Transcript About Ivara Powerpoint

Technology to Support the
Increasing Focus on
Asset Reliability
January 29, 2004
Agenda
• About Ivara
• Case study of focusing on reliability
• Industry trends
• Technology for improved reliability
About Ivara
• Ivara provides solutions to maximize asset
reliability
– Unique reliability software
– Unparalleled reliability expertise
• Our solution helps customers to
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Optimize asset performance
Improve quality and customer service (in manufacturing)
Ensure safety and environmental integrity
Identify The Right Work at the Right Time
Customers
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Oil and Gas
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EPCOR
New Brunswick Power
Southern California Edison
Pacific Gas & Electric
Brighton Beach
Food and Beverage
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Kraft
Molson Breweries
Pulp & Paper
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Domtar
Alberta-Pacific Forest Products
Slave Lake Pulp
The Price Company
Metals and Mining
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Utilities & Power Generation
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Terasen Pipelines
Citgo
Global Sante Fe
Helmerich & Payne Drilling
Noble Drilling
Parker Drilling
Rio Alto Exploration
Syncrude
Chevron Canada
•
Gallatin Steel
Alcan Smelters and Chemical
Algoma Steel
Dofasco de Mexico
Barrick Goldstrike
Inco
North Star Steel
Cargill Salt
Quebec Cartier Mining Co.
Facilities and Fleets
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Gibson Petroleum Transportation
TSI Delta Port
Case Study - Dofasco
• North American Manufacturer
• $3 Billion / Year in Revenue
• Manufacturing Equipment Replacement
Value of $5 Billion
Motivation to Improve
• Business performance reached a plateau in
the late 1980’s
• Dramatic external changes began to take
hold in the market place
• Forcing a need for internal response to
these external changes
Motivation to Improve
• Equipment Reliability identified as the key to
improvements in:
– Product quality
– Production output
– Costs
– Shareholder return
The Results
100 %
30%
% Total
Maintenance
Hours
Proactive
Maintenance
80%
70%
Reactive
Maintenance
Then
20%
Now
The Results
100 %
22%
Average
Equipment
Availability
Unavailable
78%
9%
91%
Available
Then
Now
The Results
Quality increased from 76% yield to 91%
90
85
% Prime
Yield
80
75
70
Then
Now
The Results
Market pressures to reduce costs demanded significant downsizing
12,500
# of
Employees
7,000
3,460
Maintenance
employees
Then
1,700
Maintenance
employees
Now
The Payoff
• Most Profitable North American producer in their
sector
• Ranked as #1 worldwide manufacturer in their
industry by Dow Jones 2 years running
• North American benchmark for World Class
maintenance practices and technologies
• Winner of two prestigious maintenance awards:
– Best use of Innovation and Technology in
Maintenance
– Best Maintenance for a Large Plant
Industry Trends
• Leaders are Focusing on Reliability
– After 20 years of CMMS experience
Changing Demands
Better Understanding
of Equipment Behavior
New Technologies & Practices
The Traditional View of Failure
Assumed most items
wear out at about the same age
Conditional
Probability
of Failure
Age
Preventive Maintenance
(time based)
The View of Failure Evolved
The PM itself could
cause failure
Probability
of Failure
Age
The Reality of Failure
• There are six failure patterns
<20% time based
>80% random
4%
Bathtub
7%
Condition Related
2%
Age Related
14%
Random Failure
5%
Fatigue Related
68%
Infant Mortality
The majority of failures are random, not time-based
Technology for improved reliability
• How is work identification software (such as
Ivara EXP) different from a traditional
CMMS?
• Where does it fit in?
