Banff DuPont Presentation

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP PM for Reliability AnalysisUsing SAP PM for Reliability Analysis

Vince FlynnVince FlynnE. I. DuPont deNemours & Co. Inc.E. I. DuPont deNemours & Co. Inc.

Joel BargerJoel BargerMeridium Inc.Meridium Inc.

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Outline

• Background DuPont and SAP• The Business Problem• A Reliability Process Model• Sources of Reliability Data in SAP• Meridium and Reliability Tools• Concluding remarks - Importance of deriving value from the data

already being collected• Questions and Answers

Global operations, science based corporation• Based in Wilmington, Delaware • Consists of 14 strategic business units

plus joint ventures• 2001 Sales were $27,726 (million)• Total Assets are $40,319 (million)• 79,000 Employees• 200 years young

• 50+ Manufacturing Sites• $1,200 (million) in annual maintenance costs

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

DuPont SAP Update

• Began using SAP in the early 1990s− PM used in Europe, Asia and Canada – R/2− US sites remained on Legacy Business and CMMS systems

• Now implementing a multi-year program to move North America onto SAP R/3 − Projects within the program are Business driven− “Go-Lives” are sequenced from 2002 thru 2004+− Multiple cluster architecture with leveraged configuration− Utilizing most R/3 Modules, including PM (no HR)− Bolt-on applications being used to augment SAP functionality,

including Meridium

The Business Problem

• Maintenance optimization requires:− Efficiency – Planning & Scheduling, Materials Procurement, etc…− Effectiveness – Doing the right work− Reliability Improvement - to eliminate failures and optimize

maintenance strategies.− The Stake for Reliability Improvement is BIG− The potential Uptime gain is worth 5X the maintenance cost

savings

• Identified a need for a Reliability Analysis Tool Set that would enhance the value of the data being collected in SAP PM

The Stable Domains of MaintenanceA

sset

Eff

ecti

vene

ss

ReactiveReactive

PlannedPlanned

RegressiveRegressive

Reliability Focused

Reliability Focused

Manage to the budget, Let

facilities deteriorate

Fix it when it fails, no facilities

deterioration

Fix before failure, no facilities

deterioration

UPtime and defect elimination focus,

improve the facilities

Source – Winston Ledet & DuPont CMLT

Reliability

Reliability is "the probability that a device will perform its intended function for a specified length of time when operated within the environment for which it was designed.“

Nachlas (1995)

What is reliability?

• Elimination of failures?

• Reduction in frequency & cost of repairs?

• Predictableavailability?

• Avoidanceof incidents?

…All of these

A Reliability Model – with a Systems View

DefectElimination

Operate/Maintain

FacilitiesDesign & Build

Analysis &DecisionSupport

SAP PM Business Process

RoutineMaint

TurnaroundMaint

SpecificEquipment

Plans

Work ID

Prioritize

Plan

Schedule

Execute

Confirm &Document

Work ID

Prioritize

Plan

Schedule

Execute

Confirm &Document

Operate/Maintain

Operate

TransactionalData

(Events &History)

Reliability Data from SAP• Notification Data

− Functional Location− Equipment Number

and Class− Breakdown Indicator− Catalog Codes

• Work Order Data− Cost – Labor &

Materials− Duration

PM with Defect Elimination - Reactive Reliability

RoutineMaint

TurnaroundMaint

SpecificEquipment

Plans

Operate/Maintain

Operate

TransactionalData

(Events &History)

DataAnalysis for

Stake

Prioritize Basedon Business

Impact

SelectWhat toWork on

Root CauseFailure

Analysis

EliminateSystemDefect

LeverageLearnings

Defect Elimination

• Analysis done in SAP PMIS, Excel or other tools

• Impact of lost downtime not tracked in SAP

• Maintenance Plans and Strategy changes not easily referenced to Root Cause Studies

• Data is not well organized

PM with Analysis & Decision Support

Analysis & Decision SupportStrategies

MaintenanceTurnaroundSpare Parts

TrainingOperations

AnalysisFunctional/Criticality

and/orRisk BasedInspection

Equipment Analysis Data

RoutineMaint

TurnaroundMaint

SpecificEquipment

Plans

LeverageLearnings

Defect Elimination

Operate/Maintain

Operate

TransactionalData

(Events &History)

PM with Analysis & Decision Support

Analysis & Decision SupportStrategies

MaintenanceTurnaroundSpare Parts

TrainingOperations

AnalysisFunctional/Criticality

and/orRisk BasedInspection

Equipment Analysis Data

RoutineMaint

TurnaroundMaint

SpecificEquipment

Plans

LeverageLearnings

Defect Elimination

Operate/Maintain

Operate

TransactionalData

(Events &History)

• Analysis tools linked to a common database in Meridium− Utilizes the SAP data structures

- F/L, Equipment, Class, Catalog Codes etc…

− Provides Analysis Tools not in SAP− Weibull Analysis− Risk Based Inspection− Reliability Centered

Maintenance− System Reliability, etc…

− SAP interfaced to Meridium

• Maintenance Plan and Strategy changes linked to F/L and Equipment− Recommendations are sent to

SAP as an M4 Notification Task− Replace, change inspection

interval, etc..

