WELCOME Round Tables Maintenance Follow up meeting Aad Veenman Chairman
Program 13.30 Opening bijeenkomst Aad Veenman Start MARE Learning Community Henk Akkermans Onderwijs / steunverklaring Henk Akkermans 14.00 Samenvatting Round Tables 14.30 Parallel session poster presentation 15.30 Interactieve recap session Aad Veenman 16.30 Presentation DIWCM / MARE Henk Akkermans / Leo van Dongen 16.45 Signing gmare learning community document 17.00 Closure with an informal drink
Round Tables Maintenance Follow up meeting Henk Akkermans Scientific Director Dutch Institute World Class Maintenance
Results Innovation RoundTables Round Table Innovation themes Sectors Date # 1 Maintenance organization and staff All sectors (with an initial focus on Process) # 2 Physical phenomena (e.g. corrosion, aging, life expectancy) Defense, Infrastructure, Aerospace, Maritime 12/10 8/11 # 3 Monitoring based maintenance All sectors (including High 01/12 Tech!) # 4 Maintenance oriented engineering All sectors 07/12 # 5 Overhaul/ Maintenance Systems Process, Energy, Infrastructure 14/12 # 6 Stop management Process, Energy 16/01
Roundtable #1: Maintenance Outsourcing DATE: October 12, 2011 PLACE: Tilburg University Faculty Club MODERATOR: Henk Akkermans (Tilburg) PARTICIPANTS (16): Asset Owners: BP, DOW, DSM, EPZ, Essent, SABIC, Shell, Tata Steel Contractors: Croon, Sitech, SPIE, Stork Researchers: TU Delft, DlftTU Eindhoven, RU Groningen, Tilburg Univ, UnivTwente KEY QUESTION: Maintenance outsourcing issues in the process industry: So we are so flexible now, but are we any better?
Key Issues in Maintenance Outsourcing 140 Contract Co t act ope open for o expertise input from contractor 115 120 101 92 100 98 + Incentives on short-term revenues with contractors 80 60 40 + 20 Common goals + Game-playing - R4 1995 2000 2005 2010 Technical performance of assets (1990=100) 132 140 - Willingness to share savings with contractor - + Trust between asset owner and contractor - Trust & transparency loop Transparency of goals + Everybody for themselves Purchasing focus in contract + 120 106 105 97 100 + + Antagonistic buyer-seller behavior 80 + + 60-40 Focus on producurement Negotiations savings + Procurement bias loop + R3 Fighting mode Thinking in risks vs in opportunities 20 1995 2000 2005 2010 Effort required to manage contractors (1990=100) + Maintenance performance Maintenance M i costs Procurement reporting to finance + Silo mentality
Implications for research & practice 1. Thinking beyond classical buyer supplier relationships; the BVNederland perspective 2. Long term partnership models 3. Trust, transparency, and clearly defined roles & responsibilities 4. Goalcommonalitybetween asset owners and contractors 5. Incentives onshort term term vslong term performance All these are serious candidates for joint research projects!
Roundtable #2 Physical Mechanisms DATE: November 8, 2011 PLACE: Tilburg University Faculty Club MODERATOR: Tiedo Tinga (NLDA) PARTICIPANTS (17): Asset Owners: Cargill, BP, Akzo Nobel, Min. of Defence, Gasunie, DSM Asset Manufacturers: Micro Turbine Tech., Chromalloy Contractors: Imtech, Heijmans, Operational Exc. Researchers: NLDA, RU Groningen, Tilburg University KEY QUESTION: How can understanding of physical mechanismsbe applied to make maintenance predictable?
Model based Predictive Maintenance (cf. experience based maintenance) Usage monitoring Usage Platform / Remaining life system thermal / fluid / structural model Required: Understanding physical 1 fil failure mechanisms Zoom in to the level of the physical failure mechanism Prognostics Monitoring loads / usage 0.012 Internal loads Load monitoring Failure model 2 Service life / Damage accumul. Condition monitoring Probability 0.01 0.008 0.006 0.004 wide distribution at t = t 1 increase in allowable average damage increase in safe life time: (t 2 - t 1 ) narrow distribution at t = t 2 0.002 critical damage limit 0.1% 0 0 Damage parameter D
Implications for research & practice 1. Present status: Differences per sector (chemical, infra energy) Often apply afterwards (RCA), seldomly prognostic (model based) 2. Needs identified: Knowledge sharing & application i Collection & interpretation of (monitoring) data Life Cycle Management (design/lcc + application in practice) Failure behaviour + models (generic and specific) Set-up joint research projects and facilitate sharing and application!
Roundtable #3 Monitoring Based Maintenance December 1, 2011 Location: Princeville, Breda Moderator: Geert Jan van Houtum (TU/e) 40 participants Setup: Presentations by moderator, Gert Streutker (ASML) and Bram Kranenburg (CQM) Breakoutsession to identify business cases Mini questionaire on requirements for Monitoring Based Maintenance
Requirements for Monitoring Based Maintenance litude (Units) Ampl 0.04 1. Parameter(s) to identify upcoming failures 003 0.03 2. Sufficiently large delay 0.02 time 3. Data of sufficiently many 0.01 systems 0 4. Technical possibilities to 0 200 400 600 800 1000 1200 collect data efficiently Time (Units) 5. Economically attractive to do preventive replacements 0.035 0.025 0.015015 0.005
Main findings from mini questionaire Do you have a system for which all requirements are met? Yes: around 50% of companies No: around 50% of companies Most mentioned barriers: 1. Data of sufficiently many systems 2. No parameters that identify upcoming failures Most mentioned research topics: 1. Which parameters to collect/log 2. Data mining/black box approach
Roundtable #4 Maintenance Engineering December 7, 2011 Tilburg University Faculty Club Moderator: Leo van Dongen (Universiteit Twente) 23 participants: Asset Owners: Akzo Nobel, BP, Cargill, DOW, DSM, EPZ, Heineken, HTM, Marine, ProRail, Sabic IP & Tata Steel Contractors: Cofely Consultants: ADSE, Mainnovation, PDM & Maintenance Consult Researchers: Universiteit Tilburg & Universiteit Twente Key Question: Improving asset performance and costs: How can Maintenance Engineering contribute?
