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설비관리전략의최적화방안과솔루션 - dbguide.net

/ IBM Industry Solution Summit 2008 IBM Corporation July 8th, Tuesday, 2008 ( )Tivoli SWGT hink Innovation ( ) III IV ( ) II ( ) OverviewI / IBM Industry Solution Summit3 Copyright IBM Corporation 2008 ( ) ? ( ) Lifecycle ITPlanEvaluate and DesignCreate / ProcureOperateMaintainModifyDisposeAsset StrategyLand, Offices Warehouses, Retail Space, Schools, Housing, HospitalsMining, Semi-Conductor, Textile, Chemical, Petroleum, Electronics, FoodMilitary, Airlines, Trucking, Shipping, Railroad, PublicRailways, Electric / Gas Distribution, Highways, Telecom, Water, WastewaterComputers, Routers, Networks, Software, Auto Discovery, Service Desky ( ) ( , , , , , , ) / IBM Industry Solution Summit4 Copyright IBM Corporation 2008198019801990199020002000201020101970 1970 Necessary Evil Paper Systems Corrective Maint.

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Transcription of 설비관리전략의최적화방안과솔루션 - dbguide.net

1 / IBM Industry Solution Summit 2008 IBM Corporation July 8th, Tuesday, 2008 ( )Tivoli SWGT hink Innovation ( ) III IV ( ) II ( ) OverviewI / IBM Industry Solution Summit3 Copyright IBM Corporation 2008 ( ) ? ( ) Lifecycle ITPlanEvaluate and DesignCreate / ProcureOperateMaintainModifyDisposeAsset StrategyLand, Offices Warehouses, Retail Space, Schools, Housing, HospitalsMining, Semi-Conductor, Textile, Chemical, Petroleum, Electronics, FoodMilitary, Airlines, Trucking, Shipping, Railroad, PublicRailways, Electric / Gas Distribution, Highways, Telecom, Water, WastewaterComputers, Routers, Networks, Software, Auto Discovery, Service Desky ( ) ( , , , , , , ) / IBM Industry Solution Summit4 Copyright IBM Corporation 2008198019801990199020002000201020101970 1970 Necessary Evil Paper Systems Corrective Maint.

2 Freq. based PM s New Technologies PdM Software Systems Change PM Freq Can Change Bottom Line Looking at Root Causes Mature Software Systems Focus on Components Maturing Organizations Looking at Lifecycles Upstream Improvements Wireless Technologies Software Adjusts to Business Self Diagnostics Communicating Assets RFID Technology Wearable Computers Product Improvements ( ) y ( ) , / IBM Industry Solution Summit5 Copyright IBM Corporation 2008 ( ) y ( ) ~ Life cycle , , , , Tool Tool TCO Spare parts - / - , ~ TCO SRM OEE Outsourcing Marketplace - / TCO : Total Cost of Ownership SRM : Supplier Relationship Management / IBM Industry Solution Summit6 Copyright IBM Corporation 2008y ( ) ( ) , ( ) / IBM Industry Solution Summit7 Copyright IBM Corporation 2008 Quantifiable Benefits Towards Savings / ROI: Labor Utilization up by 10-20% Asset utilization up by 3-5% Increased planned maintenance by 50-80% New Equipment purchases down by 3-5% Lost warranty recoveries down by 10-50% On-hand inventory needs down by 20-30% Inventory carrying costs down by 5 - 20% Asset acquisition costs down by 5-10%Quantifiable Benefits Towards Savings / ROI.

3 Labor Utilization up by 10-20% Asset utilization up by 3-5% Increased planned maintenance by 50-80% New Equipment purchases down by 3-5% Lost warranty recoveries down by 10-50% On-hand inventory needs down by 20-30% Inventory carrying costs down by 5 - 20% Asset acquisition costs down by 5-10% ( ) Inventory Reduced on-hand inventories Reduced capital spares requirements Improved warehouse productivity Reduced material scrap and wasteProject Management/ Engineering Improved work planning/coordination Online document managementOperations/Production Extended life of assets Improved asset reliability and availability Reduced risk of non-compliance Support for Sarbanes-Oxley compliance Improved regulatory and safety compliance Improved customer satisfactionMaintenance Improved labor productivity Enhanced quality & service Increased asset capacity Improved work planning/coordination Improved warranty recovery Performance monitoring (KPI s) Improved information on vendor performance and equipment use More accurate data for improved decision makingy ( ) Input Cost Output Revenue Think Innovation ( ) III IV ( ) II ( )

4 OverviewI / IBM Industry Solution Summit9 Copyright IBM Corporation 2008 ( ) Frameworky ( ) Leadership, Control Improvement TALM: Total asset life cycle management BM: Breakdown Maintenance TBM: Time Based Maintenance CBM: Condition Based Maintenance PM: Preventive Maintenance FLM: First Line Maintenance MTTR: Mean Time To Repair MTBF: Mean Time Between Failure MDT: Maintenance Down Time RCM: Reliability Centered Maintenance FMEA: Failure Mode and Effect Analysis ( ) ( ) (Reliability centeredmaintenance) (Reliability centeredmaintenance) redesign / KPI Product line Hierarchy, , , BM, TBM, CBM, PM MTTR/ MTBF/ M-Cost, MDT / & &Scheduling , Integration FLM: Partnership PM, FMEA , Root cause , , , Process, Management TCO , / IBM Industry Solution Summit10 Copyright IBM Corporation 2008 LeadershipyLeadership , , Level IT4.

