July 2003 Product Suite Overview. July 2003 Impacts of Unmanaged Change What is the cost of downtime...

July 2003

Product Suite OverviewProduct Suite Overview

July 2003

Impacts of Unmanaged ChangeImpacts of Unmanaged Change

• What is the cost of downtime in each part of your What is the cost of downtime in each part of your environment?environment?

• What is the cost of non-compliance with laws and What is the cost of non-compliance with laws and governmental regulations?governmental regulations?

• Is product liability a concern? Is product liability a concern? • Is there a threat of vandalism or corporate Is there a threat of vandalism or corporate

espionage?espionage?• Can damage to life or property be caused by Can damage to life or property be caused by

uncontrolled change? uncontrolled change?

July 2003

Maintenance TodayMaintenance Today

Maintenance challengesMaintenance challenges– Reduce Reduce MROMRO costs costs– Improve uptimeImprove uptime– Experienced maintenance Experienced maintenance staff retiringstaff retiring– Automation landscape is Automation landscape is increasingly complexincreasingly complex

• Distributed ArchitecturesDistributed Architectures• More configurable, intelligent devicesMore configurable, intelligent devices• Integration with information systemsIntegration with information systems

Maintenance needsMaintenance needs– Maximize uptime by proactively avoiding downtimeMaximize uptime by proactively avoiding downtime

• Cost constraints require automated systemsCost constraints require automated systems• Utilize device intelligence for maintenance purposesUtilize device intelligence for maintenance purposes

– Maximize uptime by minimizing downtimeMaximize uptime by minimizing downtime• Maintenance systems point to cause, not symptomMaintenance systems point to cause, not symptom• Automatically generate work ordersAutomatically generate work orders• Automatically suggest corrective actionsAutomatically suggest corrective actions

July 2003

RSMACC ArchitectureRSMACC ArchitectureCommon ArchitectureCommon Architecture

– RSMACC Server for collaborationRSMACC Server for collaboration– RSMACC Client common to all RSMACC Client common to all

applicationsapplications– FactoryTalk-enabledFactoryTalk-enabled

Plug In ComponentsPlug In Components– RSMACC Change RSMACC Change

ManagementManagement• Authenticate, audit, archive, Authenticate, audit, archive,

and verify device configurationand verify device configuration– RSMACC Network HealthRSMACC Network Health

• Monitor, report, and diagnose Monitor, report, and diagnose device and network healthdevice and network health

– RSMACC Enterprise Online RSMACC Enterprise Online Condition MonitorCondition Monitor

• Integrated automation condition Integrated automation condition monitoringmonitoring

– RSMACC Automated Asset RSMACC Automated Asset ManagerManager

• Automate preventive, Automate preventive, predictive, and reactive predictive, and reactive maintenancemaintenance

July 2003

RSMACC Change ManagementRSMACC Change Management

Managing Device ConfigurationManaging Device Configuration

July 2003

Could Your Facility Recover?Could Your Facility Recover?

May 8, 2003 Oklahoma City, OKA F-4 tornado ripped through the GM Plant located in Midwest City, OK devastating the facility. The west wall of the 4 million-square-foot plant was peeled off. GM officials have no specific word on damage to the equipment inside. The plant's paint shop was heavily damaged. Plant operations have been suspended indefinitely. - Online News story

July 2003

Changes Cause Problems When…

Changes Cause Problems When…

• They are not documentedThey are not documented• The old configuration can’t be recoveredThe old configuration can’t be recovered• The changes are not accessible to all who The changes are not accessible to all who

need themneed them• Access to configurations is not controlledAccess to configurations is not controlled• Multiple versions exist without accurate Multiple versions exist without accurate

identificationidentification• Multiple people are making independent Multiple people are making independent

changeschanges

July 2003

Changes Cost Money when…Changes Cost Money when…

• Obsolete configurations get Obsolete configurations get mistakenly loaded or reloadedmistakenly loaded or reloaded

• Legitimate changes are reversed or Legitimate changes are reversed or overwrittenoverwritten

