P roficy* M aintenance G ateway

Transcription

1 P roficy* M aintenance G ateway Implementing an agile maintenance solution. B arry Lynch G lobal Product Manag er G E Fanuc Intellig ent Platforms Dr Ananth S es han C EO Automatika LTD.

2 How do you.? Introduce agility in your maintenance activities to improve plant availability. D ecrease unplanned downtimes What are the challenges today in the via proactiverefinery maintenance. world?. Achieve better return on your production assets.

3 Answer The enterprise asset management capability of IB M M AX IM O partnered with the real time production management capability of G E F P roficy! +

4 What are the challenges today when applying agile maintenance practices.

5 C urrent P ractices: R E AC TIVE and AFTE R THE FAC T R eactive M aintenance (R un the as sets to failure then fix them!) C auses UNP LANNE D downtime O n average, unplanned downtime exceeds 20% of the total downtime in a plant -O R - C alendar-bas ed P reventive M aintenance (E x: firs t M onday of every quarter ) Will underes timate need leading to unplanned downtime O r, will overes timate need leading to unneces s ary cos ts

6 How to Increase P lant R eliability Move Away from Being O nly R E AC TIVE to Asset Failures! S trategy should include being P R O AC TIVE! C ritical maintenance actions should be focused on P R E VE NTING unplanned downtime E stablish an agile infrastructure between the plant and the enterprise prevent any delays in the implementation of the chosen strategy

7 What is a P roactive S trategy? P R E VE NTING failures by s cheduling maintenance at appropriate intervals bas ed on ass et criticality and failure his tories of components (M TTF,M TTR, etc.) -AND /O R P R E D IC TING imminent failures bas ed on s ymptoms and attending to them B E FO R E they occur especially, to eliminate downtime of critical, capacitycons training as s ets!

8 How to increase P lant P roduction R eadiness R educed Failure R ate Increased Asset R eliability Maintenance Practices R educed D owntime S tart Here Increased P lant P roduction R eadiness Increased P lant Availability

9 P olling Q uestion 1 D o you believe that a real time integration of the plant to an E nterprise Asset M anagement system such as M aximo is needed in the industry today?

10 Appropriate P reventive M aintenance S chedule Maintenance Based on the US AG E of the Assets to Avoi Under or O ver Maintenance S tep 1: S et a threshold for US AG E to drive P reventive M aintenance based on prior failure histories S tep 2: C ollect data from the machines regularly to compute US AG E S tep 3: O rder P reventive M aintenance when the actual US AG E exceeds the threshold

11 P redicting Failures Understand the Health of C ritical Machines by C ontinuously Monitoring the Trend of Key P rocess Variables and D erivatives If the trend is undesirable ( emerging failure symptoms ), there is a potential for a failure P revent such failures by ordering maintenance and executing the maintenance activity with agility even while the machines are still producing!

12 R eal-time is of the E ssence! Your R ight Mix of S trategies Must be Implemented with Minimal Latency for Maximum Agility Forward-Loop Latency the loop starting from data collection in the plant to generation of a maintenance Work Order in the Enterprise Asset Management System Reverse-Loop Latency the loop starting from the generation of a maintenance Work Order in the Enterprise Asset Management System to the closure of that order A gile Infras tructure: M inimize Forward-Loop Latency through real-time plant integration to E nterprise As s et M anagement S ys tems and R everse-loop Latency through real-time tracking of M TTR

13 P olling Q uestion 2 D o you have, or plan to have in the future, a real time integration between your plant and an E AM system such as M AX IM O?

14 How IB M and GE Fanuc can partner to help you achieve this agility.

15 R eal Improvements D emand R eal Time Visibility! Access to accurate, timely production intelligence is no longer optional. It s E S S E NTIAL! Plant Manag er Production Finance Operator Materials Lean/6 S ig ma Quality Maintenance Plant R eporting /Intellig ence C ompliance C ontinuous Improvement S upply C hain Integ ration/e AI R eporting, Vis ibility & Analytics Operational E xcellence Production Data with C ontext R eal-time Execution

16 P roficy P lant Applications is Focused on improving: Utilization of plant ass ets Quality of products produced Agility of production processes Integration between production and busines s systems M anufacturing costs and productivity

17 P lant Applications Today O ver 600 sites installed globally 70% are multi-site rollouts 15 different industries, same install. ( Hybrid manufacturing support) B est of class recognized by the industry D eployed in over 35 countries.

18 P lant Applications M odules

19 P olling Q uestion 3 D o you have, or plan to have in the immediate future, a P roficy M E S in your plant?

20 P roficy M aintenance G ateway Monitors the Health of All Your Assets All the Time R aw Proces s Data S tored and C ontextualized by Equipment & Events Data Flow Data Flow Maintenance Work Orders C reated, Viewed and C los ed

21 P roficy M aintenance G ateway Allows You in the Plant to C onfigure Your Maintenance R ules S ystem maps G E Fanuc S oftware to your M AX IM O S ystem C onfiguration wizards walk you through building your maintenance rules R ules can be time or event-based (for example, emerging conditions of failure) and can be edited at any time R ules configured and maintained by maintenance or production pers onnel in the plant

22 P roficy M aintenance G ateway Your Window to All Asset Maintenance and P roduction P erformance Information Leverage the P lant M odel in G E Fanuc software to navigate up to date M aintenance Information in M AX IM O. Access all the information you need for each asset O perating locations of equipment S tores, repair shops and vendors for equipment E quipment-related costs, histories, failures, etc Unstocked spare parts WO -related information

23 P olling Q uestion 4 D o you consider maintenance as a key, strategic activity, if planned and executed properly, can have a direct impact on reducing manufacturing costs and increasing the return on assets?

24 How do these two products play together..

25 E xisting M AX IM O Users P M G is THE s olution that trans forms M AX IM O into s uch a dynamic, agile as set management s ys tem. The powerful combination of P M G and M AX IM O delivers to a cus tomer higher predictability and reliability of production as s ets, and therefore more Availability, reduction in maintenance cos ts and increas e in the return on production as s ets by uncovering hidden capacity! MAXIMO C us tomers in the manufacturing vertical today find great value in inves ting in M AX IM O s ince it allows for efficient management of their production as s ets. B ut cus tomers can leverage M AX IM O more by making it automatically actionable bas ed on real-time maintenance intelligence that is extracted from real time production data. This additional component can trans form M AX IM O into a dynamic, agile as set management s olution that is not only abreas t of the current s tatus of the plant, but is always one s tep ahead of the emerging problems leading to equipment failures.

26 S ummarizing Your S teps to Transformation Move away from a R eactive-o nly Maintenance S trategy Formulate the R ight M ix of R eliabilityc entered s trategies that is appropriate for YO UR plant Will include, P reventive, P redictive and R eactive M aintenance Focus to minimize unplanned downtime Implement the R ight M ix by M AX IM IZING AG ILITY in the forward and revers e loops Us e real-time integration from the P lant to the M aintenance S ystem and real-time tracking of M TTR C ontinuous ly monitor and improve the R ight M ix to optimize the C ost of R eliability, maximize P lant Availability and increas e P lant P roduction R 2008 eadines s! G E Fanuc Intelligent P latforms

27 Q uestions?? G E Fanuc Intelligent P latforms B arry Lynch Global P roduct M anager P roficy P roduction M anagement T (434) C (540) D * barry.lynch@ gefanuc.com R t 29 North & R t 606 C harlottes ville, VA US A