CMMS: Focus on Efficient Work Execution
Crafts / Trades people
Shutdowns
Schedules
Areas
The Maintenance Function
EXP: Focus on Work Identification –
Doing the Right Work
Shutdowns
Schedules
Areas
The Maintenance Function
Asset 4
Asset 3
Asset 2
Asset 1
Crafts / Trades people
Leverage Existing Technologies
Process
Control Tools
 SCADA
 Data historians
CMMS
 Asset
Management
 Work Order
Management
Predictive
Maintenance
Tools
 Check sheets
 Hand held devices
 PdM/CBM
technology
 Planning &
Scheduling
 MRO Materials
 Procurement
 Tasks and Jobs
 Personnel &
Trades
Leverage Existing Technologies
Process
Control Tools
 SCADA
 Data historians
CMMS
 Asset
Management
 Work Order
Management
Predictive
Maintenance
Tools
 Check sheets
 Hand held devices
 PdM/CBM
technology
 Planning &
Scheduling
 MRO Materials
 Procurement
 Tasks and Jobs
 Personnel &
Trades
Leverage Existing Technologies
Doble analysis
Infrared thermography
Oil analysis
Circuit breaker
analyser results
Relay calibration tests
RCM analysis
Aladon tool kit
Work
identification
software
 Applied RCM
 Condition-based
management
 Rules-based
diagnostic
engine
 Indicator-based
job triggers
Operator rounds
Visual inspections
Electrical/Mechanical
inspections
 Performance
analysis and
tracking
The Right
Work at the
Right Time
Leverage Existing Technologies
Process
Control Tools
 SCADA
 Data historians
CMMS
 Asset
Management
 Work Order
Management
Predictive
Maintenance
Tools
 Check sheets
 Hand held devices
 PdM/CBM
technology
 Planning &
Scheduling
 MRO Materials
 Procurement
 Tasks and Jobs
 Personnel &
Trades
Leverage Existing Technologies
Process
Control Tools
 SCADA
 Data historians
Work
identification
software
 Applied RCM
 Condition-based
management
Predictive
Maintenance
Tools
 Check sheets
 Hand held devices
 PdM/CBM
technology
 Rules-based
diagnostic
engine
CMMS
 Asset
Management
 Work Order
Management
 Planning &
Scheduling
 Indicator-based
job triggers
 MRO Materials
 Performance
analysis and
tracking
 Tasks and Jobs
 Procurement
 Personnel &
Trades
How Work Identification Software Works
Set up Indicators
 Define
equipment
performance
targets
 Normal
 Non-normal
Collect & Input
Readings
EXP Analyses &
Presents Results
 Manual check
sheets
 Electronic
check sheets
 On-line data
 One place to
view the health
of all equipment
 Draws attention
where needed
Right Work sent
to CMMS
 CMMS
executes
The Right
Work at the
Right Time
Set Up Indicators
Set up Indicators
 Define
equipment
performance
targets
 Normal
 Non-normal
Set Up Indicators
Set up Indicators
• Indicator types
– Descriptive (v-belt cracked, noisy bearing)
– Numeric (pressure, temperature)
– Calculated (wear rate, efficiency/effectiveness)
– Rule-based (combination of the above)
• Indicators can be linked to suggested
corrective work
Define Performance Targets
• Normal and non-normal indicator values
– specific to asset operating context
• Assign alarm severity to non-normal values
Oil Viscosity
Critical
10
Warning
50
Normal
100
Descriptive Indicators
Numeric Indicators
Calculated Indicators
Rules-Based Indicators
Collect & Input Readings
Set up Indicators
 Define
equipment
performance
targets
 Normal
 Non-normal
Collect & Input
Readings
 Manual check
sheets
 Electronic
check sheets
 On-line data
Collect & Input Readings
• Collection methods
– Manual
• Paper check sheet
– Electronic
• Handheld check sheet, online data sources
• Input methods
– Manual
• Keyboard
– Electronic interface
• Upload handheld data
• Poll online data sources
Handheld Data Collection
Integration to Online Data
Work Identification Software Analyses &
Presents Results
Set up Indicators
 Define
equipment
performance
targets
 Normal
 Non-normal
Collect & Input
Readings
EXP Analyses &
Presents Results
 Manual check
sheets
 Electronic
check sheets
 On-line data
 One place to
view the health
of all equipment
 Draws attention
where needed
Analyses & Presents Results
• Compares current
asset condition to
performance
targets
• Analysis is
automated
– No manpower
needed
• Results are
presented
graphically
Analyses & Presents Results
Analyses & Presents Results
Analyses & Presents Results
Analyses & Presents Results
Right Work Sent to CMMS
Set up Indicators
 Define
equipment
performance
targets
 Normal
 Non-normal
Collect & Input
Readings
EXP Analyses &
Presents Results
 Manual check
sheets
 Electronic
check sheets
 On-line data
 One place to
view the health
of all equipment
 Draws attention
where needed
Right Work sent
to CMMS
 CMMS
executes
The Right
Work at the
Right Time
CMMS executes The Right Work at the Right Time
• Manual interface
– Alarm acknowledgements can be manually
transferred to your CMMS
– CMMS work document recorded in Ivara.EXP
– Acknowledgement step turns off alarm
• Automatic interface
– Feeds CMMS with suggested work
• CMMS performs Right Work at Right Time
Right Work Sent to CMMS
Software demonstration