• Effects are not fully understoodEffects are not fully understood• They break regulationsThey break regulations• Product has to be scrapped or Product has to be scrapped or

reworkedreworked• Production time is lostProduction time is lost

July 2003

RSMACC Change Management Solution


July 2003



• RSMACC Change RSMACC Change Management starts with Management starts with the core infrastructure the core infrastructure common to all RSMACC-common to all RSMACC-enabled solutionsenabled solutions

July 2003



• Allows you to control who Allows you to control who can use an application and can use an application and what actions they can what actions they can perform while using the perform while using the applicationapplication

Access Control/ Authenticate

July 2003

Maintenance Desktop ApplicationsMaintenance Desktop Applications

• Authentication Module (Security)Authentication Module (Security)– Rockwell Software's Security Server capabilities are incorporated into Rockwell Software's Security Server capabilities are incorporated into

RSMACC. RSMACC. – Restrict product functionality by user or workstation Restrict product functionality by user or workstation

July 2003



• Provides a system wide Provides a system wide repository for historical repository for historical storage of your application storage of your application configuration files, or any configuration files, or any other file you addother file you add


Archive

July 2003

Archive ModuleArchive Module

July 2003

RSMACC Change Management SolutionRSMACC Change Management Solution

• Gives you the ability to Gives you the ability to know exactly know exactly whowho has has modified a control system modified a control system configuration or application configuration or application parameter, parameter, whatwhat they they changed, changed, wherewhere they did it they did it from, and from, and whenwhen the the change was made.change was made.


Archive Audit

July 2003

Audit DatabaseAudit Database

July 2003

Event DatabaseEvent Database

July 2003

• Allows you to ensure that Allows you to ensure that the control system the control system configuration you think is configuration you think is running your application, running your application, isis running your applicationrunning your application

• Supports application Supports application restoration following a restoration following a catastrophic event catastrophic event (lightning strike, flood, fire, (lightning strike, flood, fire, etc.)etc.)



Archive Audit

Verification

July 2003

VerificationVerification

July 2003


• Allows you to generate Allows you to generate views into the Change views into the Change Management system for Management system for more detailed analysis of more detailed analysis of configuration changesconfiguration changes


Archive Audit

Verification

Report

July 2003

ReportingReporting

July 2003

“Managed Change” Means…“Managed Change” Means…• Having the ability to Having the ability to

reproduce past reproduce past configurationsconfigurations

• Keeping records of Keeping records of modifications to control modifications to control system configurations and system configurations and why the modifications why the modifications were necessarywere necessary

• Periodically archiving Periodically archiving (back-up) control system (back-up) control system configurations configurations

• Periodically verifying Periodically verifying control system control system configurations’ accuracy configurations’ accuracy

• Securing access to control Securing access to control system configurationssystem configurations

The Value of Change Management is greatest when applied proactively rather than after the fact

PROACTIVE

REACTIVEVA

LU

E

Detection

Prevention

Control

Accountability

Reconciliation

Archive

Audit

Verification/Recovery

Reporting

Access Control

Authentication

July 2003

SummarySummary• Is your organization challenged by any of the Is your organization challenged by any of the

following?following?– excess costs from downtimeexcess costs from downtime– extended product release cycles or other costs from extended product release cycles or other costs from

non-compliance with laws or regulationsnon-compliance with laws or regulations– product liability concernsproduct liability concerns– terrorism, employee vandalism, or corporate espionageterrorism, employee vandalism, or corporate espionage– managing employee efficiencymanaging employee efficiency– life or property liability caused by uncontrolled changelife or property liability caused by uncontrolled change– recovery from a natural disaster or catastrophic eventrecovery from a natural disaster or catastrophic eventRSMACC Change Management provides a robust set of

manufacturing configuration management tools to address these challenges

July 2003

Introduction toRSMACC Network Health

Introduction toRSMACC Network Health

July 2003

What is RSMACC Network Health?


• CCentralized management and monitoringentralized management and monitoring of the of the health maintenance health maintenance of networked assetsof networked assets (enterprise-wide) coupled with (enterprise-wide) coupled with distributed distributed access to the toolsaccess to the tools and facilities needed to and facilities needed to maintain those assets. maintain those assets.