Maintenance Engineering Links Short Term Experience and Long Term Investments!
Implications for Research & Practice 1. Time for reflection on long term impact of assets 2. Knowledge and application i of RAMS & LCC experience 3. Integral approach of technology and operations 4. Smart specifications i (for verification i and validation) i 5. Open cooperation in the chain with suppliers 6. Respect for different interests All these are serious candidates for joint research projects!
Roundtable #5: Overhaul/Maintenance Systems DATE : December 14, 2011 PLACE : Tilburg University Faculty Club MODERATORS: Warse Klingenberg (RU Groningen) Cees Witteveen (TU Delft) PARTICIPANTS (18): Asset Owners: GLT Plus, KLM, Marinebedrijf, SABIC, Sappi Paper, Alliander, Huntsman Contractors: Sitech, Cofely, SPIE, Stork Researchers: TU Delft, RU Groningen, Tilburg University KEY QUESTIONS: How to integrate maintenance planning & scheduling in operations?
Key issues in maintenance planning & scheduling Urgent need for methods that make relevant asset information available at an earlier stage Plan preparation is more important than the maintenance planning itself Design is an important factor in efficient maintenance planning Flexibility in planning is a must to avoid replanning Safety is a key issue in deciding when to replan
Implications for research & practice How to use condition information to schedule maintenance jobs? How to integrate maintenance planning with other planning systems in the company? How to realize robust planning & scheduling of maintenance processes? What are the do s and don ts in shutdown planning?
Roundtable #6 Shutdown Management DATE: January 16, 2012 PLACE: Tilburg University Faculty Club MODERATOR: Warse Klingenberg (Groningen) PARTICIPANTS (16): Asset Owners: BP, Sabic, Eon, Tata Steel, Huntsman, Shell Contractors and consultants: Stork, Sitech, Cofely, Lexxin, Operational excellence Researchers: University it of Groningen, Tilburg University, it KU Leuven KEY QUESTION: The organization of shutdowns has a significant impact on the overall performance of an asset. How can we improve this?
Key Issues in Shutdown Management Significant cost in terms of deferment, hours, materials Deferment by shutdowns typically 3-5% *, Shutdowns typically 30-50% of maintenance budget * Excellent performance required of multiple disciplines Complexity in terms of management, planning and co-ordination ordination *P. Casteleijn (Stork), Slides: J. Boode (Shell)
Implications for research & practice 1. Definition of roles & responsibilities. The role of management. The tripartite responsibility of operations, engineering gand maintenance. 2. How to engage external parties, e.g. the contractors and their considerable knowledge and expertise? 3. The integration of repetitive (maintenance) activities and one off (project) activities in a shutdown programme. 4. Management of scope. Stages in scope definition. Scope acceptance p criteria. Appropriate level of rigidity (or flexibility). How to deal with pop ups during the shutdown? All these are serious candidates for joint research projects!
Vervolg: MARE Lite & MARE Pro State of the art knowledge MARE Learning Community
Next steps Education: The National Maintenance Master
Maintenance Multidisciplinary Profession
Linking Maintenance g Education to Industry
Maintenance Master: First Year Plenary Courses in Kasteel Breda Physical Phenomena and Failure Mechanisms Asset Analysis Methods Condition and Health Monitoring Design for Maintenance Reliability, Availability, Maintainability, Supportability Human Factors and Safety Life Cycle Cost Engineering Planning and Scheduling Asset Management Principles Asset Management Information Systems and Certification Spare Parts Control Maintenance Organization Dynamics
Maintenance Master: Second Year Literature study & project planning Thesis project: Company internship Master s thesis: research and report Knowledge transfer to company Intensive supervision from university Supported by industry
Maintenance Master: Planning Time Activity it Jan. 2012 Finishing of exploration phase Jan. 2012 Dec. 2012 Necessity and scope approval for OCW Accreditation phase for NVAO Summer 2012 Summer school for students and young professionals Jan. 2012 Dec. 2012 Planning and preparing p organization & research plan Business Model & Financing Jan. 2013 Accreditation is ready Jan. 2013 Start of promotional activities Jan. 2013 Sep. 2013 Practice of modules Sep. 2013 Start of master program Industry Support: Prerequisite it for Success!
INTENTIEVERKLARING voor STEUN aan de Maintenance Academic Research and Education (MARE) community. Ik en mijn organisatie ondersteunen de Maintenance Academic Research and Education (MARE) Learning Community, die zich ten doel stelt de Nederlandse samenleving Maintenancebewust te maken en de kwaliteit van Maintenance in brede zin op een hoger peil te brengen door het bevorderen van: toegepast wetenschappelijk onderzoek op het gebied van maintenance, academisch onderwijs op het gebied van Maintenance een netwerk van maintenance professionals voor uitwisseling van ideeën en contacten. Aldus getekend te Breda op 23 januari 2012.