Honeywell EMEA12 Peacock Reliability Solutions

Sustain.Ability.

2012 Honeywell Users Group EMEA

1

Gary Peacock

Global Solution Marketing Manager, Asset Management

2

Agenda

1. Industry drivers

2. Time for a paradigm shift

3. Asset Management

4. RAMP solution

5. Product overview:

Asset Manager & Field Advisor

6. Next steps

3

Industry Concerns and Drivers

Common Asset Management concerns heard within Industry

Aging assets and infrastructure

Shrinking pool of experienced people

Robustness of Reliability System

Data and information overload

Market volatility and competition

4

The Data and information Problem

Reliability Maintenance Operations

EAM/CMMS (SAP, Maximo,

etc.)

Process Data (DCS, Historian,

etc.)

Control Loop Performance Monitoring Visual

Inspections

Smart Instruments (HART, FF, etc.)

Corrosion Monitoring

Condition Monitoring

Users try to determine asset status from disparate data sources

no common understanding of true status

5

Sensor

Fu

sio

n f

rom

Wik

ipedia

art

icle

Data and information: Sensor Fusion

combining data derived from disparate sources so that the resulting information is better

than when these sources are used individually.

DATA

INFORMATION

KNOWLEDGE

WISDOM

SENSE MAKING

7

Robustness of Reliability System

100% Maximum relevant utilization

One calendar year

Visualization of OEE and TEEP

TEEP

Not

scheduled to

run

Excess

capacity

Net % of Max Potential Rate (MPR) (@ best consecutive period production rate)

Rate

Loss

Lack

of

sales

de-

rate

Net % UPTIME Unplanned

Downtime

Lack

of

Sales

Down-

time

Planned

Down-

time

Net % of First Time Prime Quality Recycle or

Scrap

all TEEP Gaps are

considered, including

Scheduled Outages

OEE = 100% Maximum Scheduled utilization

TEEP = 100% Maximum Potential utilization

Total Effective Equipment Productivity

Overall Equipment Effectiveness

OEE

8

Overall Equipment

Effectiveness (OEE) Best-in-Class Middle 50% Bottom

Asset Management with

Predictive Failure Analysis 28% 17% 6%

Standardized KPIs

across enterprise 53% 40% 18%

Asset Downtime 3% 13% 34%

Plant Floor Automation 61% 45% 23%

Integrated EAM/CMMS 79% 56% 48%

Benchmarking

Table sources: 2010 Solarsoft Manufacturing Benchmark Study and Aberdeen Group, Enterprise Asset Management

Join STAN GRABILL for OEE Seminar on FRIDAY morning

OEE: Industrial Processes 90% 56% 42%

OEE: Food & Beverage 78% 62% 42%

OEE: Pharmaceuticals 45% 31% 23%

OEE = 100% Maximum

Scheduled utilization

9

To

Proactive / Predictive

Real time data

Reliability Centric

Online & Automated

Integrated RCM, CBM &

CMMS Solution

Proactive & Predictive

Asset Management with Predictive Failure Analysis

Real-Time Decision Making: A new paradigm

From

Reactive / Run-to-failure

Historical data

Inspection Centric

Paper Operator Rounds

CBM as a Point Solution

Fire fighting

10

Enterprise Asset Management Work-stream & Relationships

Think of Asset Management as 3 Distinct Areas

Many Data Sources

Condition Based Maintenance (CBM)

Real-Time & Off-Line Data

Field Inspection and rounds

Wired & Wireless

Reliability Centric Maintenance (RCM)

Enterprise Asset Management (EAM)

Computerised Maintenance Management Systems (CMMS)

11


Maintenance Management: EAM and CMMS

Maintenance Management

Work Execution Management

Work Order Generation

Document Management

Financial Management

Purchasing Management

Inventory/MRO Management

Planning & Scheduling

Integration with EAM and CMMS such as SAP and IBM Maximo

12

Alliance Partner (GP Allied)