• Each asset’s health record is maintained in a Each asset’s health record is maintained in a central data storecentral data store but consumers of this data but consumers of this data (maintenance and production staff) can make (maintenance and production staff) can make use of this data, even act upon it, from use of this data, even act upon it, from anywhere in the enterprise.anywhere in the enterprise.

July 2003



• ““Next Generation” of RSNetWorx MDNext Generation” of RSNetWorx MD– Provides Provides diagnostic monitoringdiagnostic monitoring, fault detection, and troubleshooting , fault detection, and troubleshooting

for for networked networked control devicescontrol devices– Runs in the backgroundRuns in the background based on user-defined schedules based on user-defined schedules– Provides access to the full suite of interactive RSNetWorx MD Provides access to the full suite of interactive RSNetWorx MD

configuration, diagnostics and troubleshootingconfiguration, diagnostics and troubleshooting

• RSNetWorx provides configuration editingRSNetWorx provides configuration editing• RSMACC Server provides enterprise coverageRSMACC Server provides enterprise coverage

– Add service modules as needed for auto diagnosticsAdd service modules as needed for auto diagnostics– Messages from all networks logged to one centralized RSMACC Messages from all networks logged to one centralized RSMACC

databasedatabase

• Currently supports DeviceNet, ControlNet and Currently supports DeviceNet, ControlNet and EtherNet/IPEtherNet/IP

July 2003

Networked Services Networked Services

Event Repository

Diagnostic Repository Ethernet Services

DeviceNet Services

Client Workstations

Service Monitoring

ControlNet Services

How Does RSMACC Network Health Work?How Does RSMACC Network Health Work?

NetworxMD

NetworxMD

NetworxMD

July 2003

Diagnostic LoggingDiagnostic Logging

• Centralized logging to RSMACC Diagnostics and Centralized logging to RSMACC Diagnostics and Health Log (plant-wide, enterprise wide). Health Log (plant-wide, enterprise wide). – Records all diagnostic messages from all instances of Network Records all diagnostic messages from all instances of Network

Health Services that are “plugged into” RSMACCHealth Services that are “plugged into” RSMACC

• View troubleshooting information for a particular View troubleshooting information for a particular error message from within the Diagnostic Logerror message from within the Diagnostic Log

• Change the status of a diagnostics message from Change the status of a diagnostics message from within the RSMACC Client to: Open, Closed, within the RSMACC Client to: Open, Closed, Deferred, Follow Up or IgnoreDeferred, Follow Up or Ignore

• Use RSMACC search engine to produce reports on Use RSMACC search engine to produce reports on plant-wide diagnostic data plant-wide diagnostic data

July 2003

Where Does RSMACC Network Health Fit?

Where Does RSMACC Network Health Fit?

• Configuration TimeConfiguration Time– Initial health assessment and configuration verificationInitial health assessment and configuration verification

• Planned MaintenancePlanned Maintenance– Perform periodic health snapshots Perform periodic health snapshots

• Corrective MaintenanceCorrective Maintenance– As needed when device and/or network problems ariseAs needed when device and/or network problems arise

• Preventive MaintenancePreventive Maintenance– Background unattended diagnostic monitoring (probing)Background unattended diagnostic monitoring (probing)– Device replacement detectionDevice replacement detection

July 2003

Maintenance Offerings/BrandsMaintenance Offerings/Brands

RSMACC Enabled Products and Solutions

Emonitor Family (Odyssey/Enshare)

Entrx

MAXIMO

July 2003

Ethernet

24vdc

509 -BODFLEX IOFLEX IO

The XM™ SolutionThe XM™ Solution

DataRSMACC

Client

INDUSTRY WEEK

2002

TECHNOLOGY OF THE YEARTECHNOLOGY OF THE YEAR

INDUSTRY WEEK

2002

TECHNOLOGY OF THE YEARTECHNOLOGY OF THE YEAR

“…“…innovations that have the potential to abruptly innovations that have the potential to abruptly change the conventional order of things.”change the conventional order of things.”

“…“…innovations that have the potential to abruptly innovations that have the potential to abruptly change the conventional order of things.”change the conventional order of things.”

