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asset health management Achieving a Higher - …

AhM. ion decisort supp The Changing Landscape Each piece of equipment is then given a criticality rating. Appearance on this asset health What does the asset management management list is a strong indication that the asset is world look like when utilizing an in- critically important to overall production tegrated asset performance manage- and performance goals, which would be ment approach capable of linking pre- adversely affected by its failure. dictive intelligence with asset reliability information? Figure 1 displays an APM Overall Equipment home page, which can be customized Effectiveness Higher for each user, providing a quick view of the current state of asset performance, System customization allows spe- cific objectives to be established and availability, and maintenance in a spe- Achieving a tracked. For example, once key per- cific plant. Also displayed are histori- formance indicators are identified, a cal charts showing monthly results for Figure 1 manager can very quickly determine overall equipment effectiveness, avail- whether the targets are being hit or ability, and maintenance costs.

22 april/may11 april/may11 23 O ver the years, an ever-increasing volume of data on the condition of critical production assets has been generated by …

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Transcription of asset health management Achieving a Higher - …

1 AhM. ion decisort supp The Changing Landscape Each piece of equipment is then given a criticality rating. Appearance on this asset health What does the asset management management list is a strong indication that the asset is world look like when utilizing an in- critically important to overall production tegrated asset performance manage- and performance goals, which would be ment approach capable of linking pre- adversely affected by its failure. dictive intelligence with asset reliability information? Figure 1 displays an APM Overall Equipment home page, which can be customized Effectiveness Higher for each user, providing a quick view of the current state of asset performance, System customization allows spe- cific objectives to be established and availability, and maintenance in a spe- Achieving a tracked. For example, once key per- cific plant. Also displayed are histori- formance indicators are identified, a cal charts showing monthly results for Figure 1 manager can very quickly determine overall equipment effectiveness, avail- whether the targets are being hit or ability, and maintenance costs.

2 Users Level of Maintenance and missed. can obtain greater detail on any of As indicated earlier, Higher level these factors simply by clicking on one performance, including overall equip- of the dials. ment effectiveness (OEE) and avail- To learn about critical asset failures Reliability ability, is reflected on the home page, and how much they are costing the with details available by drilling down. Augie DiGiovanni and John Renick plant, the user moves the cursor to the For example, if OEE is declining as seen Linked Reports box in the lower left- in Figure 3, the specific assets that are hand portion of the home page and contributing to the decline can be clicks on Critical asset Failures and identified with a single click, so the When a critical asset in a Progressive companies already implementing Cost Summary. The Critical asset Fail- manager knows instantly where to fo- highly complex production sys- ure and Cost Summary screen (Figure tem fails without warning, the predictive maintenance are looking for proactive 2) shows where maintenance time and cus attention to reverse the trend.

3 The same is true of critical asset availability. cost in damage and downtime solutions to manage asset performance. money are being spent, pinpointing Reported benefits from organiza- can be heavy not to mention ten pieces of equipment by tag num- tions using this type of approach to as- the potential risk to personnel ber. Failure information pulled from Figure 2 set management include: O. and the environment, as dem- ver the years, an ever- Which assets represent the greatest risk to availability and safety? predictive diagnosis applications and Maintenance savings of $10M onstrated in several recent and increasing volume of The answers to these questions, as most managers know, have cost information from CMMS records within a year of implementation, highly publicized safety-related data on the condition remained hidden in their existing asset -related data. However, new are used to illuminate these bad ac- related to the identification of bad incidents.

4 asset reliability is be- of critical production assets technology now offers the means to aggregate, analyze, and leverage tors. actors . coming a competitive business has been generated by smart this information, enabling end-users to uncover significant opportuni- The bars on Figure 2 indicate the Reductions in reactive mainte- field assets connected to ad- ties for improving reliability and asset performance. number of time-consuming failures nance by 40 percent in less than a differentiator causing organiza- vanced automation systems. suffered by each asset over the past year tions to rethink how they can Moving to asset management While this data has reduced year, and the green line shows the to- Improvements in availability leverage existing resources to machine breakdowns and as- Diagnostic information generated in the field by intelligent instru- tal maintenance cost of each piece.