5 Tactics5. Material6. Plan7. KPI8. RCM9. Autonomous10. Re-eng Matrix ID Task NameStartFinish1 Genesis Corporation - Asset Management Implementation PlanFri 5/21/04 Fri 12/29/062 Project governanceFri 5/21/04 Fri 7/16/ 0412MM5 Assign corporate contracts to Corporate PurchasingTue 6/ 15/ 04 Mon 11/1/0416MM2 Centralize MRO purchasingMon 7/5/04 Fri 11/5/0424O3 Implement a hybrid organizational st ructureTue 6/ 15/ 04 Tue 8/ 2/0533O2 Conduct a maintenance skills needs anal ysisTue 8/ 10/ 04 Mon 1/3/0539MM6 Hire three HVAC technicians Tue 2/ 15/ 05 Mon 6/ 20/0543O1 Formalize maintenance training in each areaTue 1/4/05 Mon 3/ 14/0548I1 Implement CMMS ProdMon 6/28/04 Fri 10/22/0467MM4 Implement a recognized catalogue naming convention Mon 8/9/04 Mon 12/27/0473P2 Define work history details to be recorded by techniciansMon 6/14/04 Fri 7/2/0478P1 Implement consistent work management processesMon 7/12/04 Fri

6 2/4/0590MM7 -Implement warranty tracki ngFri 7/9/04 Fri 10/29/0494K1 I mplement a balanced set of key performance indicat orsMon 8/2/04 Fri 12/3/04102MM3 Establish a virtual central warehouseMon 7/5/04 Mon 11/15/04111S2 Implement process t o involve mai ntenance i n new equipmeMon 3/7/05 Fri 4/8/05116R1 I mplement Rel i ability CentredMaintenanceMon 1/31/05 Wed 11/ 2/ 05123MM1 Identify critical spares Tue 12/14/ 04 Mon 4/ 25/05128E1 Identify Operator maintenance t asksThu 11/ 3/ 05 Wed 1/18/ 06133S1 Implement Lifecycle Costi ng (LCC)Mon 1/9/06 Fri 3/24/ 06139I1 -Phase 2 -Integration of CMMS Prod to BaanMon 6/20/05 Fri 10/7/05141I1 -Phase 3 -Enhancements to CMMS ProdMon 9/11/06 Fri 12/29/06 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1200420052006ID Task NameStartFinish1 Genesis Corporation - Asset Management Implementation PlanFri 5/21/04 Fri 12/29/062 Project governanceFri 5/21/04 Fri 7/16/ 0412MM5 Assign corporate contracts to Corporate PurchasingTue 6/ 15/ 04 Mon 11/1/0416MM2 Centralize MRO purchasingMon 7/5/04 Fri 11/5/0424O3 Implement a hybrid organizational st ructureTue 6/ 15/ 04 Tue 8/ 2/0533O2 Conduct a maintenance skills needs anal ysisTue 8/ 10/ 04 Mon 1/3/0539MM6 Hire three HVAC technicians Tue 2/ 15/ 05 Mon 6/ 20/0543O1 Formalize maintenance training in each areaTue 1/4/05 Mon 3/ 14/0548I1 Implement CMMS ProdMon 6/28/04 Fri 10/22/0467MM4 Implement a

7 Recognized catalogue naming convention Mon 8/9/04 Mon 12/27/0473P2 Define work history details to be recorded by techniciansMon 6/14/04 Fri 7/2/0478P1 Implement consistent work management processesMon 7/12/04 Fri 2/4/0590MM7 -Implement warranty tracki ngFri 7/9/04 Fri 10/29/0494K1 I mplement a balanced set of key performance indicat orsMon 8/2/04 Fri 12/3/04102MM3 Establish a virtual central warehouseMon 7/5/04 Mon 11/15/04111S2 Implement process t o involve mai ntenance i n new equipmeMon 3/7/05 Fri 4/8/05116R1 I mplement Rel i ability CentredMaintenanceMon 1/31/05 Wed 11/ 2/ 05123MM1 Identify critical spares Tue 12/14/ 04 Mon 4/ 25/05128E1 Identify Operator maintenance t asksThu 11/ 3/ 05 Wed 1/18/ 06133S1 Implement Lifecycle Costi ng (LCC)Mon 1/9/06 Fri 3/24/ 06139I1 -Phase 2 -Integration of CMMS Prod to BaanMon 6/20/05 Fri 10/7/05141I1 -Phase 3 -Enhancements to CMMS ProdMon 9/11/06 Fri 12/29/06ID Task NameStartFinish1 Genesis Corporation - Asset Management Implementation PlanFri 5/21/04 Fri 12/29/062 Project governanceFri 5/21/04 Fri 7/16/ 0412MM5 Assign corporate contracts to Corporate PurchasingTue 6/ 15/ 04 Mon 11/1/0416MM2 Centralize MRO purchasingMon 7/5/04 Fri 11/5/0424O3 Implement a hybrid organizational st ructureTue 6/ 15/ 04 Tue 8/ 2/0533O2 Conduct a maintenance skills needs anal ysisTue 8/ 10/ 04 Mon 1/3/0539MM6 Hire three HVAC technicians Tue 2/ 15/ 05 Mon 6/ 20/0543O1 Formalize maintenance training in each areaTue 1/4/05 Mon 3/ 14/0548I1 Implement CMMS ProdMon 6/28/04 Fri 10/22/0467MM4 Implement a recognized catalogue naming convention Mon 8/9/04 Mon 12/27/0473P2 Define work history