EDITOR’S CHOICE AWARDEDITOR’S CHOICE AWARD2002

EDITOR’S CHOICE AWARDEDITOR’S CHOICE AWARD2002

“…service to the industry, technological advancement, and market impact.”

“…service to the industry, technological advancement, and market impact.”

Plant Services2002

MRO PRODUCT OF THE YEARMRO PRODUCT OF THE YEAR

Plant Services2002

MRO PRODUCT OF THE YEARMRO PRODUCT OF THE YEAR

Gold Medal WinnerGold Medal WinnerGold Medal WinnerGold Medal Winner

NetworkedNetworked

Direct To ControllerDirect To Controller

Direct To HostDirect To Host

StandaloneStandaloneD

evic

eNe

t

Dev

iceN

et

The Industry’s Most Flexible H/W Architecture

ControlNet Profibus

Ethernet/IP Modbus/TCP

Industrial Bus Gateway

Ethernet Gateway

Integral Relays

4-20mA Outputs

Buffered Outputs

DeviceNet

HOW?HOW?

July 2003

RSMACC Enterprise Online Condition Monitor (CM)

RSMACC Enterprise Online Condition Monitor (CM)

July 2003

Current Limitations of CM SystemsCurrent Limitations of CM Systems

CM Software systems are powerful and CM Software systems are powerful and effective tools for condition monitoring; effective tools for condition monitoring; however, these systems arehowever, these systems are::

― Typically Typically used only by the maintenance departmentused only by the maintenance department and and machine health information is machine health information is not shared effectivelynot shared effectively throughout the organization in a timely and efficient throughout the organization in a timely and efficient mannermanner

― Very specialized and require Very specialized and require substantial trainingsubstantial training to master. to master. – Not given the full recognitionNot given the full recognition they deserve since other they deserve since other

departments within the organization do not have easy departments within the organization do not have easy access to machinery health informationaccess to machinery health information

– Not always able to gather data when and where needed Not always able to gather data when and where needed due to regulatory and/or man power limitationsdue to regulatory and/or man power limitations

– Not typically integrated with other plant information Not typically integrated with other plant information systemssystems

July 2003

What is the RSMACC Enterprise Online Solution?

What is the RSMACC Enterprise Online Solution?

It is a It is a machinery healthmachinery health information information displaydisplay system that takes digital system that takes digital images of your plant equipment and images of your plant equipment and combines them with combines them with livelive datadata from from the the XMXM and and EnwatchEnwatch family of online family of online monitors as well as other plant monitors as well as other plant information systems information systems

using using FT LiveDataFT LiveData..

July 2003

RSMACC Enterprise OnlineRSMACC Enterprise Online• Online configuration Online configuration

capabilitycapability• Graphical or hierarchy Graphical or hierarchy

display of network display of network devices in configuratordevices in configurator

• Live Time data display Live Time data display from any XM channelfrom any XM channel– Trend, Spectrum, Trend, Spectrum,

Waveform, Waveform, Waterfall, Polar, Waterfall, Polar, Orbit, Shaft-Orbit, Shaft-CenterlineCenterline

• Mimic display with live Mimic display with live data and alarm statusdata and alarm status

July 2003

RSMACC Enterprise Online Benefits


• Reduces human exposure to dangerous situations Reduces human exposure to dangerous situations (lives)(lives)– Hard to access areas of a machine, machine train or lineHard to access areas of a machine, machine train or line– Hazardous environment areas are avoidedHazardous environment areas are avoided

• Allows people to concentrate on problem-solving Allows people to concentrate on problem-solving instead of manual data collection (time)instead of manual data collection (time)– Consistent collection techniqueConsistent collection technique

• Enables data acquisition to be scheduled more Enables data acquisition to be scheduled more frequently for earlier fault diagnosis (machinery)frequently for earlier fault diagnosis (machinery)– Capture more data, more frequently and from a wider array of Capture more data, more frequently and from a wider array of

sourcessources

• Compact size of hardware allows it to be installed Compact size of hardware allows it to be installed close to the machine under surveillance reducing close to the machine under surveillance reducing costs ($)costs ($)

