and control assets 4. Modular and scalable 5. Change Management is woven into the deployment 24 Integration of People, Processes and Technology

24 Asset Manager R410 Built on the Intuition Platform Single Location for Asset Management Wired & Wireless Vibration Monitoring Real-time Corrosion management Control System & Instrumentation Monitoring Inputs from OPC, PHD, any Experion site,.. Integration with Honeywell and 3 rd Party Products & Solutions Aptitude Analyst & DMx (SKF Corp) ireliability Suite; including a fault model library (GP Applied) See these in the demo room!! Integrate information Fault Models Alerts Alert-based Automatic Actions Problem Solving Multiple sources Future proof Based on integrated information Based on the fault model execution Operator notifications notification Collaboration between teams Historical information Link to relevant documentation 25 Another bridge between Operations and Maintenance

25 Field Advisor R200 and R201 (2012 releases) Technology Refresh Honeywell Intuition framework and modernized handheld user interface Microsoft SQL Server Standard edition Updated configuration tools with graphical configuration New rounds scheduling, tracking and reporting calendar Efficient Installation/Migration and Integrated Security Automatically trigger and track operator tasks Select Work Execute Tasks Enter comments Review Consequences When limits are exceeded Review History Corrective Actions Execute reconditioning tasks Upload Work 26

26 Tremendous Benefits Received Improve Safety Improve Reliability Reduce incidents by up to 40% Increase operator competency Support continuous improvement Improve Efficiency Reduce off-spec material up to 50% Reduce transition material up to 30% Catalyst consumption down by 1% Improve throughput 2-8% Reduce energy use 5-10% Improve forecast accuracy 4-20% Reduce inventory % Improve plant availability 3-8% Preserve and extend asset life Reduce maintenance costs 3-5% Improve customer service 5-15% Improve Sustainability Green house gas emissions reduced by 25% Ensure compliance standards Reduced total cost of ownership Reduce energy consumption >$5B US in measurable benefits has been added to our customers bottom-line *Results based on past customer experience 27 Typical Return on Investments are 3 Months to 1 Year

27 Recommended Next Steps (At HUG) Visit the demo room Honeywell Asset Management and RAMP Asset Manager R410 Field Advisor Corrosion SKF Vibration GPAllied ireliability RCM Attend the OEE Seminar Friday 16 th November, 09:00 12:00 Presenter: Stan Grabill 28

28 Recommended Next Steps (When you get back) Ask for an assessment at your site Start small if needed Solutions are scalable Be a champion for your company Must get operations and management involved Do something 29

29 Questions? 30