Reliability for New Facilities

RoutineMaint

TurnaroundMaint

SpecificEquipment

Plans

Defect Elimination

Design Procure

ComissionConstruct

Operate/MaintainFacilities Design & Build

Operate

Analysis & Decision SupportStrategies

MaintenanceTurnaroundSpare Parts

TrainingOperations

AnalysisFunctional/Criticality

and/orRisk BasedInspection

Equipment Analysis Data

Reliability for New Facilities

RoutineMaint

TurnaroundMaint

SpecificEquipment

Plans

Defect Elimination

Design Procure

ComissionConstruct

Operate/MaintainFacilities Design & Build

Operate

Analysis & Decision SupportStrategies

MaintenanceTurnaroundSpare Parts

TrainingOperations

AnalysisFunctional/Criticality

and/orRisk BasedInspection

Equipment Analysis Data

• Closing the Loop on New and Upgraded Facilities

− Project Engineers can look at performance data to make Life Cycle Cost Evaluations

− Mean Time Between Failures− Reliability Centered Maintenance− System Reliability, etc…

A Reliability Model – A Systems View

DefectElimination

Operate/Maintain

FacilitiesDesign & Build

Analysis &DecisionSupport

Data Requirements for Reliability

PM data enables analysis!

Available Data

What and Where?

SAP Fields Used

Functional Location, Eq Class

Failure Times Malfunction Start and End Date

Failure Modes Damage Code

Failure Costs Total Work Order Cost

Failure Effects Failure Effects

Failure Causes Cause Code

Equipment Classes, Characteristics and Catalog Codes

• The PM Equipment Class is a structured catalog of Equipment based on:− Legacy equipment types− Benchmarking

What does it cost to maintain a specific class of equipment

− ISA, ISO and other Standards

• For DuPont over 400 Classes have been defined− Characteristics have been defined for each Class

• Catalog Codes (Failure Codes) are related to an Equipment Class− Used ISO Standard 14224 as a basis for coding

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Failure ModeCode Type (Y)

Rotating Equipment (PM-RTGEQ)Excessive Vibration (VIB)

Object PartCode Type (B)

Rotating Equipment (PM-RLH)Bearing - Radial (0450)

Damage CodeCode Type (C)

Rotating Equipment (PM-RLH)Bent (0400)

Cause CodeCode Type (5)

Rotating Equipment (PM-RLH)Assembly Error (0500)

Meridium

Catalog ProfilePM-RLH Equipment

Failure Codes

Caus esof Damage

Follow-upTas ks

ActivitiesPerformed

ComponentParts

FailureModes

DamageConditions

Codes

Abnormaloutput - high

Abnormaloutput - lowBreakdown

External leakageproces s

Failed to StartFailed to Stop

Internal leakageMinor in-s ervice

problemNois e

OverheatingStructuraldefic iency

Unexpecteds tart

Unexpecteds top

Vibration

Codes

AcceptableAnalyze trends

Change PMfrequency

Create workreques tEvaluate

probable caus esNotify

OperationsNotify Technical

Engineer

Codes

AlignmentIncorrect

As s embly ErrorClearanceIncorrectCorros ionCrackingEros ionExces s

Pres s ureExces s

TemperatureFabrication

DefectFatigue

ImproperMaterial

ImproperLubrication

Operation ErrorWelding Defect

Codes

Bearings - radialBearings - thrus t

Bus hingsCas ing

CouplingCylinder Liner

DiaphragmGas ket

ImpellerLubrication

Pis tonPumpSealsShaft

SleevesSupports

Wear Rings

Codes

Acceptable / OKBent/Deformed

Broken/ShearedCavitationCorrodedCrackedCrus hedEros ionFatigueFouledLeakingLoos e

LubricationPluggedSeized

StickingWrong Material

Wrong SizeWrong Type

Codes

Adjus tCheck

Ins pectModify /Relocate

No Action TakenOverhaul

ReconditionRemove from

ServiceRepair

ReplaceService /Calibrate

Tes t

B C A 5 Y 2

• Failure Date− Date that the equipment failed

• Planning Start Date− Date that planning begins

• Maintenance Start Date− Date that physical work is started

• Maintenance Completion Date− Date that physical work is completed

Event Date/Time Stamps

Failure Effect in SAP

Code 1: Safety“Failure causes injury or death”

Code 2: Environment“Failure causes hazardous emission”

Code 3: Production“Failure causes process downtime”

Code 4: Quality“Failure causes off spec product”

Code 5: No Effect“Failure causes no adverse effect”

Failure EffectFailure Effects are defined in RCM for each Failure Mode. Whencaptured from PM they can be used to update tasks and plans in PM

Data Requirements for Reliability

How PM data enables analysis

Available Data

What and Where?

