Integrated Reliability Programs = Integrated Data Management White Paper Design Maintenance Systems Inc.
Integrated Reliability Programs = Integrated Data Management An Integrated Reliability program starts with the data collected by operators, mechanics, and lubrication technicians and continues through to data analysis and information dissemination by Reliability, Operations and Maintenance departments ending with decision making and prioritizing by Reliability, Operations, Maintenance, Sales / Marketing and Purchasing. At the primary level, the data collected from all asset care disciplines are brought together to make informed decisions that pertain specifi cally to asset life. At the secondary level, the disseminated information is spread throughout the corporation to the all departments that can utilize that information to make intelligent decisions to achieve corporate goals (profi tability). The key element of this process is integrated data management - both within the reliability program (internal) and outward to the EAM/ERP/Control system used (external). Integrated Data Management can take place in a variety of forms. The two main areas of integration can be grouped as internal and external. Internal integration brings multiple asset care disciplines together under a single system. Internal integration benefi ts the collection/analysis/distribution cycle specifi cally data, collection, data analysis and the distribution of the results. External integration concerns the exchanging of this data with existing ERP, EAM and plant operations systems. External integration greatly enhances the ability to use reliability information to manage maintenance and production scheduling. As a result integrated reliability processes make the decision-making process less costly and more accurate. About DMSI For two decades, DMSI has been providing the tools industrial, military and transportation organizations need to get their maintenance programs up and running quickly with maximum value and minimal inconvenience. You may even have used our systems without ever hearing the name DMSI, because many of our products have been marketed through OEM relationships. In fact, DMSI is a leader in the number of installed maintenance systems worldwide. At DMSI, we are looking forward to helping you achieve your operations and maintenance goals more easily, effi ciently and costeffectively than ever before. DMSI is fi rmly established as an industry leader for integrated asset care and predictive maintenance. Our corporate headquarters is North Vancouver, BC with sales and support outlets throughout the US, Canada, UK/Ireland, South Africa, Benelux, Scandinavia, India and Korea. Integration Benefits The following are case histories from companies that have integrated their reliability programs. The companies have asked DMSI to not disclose their names as the information is considered proprietary in nature. Case One: Paper Mill in Florida, USA Integrated inspection program initiated in Woodyard in 1999. By 2003, 70% reduction in reactive repairs compared to 1998. Operators responsible for identifying over 25% of critical asset issues. Year-to-year maintenance budget reduced by over 35%. Case Two: Paper Mill in Virginia, USA Integrated inspection program started in 1996 with one trial area using four handhelds. Trial program saw 35% increase in planned work in that area. Now over 130 handhelds in 8 areas largest single-plant automated inspection program in world. Production up from 2200 tpd (6 PMs) to 2800 tpd (5 PMs) in the last fi ve years and the inspection program is credited as the major contributor. Case Three: Refinery in Tennessee Inspection program began (on paper) in 1999 but the integrated, automated system was installed in 2002. Interface to external process historian system added to system in 2003. MTBF for rotating equipment improved from 42 months to 53 months. Maintenance expense shifting from reactive maintenance to proactive work, moving to 15% unplanned from 80% unplanned. Savings - $1 million dollars (US) in reduced maintenance costs per year. Design Maintenance Systems Inc. 1
Integrated Data Management Integrated Data Management is one of the keys to a successful implementation of a corporate reliability program. In small, single plant environments, non-integrated reliability tools can be used independently, with little or no formal integration. However, in large or multi-plant environments, the effort of accessing and managing data from non-integrated reliability tools can quickly overwhelm the benefi ts of those tools. Integration has the largest positive affect on processes involving plant personnel from different fi elds because it shifts the focus to a shared process from an individual departmental focus. The following chart illustrates the reliability task and the plant personnel that might be involved. When working with an integrated system, the focus shifts to a team approach, as the individuals involved are able to view the information in the manner most meaningful to each. Process Data Collection Data Analysis Information Dissemination Decision Making / Prioritizing Plant Personnel Operators, Mechanics, Lubrication Techs Reliability, Operations, Maintenance Reliability, Information Technology Reliability, Operations, Maintenance, Sales / Marketing Systems Integration distributes the fi ndings of the reliability program to decision makers within the plant. The following diagram illustrates an integrated reliability system where the internal (the reliability program ) is represented by the pyramid and the external (EAM/ERP/Control system). Design Maintenance Systems Inc. 2
Internal Integration Internal integration brings multiple asset care disciplines together to present a cohesive view of the operating state of the asset. The advantages are: 1. Data Collection an integrated system provides a single mechanism for gathering route-based, sample-based and continuously collected data. 2. Exception Handling a single location is provided for viewing ALL alarms generated from the data collection process. 3. Data Analysis there is a single set of diagnostic methods that allows for consistent analysis of data from multiple disciplines. Integrated Data Collection Administering data collection from multiple sources of data requires the following capabilities from the central software being utilized: A single hierarchical data structure capable of handling all types of data (numerical, text, image, and vector data). The cross-referencing of the data collected to the corresponding date, collection meter value, sample id, speed/load factor, operator id, as well as other factors. The data structured to accommodate multiple data sources by having an alternate key identifi er - alias capability. Design Maintenance Systems Inc. 3