8 Details to be recorded by techniciansMon 6/14/04 Fri 7/2/0478P1 Implement consistent work management processesMon 7/12/04 Fri 2/4/0590MM7 -Implement warranty tracki ngFri 7/9/04 Fri 10/29/0494K1 I mplement a balanced set of key performance indicat orsMon 8/2/04 Fri 12/3/04102MM3 Establish a virtual central warehouseMon 7/5/04 Mon 11/15/04111S2 Implement process t o involve mai ntenance i n new equipmeMon 3/7/05 Fri 4/8/05116R1 I mplement Rel i ability CentredMaintenanceMon 1/31/05 Wed 11/ 2/ 05123MM1 Identify critical spares Tue 12/14/ 04 Mon 4/ 25/05128E1 Identify Operator maintenance t asksThu 11/ 3/ 05 Wed 1/18/ 06133S1 Implement Lifecycle Costi ng (LCC)Mon 1/9/06 Fri 3/24/ 06139I1 -Phase 2 -Integration of CMMS Prod to BaanMon 6/20/05 Fri 10/7/05141I1 -Phase 3 -Enhancements to CMMS ProdMon 9/11/06 Fri 12/29/06 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1 Qtr 2 Qtr 3 Qtr 4 Qtr 1200420052006Do FirstDo LastHighHighBenefitsDifficultyLowLow1A2B 3A9A / IBM Industry Solution Summit11 Copyright IBM Corporation 2008 ControlyControl Data management, Maintenance tactic Material management , , , Utilization TCO TCOC apacity &Demand balanceCAPEX and OPEXO rganization &OutsourcingAsset InformationAsset Utilization Total asset visibility Plan, Evaluate, Operate Cap , Load Operate, Maintain OEE(Overal EquipmentEfficiency)

9 , TCO Workingcapital CAPEX OPEX Balance ~ , Outsourcing / IBM Industry Solution Summit Copyright IBM Corporation 2008 Age A small number of random failuresLife Control > / IBM Industry Solution Summit Copyright IBM Corporation 2008y1960s 1970s A A:The Bathtub Curve High infant mortality, then a low level of random failure, then a wear out B:The Traditional View A low level of random failure, then a wear out E:Random Failure 14%F F:The Reversed J curve 68%C C:A steady increase in the probability of failure but with no identifiable wear out D: 7%Age related 11%Not agerelated 89%Source: Report on Reliability Centred Maintenance, Nowlan & Heap, US DoD 1978 Control > / IBM Industry Solution Summit14 Copyright IBM Corporation 2008 PlannedMaintenance PM(PreventiveMaintenance) TBM(Time Based Maintenance) CM (Corrective Maintenance) PBM(Planned Breakdown Maintenance) EM(Emergency Maintenance)BM(Breakdown Maintenance) Trend PdM(Predictive Maintenance)CBM(Condition Based Maintenance) MP (Maintenance Prevention)P-Cost < F-CostP-Cost> F-CostFMEAP-Cost : Preventive CostF-Cost : Failure Cost y NoteNotePM (Preventive Maintenance) : , , , BM (Breakdown Maintenance) : CBM (Condition Based Maintenance) : TBM (Time Based Maintenance).

10 Control > ( ) / IBM Industry Solution Summit15 Copyright IBM Corporation 2008 Improvement > RCM (Reliability Centered Maintenance) .. ( ) .. yPM , , y PM Tool / IBM Industry Solution Summit16 Copyright IBM Corporation 2008 Improvement > (RCM) ?YY ?YNN ?NOn-conditiontask?Scheduledrestoration? Scheduleddiscard?Combinationof task?On-conditiontask?Scheduledrestorati on?Scheduleddiscard?On-conditiontask?Sch eduledrestoration?Scheduleddiscard?On-co nditiontask?Scheduledrestoration?Schedul eddiscard?Redesign isbe compulsoryNo scheduledmaintenanceRedesign maybe desirableNo scheduledmaintenanceRedesign maybe desirableFailure-findingtask?Redesign maybe compulsory RCM matrix.


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