Analysis Enabled

Pareto’s and Bar Charts

Failure Times Trends

Failure Modes Life Distributions

Failure Costs PM/Spares Optimization

Failure Effects Failure Modes/Effects Analysis

Failure Causes Root Cause Analysis

Where Do the Reliability Tools Fit?

Equ

ipm

ent C

ompl

exity

Cost of Downtime

Risk BasedInspection

System ReliabilityReliability

Centered Maintenance

Weibull Analysis

Root CauseAnalysis

The Business Solution for DuPont

• Use state of the art Reliability Analysis tools with our SAP PM solution− Utilize the Meridium ERMS System as a Bolt-on for

Analysis and Decision Support

• Configure SAP to capture the data for Reliability− Functional Location, Equipment Classification, Catalog

Profiles, etc…

• Configure Meridium to mirror the SAP data structures• Interface SAP to Meridium to push the data both

ways

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

• Founded in 1993• Focused on key process industries – refining, chemicals,

power• 18 Fortune 500 corporate customers in North America,

Europe, Asia• Profitable for 9 consecutive years• 100+ employees• Roanoke, VA / Houston, TX• SAP Software Partner

Metrics Manager:

• Highlights problem areas

• Multi-dimensional Analysis

• Drill Down Analysis

Registry

Allows user to:• Perform data

searches• Create queries• Create reports• Create graphs• Store

snapshots of data

• Store analyses

Statistical Analysis - Weibull

• Leverages small amounts of data

• Provides an indication of how the equipment is failing:− Infant Mortality− Random− Wear-out

PM Optimization

• When a PM is appropriate it calculates the optimal interval

• Used to update Maintenance Plans in SAP

System Reliability

• Can use stored Component Analysis or Estimated Values

• Tells you what is expected to fail next and what fails the most often.

• Often used to determine most cost effective re-design alternatives.

• Simulation provides:− Failure Counts− Downtime− Availability− Failure Cost

Criticality Calculator

• Risk Based Inspection− Failure Probability− Failure

Consequence− Equipment Criticality− Inspection Priority

Used to Determine the optimal inspection interval relative to the probability and consequence of failure

• Process Requires little or no historical data

• RCFA business process• Fault Tree Analysis• Recommendation

Tracking

Root Cause Failure AnalysisUsed to identify and eliminate the source of a Problem

Dynamic RCM

• Methodology helps determine the optimal set of operational and maintenance tasks to perform based on the functions of a system.

• Can be used before a plant goes into operation.

• Resulting analysis tasks can be used to update existing SAP Maintenance Plans

United AirlinesAge-Reliability Analysis of Boeing 727 JT8D Engine

Results of overcoming dominant failure modes by engineering improvements

Inspection Manager

• Visual Inspection Data Management

• Observations• Findings• Recommendations• Reports

Provides for Compliance Inspection and Recommendation Tracking

Instrument ManagerTools to Manage Instruments and Calibration data

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Codes are Created based on standards or RCM analysis

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Notifications are Created

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Work is Performed

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Failure Coding is Completed

Work Order is Completed

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Inspection Manager uses Component Codes as the basis of components to

inspect (observations and findings)

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Metrics Manager uses the codes to drill down on

reliability problem areas

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Component Reliability tools like Weibull Analysis use the

component and failure mode data to determine failure patterns (infant mortality, wear-out and random

failure)

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

Root Cause Analysis is performed on chronic failures often identifying new codes that should be added.

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Using SAP for Reliability

The process repeats. RCM reviews are used along with

all of the other reliability tools to keep the codes

current.

Conclusions

• Leading companies have begun to shift to Reliability Improvement (RI) as a way to drive asset productivity

• SAP PM can provide the transactional data for RI if configured to support reliability

• Enterprise Reliability Management Systems (ERMS) can provide tools for managing the data and providing analysis and decision support tools

• The integration of ERP and ERMS has begun• SAP and Meridium are working together to provide

an integrated solution− e.g. BAPI developments that open the architecture

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Questions & Answers

Plant Maintenance User Group meeting November 10 - 13 2002

Banff, Canada

Thank You