• Allows “non-PdM experts” a snapshot overview of Allows “non-PdM experts” a snapshot overview of the plant machinery healththe plant machinery health– Allows staff to respond quickly to machine problems to minimize Allows staff to respond quickly to machine problems to minimize

costly downtimecostly downtime

July 2003



• Gives intuitive visual display of the plant Gives intuitive visual display of the plant status at a glancestatus at a glance

• Transfers data over existing Ethernet LAN for Transfers data over existing Ethernet LAN for sequential monitoring of machines sequential monitoring of machines distributed throughout the plantdistributed throughout the plant

• Offers remote monitoring of equipment Offers remote monitoring of equipment anywhere in the world via the Internetanywhere in the world via the Internet– Performs “live-mode” monitoring of spectra, time waveforms, Performs “live-mode” monitoring of spectra, time waveforms,

trends, spectral maps, orbits and polar plots as well as transient trends, spectral maps, orbits and polar plots as well as transient types of data types of data

– Allows data from any channel of a specified unit to be Allows data from any channel of a specified unit to be transferred, processed and displayed on your workstation transferred, processed and displayed on your workstation

– Permits people to quickly diagnose machines in alarm Permits people to quickly diagnose machines in alarm condition without having to walk out to the machine condition without having to walk out to the machine with a portable data collector to troubleshootwith a portable data collector to troubleshoot

RSMACC Automated Asset Manager


RSMACC Integration with MAXIMORSMACC Integration with MAXIMO

Critical Issues Affecting BusinessCritical Issues Affecting Business

• Improve YieldImprove Yield• Improve AvailabilityImprove Availability• Improve Production RateImprove Production Rate• Reduce Maintenance Reduce Maintenance

CostCost• Extend Asset LifeExtend Asset Life• Defer Maintenance Defer Maintenance

ActionsActions• Decrease MTTRDecrease MTTR• Increase Machinery Increase Machinery

UptimeUptime

• Reduce Time to MarketReduce Time to Market• Reduce Asset BaseReduce Asset Base• Reduce InventoryReduce Inventory• SafetySafety• Regulatory ComplianceRegulatory Compliance• Meeting Delivery Meeting Delivery

SchedulesSchedules• Increase Operating Increase Operating

EarningsEarnings

Overall Equipment Efficiency ImpactOverall Equipment Efficiency Impact

• At a large cement manufacturer, a one point At a large cement manufacturer, a one point improvement in OEE is estimated to improve improvement in OEE is estimated to improve operating earnings by $10M annually.operating earnings by $10M annually.

• Since installing an integrated solution, a large Since installing an integrated solution, a large consumer products company improved OEE from consumer products company improved OEE from 63 to 93! In addition, planned shutdowns have 63 to 93! In addition, planned shutdowns have now been reduced from one day a week to one now been reduced from one day a week to one day every six weeks!day every six weeks!

Improving the Bottom LineImproving the Bottom Line

• How can RSMACC improve OEE?How can RSMACC improve OEE?– Automated Asset ManagerAutomated Asset Manager

• Provides the means to reduce the time required for Provides the means to reduce the time required for maintenance actionsmaintenance actions

• Improves uptime by allowing for better maintenance Improves uptime by allowing for better maintenance planning and schedulingplanning and scheduling

• Improving OEE helps achieve business goalsImproving OEE helps achieve business goals

What You HaveWhat You Have

Meter Readings

Audit TrailDevice HealthNetwork Statuses

Work OrdersPreventive Maintenance Vibration Data

Oil DataThermo-graphic DataProcess Data

PLC Program Archive

Condition Monitoring

Asset Management

Change ManagementNetwork Health

System ConceptSystem Concept• Move data from plant systems to MAXIMOMove data from plant systems to MAXIMO• Move information from plant systems to MAXIMOMove information from plant systems to MAXIMO• Move analyses into MAXIMOMove analyses into MAXIMO• Consolidate the connections to MAXIMOConsolidate the connections to MAXIMO

– Standard InterfacesStandard Interfaces– One system handles the integrationOne system handles the integration

• No need to setup interface multiple timesNo need to setup interface multiple times

• Track status of work orders and dataTrack status of work orders and data– Plan for work based on status and changesPlan for work based on status and changes– Adjust schedules and priorities of planned workAdjust schedules and priorities of planned work

