CMMS: Integration With Other Information Sources

Steve Shores, Vice President Asset Management

SolutionsThe DEI Group

Operations/Maintenance Partnership:The Road to Process ReliabilitySpecialty ConferenceMarch 9-11, 2005

Introduction

2001: A Space Odyssey (1968) HAL : I've just picked up a

fault in the AE35 unit. It's going to go 100% failure in 72 hours.

Reasons why it won’t work

• The Reason Why You Want It To Work

Why It Won’t Work

• Equipment is too complicated and too hard to maintain and too difficult to identify ways to prevent failures

• Culture –lack of interest, attitudes, etc

Business Case: Why You Want It to Work

• Financial Incentive– Company Reason – make more money

• Maintenance and Operations Folks – Weekends off

Data to Information to Knowledge

What will the reliability tools of the future be?

How will maintenance and operations managers and engineers use these tools to better support

production requirements? Companies that transform their work processes and take advantage

of the knowledge achievable from integrated data sources will reap financial benefit now and will be the Next Generation Steel Producers of the future.

Data to Information to Knowledge

Office of Naval Research (ONR) Workshophosted by the CAD Research CenterQuantico, VA, June 5-7, 2001.

Data Overload

WithCONTEXT

WithRelationships

1960 to 1979

Eighties and Nineties

Humans and Computers

Dr. Pohl’s Conclusions

“While the capabilities of present day computer-based agent systems are certainly a majoradvancement over data-processing systems, we are only at the threshold of a paradigm shift ofmajor proportions. Over the next several decades, the context circle shown in Fig.17 willprogressively move upward into the computer domain, increasing the sector of "relevantimmediate knowledge" shared at the intersection of the human, computer, data, and contextdomains.”

Next Generation Reliability

Not at My Plant

• If computers have Context thus information, then

• The behaviors of personnel must change to utilize the new knowledge

• Old habits must be converted into new behaviors

Weekends Off

• What prevents you from having weekends off?– Equipment failures– Poor scheduling– Lack of System/ Equipment knowledge– No advanced warning system

Weekends Off

• What does it take to have weekends off?– Ability to plan one to two weeks in

advance (planning horizon)• Equipment failure knowledge• Equipment failure prediction and prevention

knowledge• An advanced warning system• People using the system• People doing the right maintenance

activities at the right time.

Why Are They Too Hard to Maintain

• Too complicated• Unpredictable• Too many variables and not predictable• Operators don’t run it properly• Business demands us to push the

equipment harder than it was originally designed

• We don’t have the people to do the PM’s• We aren’t given the time to do the right

maintenance activities

Equipment Failure Knowledge

• How do you get it?• What do you do with it?• RCM Analysis

A Simple Example

Tire• Identify purpose for Tires (functions)• Identify the Reasons that Tires Fail• Wear is a symptom not a cause• The only failure causes are:

– Loss of Pressure and – Irregular Tire Surface degradation

• Loss of Pressure (External Leak) has a few causes:– External impact– Rupture due to wall thinning due to abrasive contact– Valve stem mechanical failure

Tire Failure Prevention

• External Impact– Can it be eliminated?– Can it be monitored?– Can it be predicted?

• Abrasive wear– Currently, Cannot be eliminated– Can it be monitored?– Failure can be predicted

• Valve stem mechanical failure– Cannot be eliminated– Can it be monitored?

Pictures of Tire Wear

If there are 3 trucks that must operate over the weekend, which set of tires is most likely going to allow you to have a weekend off?

Typical RCM Analyses

• Focused on Time Based Activities– That is what the Analyst knows

• Doesn’t include condition monitoring tasks– Because the Analyst doesn’t know enough about

monitoring equipment degradation

• Or, Considers only Portable Condition Monitoring Tasks– Because the Analyst doesn’t know enough about online

condition monitoring

• Doesn’t use Induced Symptom Analysis– Analyst doesn’t consider monitoring induced effects of

failure

• RCM typically done as a stand alone product

Closed Loop Cycle

Define MaintenanceStrategies

(RCM Analysis)