5 By totaling $3-5M per plant, per year improve the performance of sociated costs, asset availabil- ments and condition monitors provides critical information on plant clicking on tag number GC0036-083. their critical production assets. ity and uptime often remain assets in order to: (a gas compressor), the user finds out Conclusion below targeted levels. To Raise alarms when signs of impending failure appear so immedi- why that particular unit is costing more Predictive maintenance was a piv- facilitate an understanding of the reasons behind this problem, let's ate corrective action can be taken to avoid unplanned downtime, than $200,000 per year to maintain. otal first step in increasing reliability examine how asset data is used within an organization. reduce maintenance costs, and increase equipment reliability. Five failure modes for the compressor and lowering costs. Now, organizations Personnel in plants with thousands of pieces of equipment gener- Enable plant personnel to determine with some precision if re- are highlighted on the subsequent are identifying the necessity for a more ally have no good way of knowing if routine maintenance is being pairs can be delayed until the most favorable time, such as a screen, along with exactly which root comprehensive approach to the man- Figure 3.

6 Done too frequently or not often enough. Nor can they easily identify scheduled maintenance shutdown. cause is most costly. These reports can agement of their critical production the bad actors -- those few machines and field devices that cause the Predictive maintenance has proved to be less expensive than pre- be updated as frequently as required assets. Linking EAM with performance most problems. According to the Boston-based ARC Advisory Group, ventive maintenance and far less costly than reactive maintenance. by the end-user, so decisions can be made in real time. management , analytics, and predictive maintenance can offer an orga- plants in the process manufacturing industries typically operate 20 Given the significant advantages associated with using predictive By clicking on Risks to Reliability in the Linked Reports box, the user nization the opportunity to leverage their existing asset -related data to percent below full operational capacity, and equipment reliability is- technologies for asset care, organizations are now looking for ways can access a report showing the highest priority assets with degraded identify optimal asset strategies in support of their key business drivers.

7 Sues have been identified as one of the largest sources of Addi- to more fully utilize the huge volume of their existing field-based health . All plant equipment is prioritized on the basis of failure modes and 1 Woll, Dave. Emerson and Meridium Partner to Help Resolve the asset Performance management Puzzle, . tionally, organizations struggle to answer: data to develop optimal strategies for the management of their as- effects, understanding its operational significance, and the risk of failure. November 1, 2010. Are people spending their time on the right things every day? sets. According to Aberdeen Group's October 2010 report, The Role of Are the predictive tools being fully utilized? Software in asset Performance management , Linking Enterprise asset management (EAM) with performance management , analytics, and Augie DiGiovanni is Vice President of asset Optimization Services John Renick is the Partner Solutions Manager for Meridium, Inc.

8 He Are maintenance dollars being spent correctly to achieve high in Emerson's asset Optimization business. He is responsible for has over 12 years of experience working with asset -intensive indus- predictive maintenance are critical components/functionalities of an tries. In his current role, John oversees Meridium's partnerships and reliability? leading the design, implementation, and completion of service asset Performance management (APM) solution enabling companies ensures those partnerships deliver valuable solutions. Prior to serv- How can maintenance practices be changed to produce better projects, Machinery health management programs, and reliability to understand the value of both production and maintenance data ing as Partner Solutions Manager, John was the Product Manager results? solutions. This follows years of experience in reliability in a mission- overseeing Meridium's APM framework, Production Loss Accounting which is critical to the success of any reliability driven strategy.

9 The critical marine environment. Module, Mobile Framework, and Meridium mobile solutions. What equipment fails most often, and what's behind that failure report stated that 44 percent of survey respondents are planning on frequency? investing in this type of solution. 22 april/may11 april/may11 23. AhM. ion decisort supp The Changing Landscape Each piece of equipment is then given a criticality rating. Appearance on this asset health What does the asset management management list is a strong indication that the asset is world look like when utilizing an in- critically important to overall production tegrated asset performance manage- and performance goals, which would be ment approach capable of linking pre- adversely affected by its failure. dictive intelligence with asset reliability information? Figure 1 displays an APM Overall Equipment home page, which can be customized Effectiveness Higher for each user, providing a quick view of the current state of asset performance, System customization allows spe- cific objectives to be established and availability, and maintenance in a spe- Achieving a tracked.

10 For example, once key per- cific plant. Also displayed are histori- formance indicators are identified, a cal charts showing monthly results for Figure 1 manager can very quickly determine overall equipment effectiveness, avail- whether the targets are being hit or ability, and maintenance costs. Users Level of Maintenance and missed. can obtain greater detail on any of As indicated earlier, Higher level these factors simply by clicking on one performance, including overall equip- of the dials. ment effectiveness (OEE) and avail- To learn about critical asset failures Reliability ability, is reflected on the home page, and how much they are costing the with details available by drilling down. Augie DiGiovanni and John Renick plant, the user moves the cursor to the For example, if OEE is declining as seen Linked Reports box in the lower left- in Figure 3, the specific assets that are hand portion of the home page and contributing to the decline can be clicks on Critical asset Failures and identified with a single click, so the When a critical asset in a Progressive companies already implementing Cost Summary.


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