The Old WayThe Old Way• Paper TransactionsPaper Transactions• Maintenance is an islandMaintenance is an island• Work done not effectively tracked against Work done not effectively tracked against

conditionsconditions• Integration between various systems often Integration between various systems often

cumbersome and expensivecumbersome and expensive• The causes of maintenance problems often go The causes of maintenance problems often go

unsolved due to lack of resourcesunsolved due to lack of resources

The New WayThe New Way• Every system communicates information and Every system communicates information and

data along a common infrastructuredata along a common infrastructure• Upgrading software does not break integration Upgrading software does not break integration

linkslinks• Work done is correlated with asset conditionWork done is correlated with asset condition

– Work effectiveness is easily determinedWork effectiveness is easily determined

Automated Asset Manager Architecture

Automated Asset Manager Architecture

MAXIMO Server (Web Server)

Condition Monitoring – Predictive Maintenance System

PLC and Meter information

OPC Server


Complete Automation Integration

Work Order Information

OPC Data

Other Automation Systems (Network Health, Change Management…)

Work Order Information

Ethernet

24vdc

509 -BODFLEX IOFLEX IO

RSMACC Automated RSMACC Automated Asset ManagerAsset Manager®®

System ArchitectureSystem Architecture

• Preventive DataPreventive Data– Primarily metric, from PLC,s etc.Primarily metric, from PLC,s etc.– Can be in the form of meter readings, cycles, process dataCan be in the form of meter readings, cycles, process data– Represents data that defines predefined maintenance Represents data that defines predefined maintenance

schedulesschedules• Oil ChangeOil Change

• Reactive DataReactive Data– Allows immediate action on any event in RSMACC systemAllows immediate action on any event in RSMACC system– As events occur, work orders are generatedAs events occur, work orders are generated

• Network device failsNetwork device fails

• Predictive DataPredictive Data– allows for scheduling and minimal disruptionallows for scheduling and minimal disruption– Condition monitoring, predictive maintenanceCondition monitoring, predictive maintenance

• Bearing life estimations, cycle & pattern analysisBearing life estimations, cycle & pattern analysis

• Status screens in RSMACC clientStatus screens in RSMACC client– Instant feedbackInstant feedback

RSMACC Automated Asset Manager DataRSMACC Automated Asset Manager Data

• Sources of Data and InformationSources of Data and Information– RSMACC Network HealthRSMACC Network Health– RSMACC Enterprise Online Condition MonitorRSMACC Enterprise Online Condition Monitor– PLC’sPLC’s– Motor Control CentersMotor Control Centers– Any data nodeAny data node– EventsEvents

• Data FlowData Flow– Pass through to external systemPass through to external system– Evaluate to generate work request actionEvaluate to generate work request action

Sources of DataSources of Data

RSMACC Automated Asset Manager Interface

RSMACC Automated Asset Manager Interface

Industry MetricsIndustry Metrics

• Better manage maintenance practicesBetter manage maintenance practices– Conservative estimatesConservative estimates

• 10% extra maintenance staff exists due to poor planning, 10% extra maintenance staff exists due to poor planning, unnecessary PM tasksunnecessary PM tasks and not involving operators and not involving operators

• 25% extra administrative staff due to lack of EAM integration25% extra administrative staff due to lack of EAM integration• 5% of capacity lost due to poorly managed maintenance 5% of capacity lost due to poorly managed maintenance

practicespractices

– By automating the work request creation By automating the work request creation process, the efficiency of creating and managing process, the efficiency of creating and managing work orders increaseswork orders increases

(source: (source: Strategic MRO, Strategic MRO, MacInnes & Pearce, 2002)MacInnes & Pearce, 2002)

Industry MetricsIndustry Metrics

• Integrate Production and Maintenance Integrate Production and Maintenance PlanningPlanning– Average 35% labor utility in maintenance Average 35% labor utility in maintenance

departmentdepartment– 30% excess MRO inventories30% excess MRO inventories

• Wrench Time for a typical work order is 20-Wrench Time for a typical work order is 20-25%25%– Opportunity to save 80% of typical work order timeOpportunity to save 80% of typical work order time