Create MaintenanceTasks In EAM

Identify FailureCauses to Prevent

Fix EquipmentThat Fail

DocumentWork Done

Evaluate Effectivenessof the

Maintenance Strategy

Identify the Reasonfor the Failure

(Failure Causes)

Do the PM Tasks

Monitor AssetPerformance and

Do ConditionDirected Tasks

Failure Prediction And Prevention Knowledge

• Must be able to detect a degradation• Or, be able to detect changes that

occur at other locations• Rate of change must be slow enough

to predict failure and respond• The degradation intervals are

consistent• The degradation can be practically

monitored

Remaining Useful Life

• A key element is the ability to estimate the Remaining Useful Life

Time

Number ofFailures

Degradation Identified

Failure Occurs

T1 T2

Time to Schedule a RepairA

B

T3

Detecting Degradation

Advanced Warning System

• What is it?• HAL : I've just picked up a fault in

the AE35 unit. It's going to go 100% failure in 72 hours.

• How do you get it?• What do you do with it?

Context

• Adding context to the computer allows the computer to sort the data and create information

• Computer can interpret the data so fewer but smarter humans are needed

• With the right context and rules, computers can predict future performance

Sensors

• Traditional and wireless• Current and future expectations

– more and more data available

• How do fewer people review more and more data?

A Culture Change

• People using an integrated computer system

• People doing the right maintenance activities at the right time.

Software tools

• Step 1 Integrate the data – Software solutions that can combine

data from multiple sources with rules• Step 2 Define trend rules

– If these things occur then this will happen therefore do this now

• Step 3 Prepare for the do this now activities– Create pre-planned work orders

Integration

Data is obtained from multiple sources

Vibration Data

EXTERNAL INFLUENCES

PRODUCTION FORECAST

CONTRACTS

ENERGY/ RAW MATERIALS COSTS

Outage TimingOutage ScopeProduction SchedulingDashboard Data

Operation & MaintenanceRecommendation

Production & Process Control Data

Thermography Data

Motor Analysis Data

Oil Analysis, and Water Chemistry Analysis Data

Strategy Manager

Enterprise AssetManagement System

Decision Manager

Asset ConditionAssessment & Forecasting

Dashboard

DCSEXTERNAL

DATASOURCES

I NTELLI GENT ASSETMANAGEMENTSM SYSTEM

Culture Change

Software solutions alone are not enough.

You have to want to have WEEKENDS OFF!

How Far Away is the Solution?

• Automobile Gas Gage• Mechanical• Alarms• Automobile Computer• Distance to Empty• Instantaneous Fuel Consumption• Future:• HAL : I've just picked up a fault in this vehicle.

There is a 100% probability that you are going to run out of fuel in the next 20 minutes. The closest gas station is 12 miles away.

New Eyes

• What if we applied the same logic to maintenance?

• Capture instantaneous fuel consumption whenever steady state occurs

• Capture all of the other variables that computer currently stores only when they exceed an alarm value (check engine light)

• Create a graph of the performance• Determine when failure will occur• Pre-plan the maintenance (automobile repair

manuals)

Measuring Performance

Engine Performance

2.5

2.6

2.7

2.8

2.9

3

3.1

3.2

3.3

3.4

3.5

Jan-04 Feb-04 Mar-04 Apr-04 May-04 Jun-04 Jul-04 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04

Date

Fu

el C

onsu

mp

tion

(ga

llon

s/h

our) Failure Level

Heuristic ALgorithmic computer

Of or relating to exploratory problem-solving techniques that utilize self-educating techniques (as the evaluation of feedback) to improve performance

Holistic Algorithmic Computer

HAC• relating to or concerned with wholes or with

complete systems rather than with the analysis of, treatment of, or dissection into parts

• HAC : I've just picked up a fault in production line 1 equipment 22. There is a 92.3% probability that the widget will fail three weeks from now causing the equipment and system to shutdown. There is a scheduled shutdown in 10 days, do you want to add this task to the shutdown schedule?

Summary

• Where do you start?• One system/one piece of equipment

at a time• One common vision: Intelligent Asset Management

If you don’t know where you are going, then it doesn’t matter which path you take.

Cheshire Cat (Lewis Carroll)