400 Consultants Globally

Excellent Industry Reputation

Experience in all Industrial sectors

iReliability Suite of tools

Reliability Programs & Strategies

RCM / RCA

Asset Health Matrix

Equipment Maintenance Plan

KPI/Benchmarking

Change Management

Training (including craft skills)


Reliability: GP Allied

13


Condition Based Monitoring

Real-Time


Real-Time Corrosion monitoring

DCS & Historian

Simulation (UniSim)

Real-time Vibration Monitoring

Smart Instruments (FDM)

Operator Rounds (Field Advisor)

Oil Analysis

Other Condition Monitoring

14

CMMS / ERP

Integration

Corrosion Monitoring

Smart Instruments

Visual Inspections

DCS & Historian

Process and Alarm Data

Downtime Reporting

Control Loop Monitoring

Equipment Condition

Monitoring

Asset Performance & Health Assessment

Rotating

Machinery

Monitoring

Management

Reporting & KPIs

Maintenance &

Reliability Users

Integrating Real-time Asset Management

15

Single view of Asset Performance and Health

Data Management Applications

Very Clear & Easy to Understand

16

Key Performance Information

17

Abnormal Condition Assessment

18

Downtime Dashboard

19

Asset Manager

info used in

Reliability programs

Asset Manager

Notifications sent to EAM/CMMS

Reliable Asset Management Performance

RAMP

DATA SOURCES


DCS & Historian

Smart Instruments

Operator Rounds

Corrosion Data

Simulation (UniSim)

Oil Analysis

Vibration Monitoring

OUTPUTS

Alerts & Notifications

Management Reporting & KPIs

Maintenance & Reliability

Scorecards

Downtime Reporting

Health Assessment

Automatic Work Order Generation

Honeywell

Asset Manager

EAM/CMMS

Work Execution Mgmt

Maintenance Mgmt

Workflow

Document Mgmt

Financial Mgmt

Purchasing Mgmt

Inventory/MRO Mgmt

Scheduling

Programs & Strategies RCM/RCA Asset Health Matrix Equipment Maintenance Plan KPI/Benchmarking Change Management Training

20

Asset Manager offers a single view of performance and health

Integrating Real-time Asset Management

Equipment

Condition

Monitoring

Downtime

Reporting

Visual

Inspections

Corrosion

Monitoring

Smart

Instruments

DCS &

Historian

Asset

Manager

Downtime

Reporter

Corrosion

Field

Advisor

Vibration

Products

Smart

Instruments

UniSim

Wireless Asset Health

Management

Process

Reliability

KPI /

Benchmarking

Trending

RCM

Rotating

Machinery

Monitoring

RCM

Partners

and tools

Integration

with CMMS Integration

with EAM

21

Asset Manager

Real-Time Condition Based

Maintenance (CBM)

Reliability Centred

Maintenance (RCM)

Total Effective Equipment

Productivity (TEEP)

Overall Equipment

Effectiveness (OEE)

Computerized Maintenance

Management Sys. (CMMS)

Enterprise Asset

Management (EAM)

Real-Time Data Acquisition

STRATEGIC

TACTICAL

BENCHMARKING

TECHNOLOGY

INFRASTRUCTURE

Abnormal Situation

Management (ASM)

Operator Driven Reliability

(ODR)

Asset Health Monitoring

(AHM)

Risk Based Inspection

(RBI)

Reliability Centred Design

(RCD)


(WEM)

Reliability & Maintenance

Engineering (RME)

Operational Performance

Monitoring (OPM)

Scalable Solutions integrated through Asset Manager

Applying RAMP

22

Abnormal Situation

Management (ASM)


(ODR)


(AHM)


(RBI)


(RCD)


(WEM)


Engineering (RME)


Monitoring (OPM)


Applying RAMP: Tactical AHM

accurate view of asset health Field Advisor SKF Vibration Corrosion Monitoring Field Device Manager OneWireless Mobile Equipment Monitoring ..