(source: Strategic MRO, MacInnes & Pearce, 2002)

Workflow TerminologyWorkflow Terminology

* From Strategic MRO, MacInnes & Pearce, 2002

GOAL – Reduce the time from Failure Prediction or Occurrence to Asset Restoration

SupplyLead Time

AssetRestored

WorkRequest

BatchDelay

WorkOrder

ApprovalProcessDelay

WorkOrderBatchDelay

WorkOrderCycleTime

DemandCommunicationProcess Delay

FailurePredicted

orOccured

Potential orActual Failure

Communicated

Industry ExampleIndustry ExampleFood ManufacturerFood ManufacturerThe seal on a mixture pump is failing, causing incorrect The seal on a mixture pump is failing, causing incorrect

pressures and mixture settings in the final product pressures and mixture settings in the final product area. The scheduled collection of data isn’t due for area. The scheduled collection of data isn’t due for a week, when a manual collection occurs. By the a week, when a manual collection occurs. By the time the pressure reading is recorded, four batches time the pressure reading is recorded, four batches of final product is already ruined.of final product is already ruined.

• RSMACC Automated Asset Manager ‘automates’ the RSMACC Automated Asset Manager ‘automates’ the process of data collection. This can be done at process of data collection. This can be done at shorter time intervals. Because this data is entered shorter time intervals. Because this data is entered directly into the system that makes decisions about directly into the system that makes decisions about maintenance schedules, the corrective actions can maintenance schedules, the corrective actions can be quickly and efficiently executed.be quickly and efficiently executed.

• RSMACC Automated Asset Manager Value RSMACC Automated Asset Manager Value PropositionProposition– Automated, timely data acquisitionAutomated, timely data acquisition

Current Customer InstallationCurrent Customer Installation• Factory EnvironmentFactory Environment• Using AAM to monitor the cycles on 64 Wall Using AAM to monitor the cycles on 64 Wall

DampersDampers• Want maintenance performed after 20 hours of Want maintenance performed after 20 hours of

operationoperation– During a given time frame, one damper may operated for 20 During a given time frame, one damper may operated for 20

hours, while another may operate for 0 hourshours, while another may operate for 0 hours• Time based maintenance not very efficientTime based maintenance not very efficient

– Takes 8 hours to get to a wall damper to determine if it needs Takes 8 hours to get to a wall damper to determine if it needs maintenancemaintenance

– On the average, only 50% of dampers need maintenanceOn the average, only 50% of dampers need maintenance– Assuming industry labor rates to be $45/hour, thenAssuming industry labor rates to be $45/hour, then

8 hour * $45/hour = $360/Wall Damper * 64 Wall Dampers = 8 hour * $45/hour = $360/Wall Damper * 64 Wall Dampers = $23,040$23,040

– Assuming only 50% needed $23,040/2 = $11,520 saved each Assuming only 50% needed $23,040/2 = $11,520 saved each quarterquarter

System Value SummarySystem Value Summary• Automates data collection processAutomates data collection process

– Less expensive than walk around data collectionLess expensive than walk around data collection– Accurate data collectionAccurate data collection

• Direct from sensor to databaseDirect from sensor to database

– Data is collected and stored on a regular basisData is collected and stored on a regular basis

• Work orders triggered automatically based on Work orders triggered automatically based on events in systemevents in system

• Reduces the time between the presentation of a Reduces the time between the presentation of a maintenance issue and its resolutionmaintenance issue and its resolution

System Value SummarySystem Value Summary• Work orders generated as soon as a problem presents Work orders generated as soon as a problem presents

itselfitself– No delay between reporting the problem and initiating No delay between reporting the problem and initiating

the solutionthe solution

• Track status and effectiveness of work practicesTrack status and effectiveness of work practices• Interface does not ‘touch’ customer’s MAXIMO Interface does not ‘touch’ customer’s MAXIMO

databasedatabase– No database triggers or other custom workNo database triggers or other custom work– No database modificationsNo database modifications

July 2003

July 2003 Product Suite Overview. July 2003 Impacts of Unmanaged Change What is the cost of downtime...

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