Integrated Data Analysis A common data analysis model requires a system with the following capabilities: The fl exibility to manage exceptions from all monitoring / inspection data types. The ability to drill down through the exception to full data sets for the verifi cation of an anomaly in the asset. For the top level integration to occur, then an automated diagnostics system with integrated diagnostic tool such as an expert system or neural net that can access both exceptions and underlying data sets is required. It is essential whatever system is being used has the ability to save asset health evaluations, made by human expert or the diagnostic system, in a format that allows the evaluation to be recalled and reported in the future. Design Maintenance Systems Inc. 4
External Integration External integration involves exchanging reliability data with existing ERP, EAM and operations systems. External integration allows the sharing of key data through the plant in two areas. 1. The existing operations data display is integrated with the reliability program to allow operations to access condition / inspection collected data on their plant information systems. 2. The existing EAM/ERP system is integrated with the reliability program for workfl ow management information through a single mechanism managing condition and inspection-trigger work requests/ notifi cations in the EAM/ERP systems. The following are two examples that illustrate both of these. Example One: Operations Data Interface Implement An Operator Driven Basic Care Program, But Make It Fit In With Current Site Practices. Issue A key element of external integration is the ability to display basic care equipment status on PI operator screens. Resolution Implement an automatic interface that integrates data from integrated inspection system into the operations data fl ows in an OSISoft PI system. Operations can determine the status of all plant equipment from the PI system, either from inspections or process control sensors. Design Maintenance Systems Inc. 5
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Example Two: Workfl ow Management Communication between EAM/ERP System and Reliability System. Issue A key element of external integration are automated links between reliability systems and EAM/ERP systems. Resolution Implement an automatic interface that uses results from integrated reliability systems as triggers for work requests/notifi cations in an EAM/ERP system. Implement Feedback Loop from EAM/ERP system directly to operator s handheld devices. Design Maintenance Systems Inc. 7
MAINTelligence is a fully integrated reliability software - all the tools in one database and one software. For more information, please contact us at 1.800.923.3674 or email info@desmaint.com. Design Maintenance Systems Inc. 8
MAINTelligence Options Connect MAINTelligence with Your Enterprise System Inspection and PdM Direct Link Add Operator Driven Reliability and PdM to your Enterprise System MAINTelligence is a comprehensive system focused on visual inspections, rounds automation and instrumented predictive maintenance. It provides the tools for operations, maintenance, lubrication and reliability departments to manage their data collection processes, and use that data to automatically trigger maintenance notifications in SAP and other enterprise systems. MAINTelligence Enterprise Connect benefits your existing enterprise asset management system with: 1. Simplified Work Notification. 2. PDA inspections with automatic corrective maintenance notification. 3. Full diagnostic analysis for integrated PdM. 4. Optimal tools for the collection, verification and management of asset condition. All of the rich, complex information gathered by operator rounds, lubrication rounds, safety / health / environmental inspections and predictive maintenance procedures are managed within MAINTelligence. When the link to the ERP system is activated, any alarms or exceptions noted during rounds can automatically trigger corrective maintenance orders in the ERP system. Intelligent Diagnostics Built into MAINTelligence is a highly capable intelligent (rule-driven) diagnostic system. Use it to augment simple alarms with business rules to generate maintenance notifications based on many data values from multiple measurement points. SAP Specific Features MAINTelligence offers enhancements to our standard workflow interface to meet the specific requirements of SAP users. MAINTelligence plant hierarchy objects (equipment and components) are linked either to Equipment objects or Functional Locations in SAP R/3. Whenever an alarm, a diagnostic or a work request is created on a MAINTelligence equipment or component object, an associated Maintenance Notification is created in R/3. MAINTelligence can communicate with SAP R/3 or ECC either through the standard BAPI interface or using XI/Netweaver and web services. Both methods deliver the same information, and have the same tools to automatically link MAINTelligence alarms / diagnostics / work requests to SAP.
Get Connected with MAINTelligence MAINTelligence Is... Connected A great reliability program is backed by a partnership between maintenance, operations and other departments within an organization. It is built with tools that facilitate and create these partnerships, fostering company-wide support. MAINTelligence has been engineered to encourage information sharing in multiple ways so that it works to enhance an organization s current resources. Automate Your Data Collection DMSI is the world leader in automating maintenance inspection rounds using industrial handheld tools. With several thousand industrial handhelds operating every day, MAINTelligence has the breadth of capability and the rugged reliability you need for your plant s operation. Choose from many different makes of industrial handhelds - MAIN- Telligence works on all Windows Mobile devices, regardless of the manufacturer. Bring in reliability data from any or all of these sources: Vibration Analysis (both data collectors and online systems) Oil Analysis (extensive list of laboratories) Ultrasonics Thermography Process Data (DCS / PLC / Data Historians / OPC) Send reliability data to any or all of these destinations: Data Historians (OSIsoft PI, Aspentech IP.21) ERP / EAM systems (SAP PM, IBM MAXIMO, Ventyx, JD Edwards etc.) MAINTelligence Is... Open MAINTelligence is built upon the MAINTelligence API, a set of published interfaces that define how to move data in and out of MAIN- Telligence. These APIs allow end users or third party OEMs to move data in and out of MAINTelligence to suit their needs. Using these APIs, clients have customized MAINTelligence in numerous ways to fit all sorts of environments and other systems. Design Maintenance Systems Inc. 38 Fell Avenue, Suite 201 North Vancouver, BC, Canada V7P 3S2 Toll Free 1.800 923-3674 Tel 1.604 984-3674 www.desmaint.com