Transcript Alcoa Reliability Team Tango Asset Management Capabilities

Tango Asset Management
Capabilities Presentation
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2.
3.
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5.
Desktop & Web Architecture
Equipment Management
Condition Management
Data Mining
Parameter Trending & Rounds Logging using a
PDA
6. Test & Inspection Task Management
7. Implementation
Problem
For every critical machine there are:
• Multiple condition assessment technologies
• Hundreds of design and maintenance
documents
• Multiple repair and overhaul failure and
repair reports
• Multiple installations at various locations
To Increase reliability the plant
must measure it
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Mean Time Between Failure MTBF
Root Cause of Failure
Cost of Failure
Inventory of Condition Problems
Equipment Life Cycle History
Location History
Mission
Integrate, communicate, and analyze
PLANT RELIABILITY INFORMATION
from multiple plant condition, repair,
overhaul, installation, and inspection data
sources
Tango Equipment Life Cycle Functions
Equipment
Installation
Equipment
Purchased
Calculate MTBF
Equipment
Failure
In Place
Maintenance
Plant
Receives
Equipment
Equipment
Removed From
Service
Stores
Task Sheet
Condition
Assessment
Management
Inspections &
Data Logging
NO
Is
Equipment
Repair
Practical?
Shop
Ships
Equipment
YES
Scrap
Shop
Repairs
Equipment
Cost of Failure
Failure Root Cause
Failure Progression
Equipment
Sent For
Repair
NO
Repair Quote
Approved?
YES
Copyright 24/7 Systems, Inc. 2002
Desktop & Web Software
Desktop Tango
Capabilities
Tango DB
on Plant
Web Server
Plant
Intranet
Reports
Via Web
Browser
Tango Web Services
Plant LAN
Administrative
Users Desktop
Software
Repair Shop 1
Repair Shop 2
TANGO Web Service: Basic Level
Internet Server Farm
Secure & reliable
web server
Web-hosted
TANGO Dbase
Web Reports
& Check-off
only
TANGO Web Reports
User
Reports and work
check-off via TANGO
web browser
No local software
Industrial Plant
Service Shop
Complete
TANGO
functionality
TANGO Software
User
TANGO Web Service: Enhanced Level
Internet Server Farm
Secure & reliable
web server
Web-hosted
TANGO Dbase
Service Shops
Our Shop, with
TANGO Software
TANGO Web Reports
User
TANGO Software
User (Contractor?)
Preferred Partner
Plant
Server
Reports and work
check-off via TANGO
web browser
No local software
needed
Industrial Plant
TANGO installed on
desktop(s)
All history, tracking,
and status functions
available
TANGO Shopform
via e-mail ??
Condition Management
1. Integrate information from multiple PDM
technologies
2. Facilitate communication of condition
information
3. Allow better planning and prioritization of
overhaul work
4. Maintain a history of condition results
Tango | Condition Manager Program
Integrate, Organize, and Communicate Predictive Maintenance Results
Oil
E
l
ca
tri
c
le
Thermogra
phy
Vibration
Electrical
Ultr
aso
nic
Pr
oc
es
s
Tango | Integrated Condition Report
Pie chart quickly shows
how many assets in a
user’s area are in states
of problem severity
Color coded list shows
most severe problems
at top of the list
Findings from multiple
condition monitoring
technologies are
shown for each asset
component
Work Order Status shows if
work has been initiated by
each Condition Entry
Case Closure shows that work
has been completed and is
ready for condition confirmation
Navigate from Integrated Condition Monitoring Warnings
to more detailed reports
Double Clicking on Severity
opens the Technology Status
Reports
Double Clicking on
Component opens the
Tree for fast access to
Location, Equipment,
and Condition History
Reports
Clicking on Paper Clip
opens Linked Documents
such as Analyst’s
Technical Report
Equipment Management
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Inventory of Locations
Inventory of Equipment
Design Data of Equipment
Installation, Repair, and Failure record of
Equipment
Linked Documents
Installation, Repair, and Failure record of Location
Reliability Reports and Analysis
Out for Repair
Spares
Search for Equipment
Tango | Equipment History Report
Click paper clip icon to view
design attachments.
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Drawings
Service bulletins
Manuals
Click to view repair
shop report.
Click on the line to
unfold location and
cause of failure
information.
Click on the line to unfold
equipment design data.
Click to provide purchase
and design warranty
details.
Tango | Location History Report
Click to unfold
equipment design
information
Linked Documents
Tango allows the linking of Plant documents
to Tango Reports for:
Document
1. Design manuals,
Drawings, Service
Bulletins
2. Repair Shop Overhaul
3. Location Information:
Procedures & Checklist
4. Condition Data: Trends,
Thermography Images,
Oil Reports
Linked to Tango Report
1. Equipment Design &
Equipment History
Report
2. Equipment Repair &
Equipment History
Report
3. Location History Report
4. Technology Status
Report
Industrial Motor Life Cycle Path
Motor
Failure
Calculate MTBF
Motor
Removed From
Service
Motor
Installation
Motor
Purchased
NO
For every
Blue Box event
TANGO
Plant
Receives
Motor
®
Buy
Replacement?
(New ID)
provides practical
Motor Management
tools
Scrap
Stores
Is
Motor Repair
Practical?
YES
Motor
Sent For
Repair
NO
Shop
Ships
Motor
Cost of Failure
Copyright 24/7 Systems, Inc, 2002
2/11/2003
Repair Quote
Approved?
Shop
Repairs
Motor
YES
Failure Root Cause
Failure Progression
1
Data Mining
The Developers of Tango cannot develop
reports which answer every question a user
may have.
Data Mining was developed to allow users to
investigate their data and interact with it to
provide answers and solutions unique to the
plant and user.
What Exactly is Data Mining?
A way of finding relationships and patterns in data
Examples:
MTBF by Equipment and Location
High cost equipment and Locations
Cause of failure for equipment and locations
Failures by design, vendor, equipment type
You can’t improve what you can’t measure!
Standard Data Mining Tools
• Tango’s Data Mining uses OLAP to provide
a standardized Data Mining database
• Many commercial Data Mining tools exist
for operators on OLAP databases
Parameter Trending and
Rounds Logging
• Define for any component any type of
measurement
Temperature
Pressure
Flow
Resistance
• Allow the entry of measurement data through the
keyboard or PDA
• Allow the assembly of multiple assets/components
into a route for collection by the PDA
Rounds Logging of Parameters &
Observations
•Measurements
•Gauge Readings
•Observations
•Barcode Point ID
Test and Inspection Task
Management
• Many plant tasks require the completion of an
inspection or test document to record results and
preserve a record of the inspection.
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Breaker Testing
Crane Inspection
Transmitter calibration
Thickness testing
SRV Inspection / Test
Validation of PDM Surveys by component
Validation of Lubrication by component
Test and Inspection Task
Management Contd.
• The Plant CMMS typically will not handle
the management of these task documents.
Often the plant tracks these items in home
grown systems.
• Tango allows the definition of a Test /
Inspection task, its interval, Next / Last
Performance date and an Excel spreadsheet
to be completed for the task.