STRATEGIC

TACTICAL

BENCHMARKING

TECHNOLOGY

INFRASTRUCTURE


Maintenance (CBM)

Reliability Centred

Maintenance (RCM)

23

Abnormal Situation

Management (ASM)


(ODR)


(AHM)


(RBI)


(RCD)


(WEM)


Engineering (RME)


Monitoring (OPM)


Applying RAMP: Tactical OPM

one view of the truth UniSim Design Downtime Reporter Corrosion Monitoring Well Performance Monitoring

OMPro .

STRATEGIC

TACTICAL

BENCHMARKING

TECHNOLOGY

INFRASTRUCTURE


Maintenance (CBM)

Reliability Centred

Maintenance (RCM)

24

1. Relentless integration of all aspects of people,

processes, and technology

2. Applied across the entire asset life cycle:-

Capital Delivery (CapX)

Operations (OpX)

Maintenance (MaintX)

3. Includes the management of all assets

mechanical, electrical, stationary, process automation and control assets

4. Modular and scalable

5. Change Management is woven into the deployment

RAMP Underlying Principles

Integration of People, Processes and Technology

25

Asset Manager R410

Built on the Intuition Platform

Single Location for Asset Management

Wired & Wireless Vibration Monitoring

Real-time Corrosion management

Control System & Instrumentation Monitoring

Inputs from OPC, PHD, any Experion site, ..

Integration with Honeywell and 3rd Party Products & Solutions

Aptitude Analyst & DMx (SKF Corp)

iReliability Suite; including a fault model library (GP Applied)

See these in the

demo room!!

Integrate information

Multiple sources

Future proof

Fault Models

Based on integrated information

Alerts

Based on the fault model execution

Alert-based Automatic Actions

Operator notifications

E-mail notification

Problem Solving

Collaboration between teams

Historical information

Link to relevant documentation

Another bridge between Operations and Maintenance

26

Field Advisor R200 and R201 (2012 releases)

Technology Refresh

Honeywell Intuition framework and modernized handheld user interface

Microsoft SQL Server Standard edition

Updated configuration tools with graphical configuration

New rounds scheduling, tracking and reporting calendar

Efficient Installation/Migration and Integrated Security

Automatically trigger and track operator tasks

Select Work

Execute Tasks

Enter comments

Review Consequences

When limits are exceeded

Review History

Corrective Actions

Execute reconditioning tasks

Upload Work

27

Tremendous Benefits Received

Reduce incidents by up to 40% Increase operator competency Support continuous improvement

Improve Safety

Reduce off-spec material up to 50%

Reduce transition material up to 30% Catalyst consumption down by 1% Improve throughput 2-8% Reduce energy use 5-10% Improve forecast accuracy 4-20% Reduce inventory 15-30 %

Improve Efficiency

Improve plant availability 3-8% Preserve and extend asset life Reduce maintenance costs 3-5% Improve customer service 5-15%

Improve Reliability

Green house gas emissions

reduced by 25%

Ensure compliance standards Reduced total cost of ownership Reduce energy consumption

Improve Sustainability

Typical Return on Investments are 3 Months to 1 Year

>$5B US in measurable benefits has been

added to our customers bottom-line *Results based on past customer experience

28

Recommended Next Steps (At HUG)

Visit the demo room Honeywell

Asset Management and RAMP

Asset Manager R410

Field Advisor

Corrosion

SKF Vibration

GPAllied iReliability

RCM

Attend the OEE Seminar Friday 16th November, 09:00 12:00

Presenter: Stan Grabill

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Recommended Next Steps (When you get back)

Ask for an assessment at your site

Start small if needed Solutions are scalable

Be a champion for your company

Must get operations and management involved

Do something

30

Questions?

[email protected]

Honeywell EMEA12 Peacock Reliability Solutions

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