Diagnostics Management for maximum Process Reliability · SM-K3/Dipl. Ing. Eberhard Klo tz, MBA Diagnostics Management F-NL -F&P Seminar 6. ... November 2007 geändert: 6. November

SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ

Diagnostics Management for maximum Process Reliability

Subjects:

1.Basic Definitions2.Management Topics, Objectives3.Technical Solutions today/tomorrow4.Projects with customers

13. November 2007Dipl. Ing. Eberhard Klotz, MBA


Diagnostics – How are “we” today?Diagnosis (Greek διάγνωση, pronounced di´əg no´sis, …)• investigation in the sense of “differentiation”, “decision”; from δια-, dia-, “by-” and • γνώση, gnósi, in the sense of knowledge, judgement• Health care, medicine …the precise allocation of findings • Differential diagnostics – combined expert knowledge on several symptoms

In the broader sense, diagnostics is the classification of phenomena to a category.


Diagnostics – Basic Terminology for Technical ApplicationsDiagnostics • Person already ill, machine already down • How quick can we be back to work • Which diagnostic functions in the machine/device can help

e.g. upgrade from module to single channel-oriented diagnostics

Time based Maintenance• Usual since years, restrictions: maintenance work is

executed too early, too late or unnecessarily


Diagnostics – Basic Terminology for Technical ApplicationsCondition Monitoring (System – CMS) • Persons checked regularily, machine values continuosly• What and where should be measured?• Which conclusion can we make

Preventive and predictive Maintenance• When will the machine / a device / a component be down • How should CMS data be interpreted best • Which process knowledge and experience do we need• How precise and reliable are our forecasts• Where are the critical success factors in the machine / production site


Diagnostics – Summarising Basic Trends and DevelopmentsDiagnostics within Festo Products&Services: • 1990: Diagnostics in all valve terminals• 2000: Integrated CMS, advanced diagnostics,

Ethernet, broad sensor portfolio• 2001: Intelligent air preparation incl.

flow and pressure sensors• 2002: Compact camera and vision systems • 2003: Web-Monitor, E-Mail/SMS alarm …• 2004: Energy saving products and services• 2005: SCADA software, touch panels FED• 2006: Function integration (pressure sensors)• 2007: Diagnostic controllers & software…..• 20xx: Expert systems for full pneumatic

sub-system diagnostics


Diagnostics – why is it a Management Topic


Diagnostics – why is it a Management TopicTypical key data for production costs and

downtime:

Power plant: €90,000 per minuteAMI: 97 seconds amount to

one car (manufacturing costs) Capital goods: €10,000 per minuteMachinery mfg.: €250 to €1000 per minutePaper machinery: €333 per min.,

€20,000 per h.

IT-Production: 5.000 … 10.000 $ / min

IT availability 99,5% 24/7 shift

System down time 43,8 h p.a.

99,9% 8,8 h p.a.Financial risk: 2,6 Million $in case of an IT production

99,99% 260.000 … 520.000 $

+++++++++++++++++++++++++++++++++++Overall system efficiency (GEFF):85% for „traditional maschine“

99% Quality x 95% speed x 90% operation hours


24/ 7 shift min p.a. h p.a. Day p.a. IT / Capital goods Machines Power100,00% 525600 8760 365 - € 99,90% 525,6 8,76 0,365 5.256.000 € 525.600 € 47.304.000 € 99,50% 2628 43,8 1,825 26.280.000 € 2.628.000 € 236.520.000 € 90,00% 52560 876 36,5 525.600.000 € 52.560.000 € 4.730.400.000 € 85,00% 78840 1314 54,75 788.400.000 € 78.840.000 € 7.095.600.000 €

16/ 5 shift min p.a. h p.a. Day p.a.100,00% 211200 3520 146,799,90% 211,2 3,52 0,1 2.112.000 € 211.200 € 19.008.000 € 99,50% 1056 17,6 0,7 10.560.000 € 1.056.000 € 95.040.000 € 90,00% 21120 352 15 211.200.000 € 21.120.000 € 1.900.800.000 € 85,00% 31680 528 22 316.800.000 € 31.680.000 € 2.851.200.000 €

8/ 5 shift min p.a. h p.a. Day p.a.100,00% 105600 1760 73,399,90% 105,6 1,76 0,1 1.056.000 € 105.600 € 9.504.000 € 99,50% 528 8,8 0,4 5.280.000 € 528.000 € 47.520.000 € 90,00% 10560 176 7 105.600.000 € 10.560.000 € 950.400.000 € 85,00% 15840 264 11 158.400.000 € 15.840.000 € 1.425.600.000 €

max. Risk of Downtime p.a.

Diagnostics – why is it a Management Topic


Diagnostics – what Management should considerA machine/system is only as good as its construction (and as the weakest part in the

whole chain) !

Think about:• Reliability • Cycle time• ….• Downtime• Ease of maintenance• Diagnostics / Visualisation• Condition Monitoring• …• Consumption• Direct and indirect costs• …Overall system efficiency


Diagnostics – a Management Topic between OEM and End User

Life cycle costs (LCC) versus procurement costs

Important arguments for manufacturers as well as with end users:

• How high is the proportionate share of procurement costs in your case, and for how long should the system run?

• If procurement costs amount to XX%, how much of this is attributed to pneumatics? (perhaps 1 to 7%)

• How high are the additional costs for comprehensive diagnostics – e.g. in the pneumatic system?

(less than 10% for Festo flagship CPX/MPA)

1. In an actual case (with/without diagnosis), how greatly does engineering influence overall system efficiency – direct and indirect operating costs?

2. Where does it pay for itself to invest in more diagnostics or condition monitoring?


Diagnostics – manage a win-win situation for OEM and EUSimplified calculation (example) of LCC

effects:

Procurement (installation):

15%

Pneumatics: 2% è 0.3% of LCC

Additional costs for diagnosis:

10% è 0.33% of LCC**

**based on Festo CPX/MPA

OE M

Please note:35% of downtime can be avoided by CMS !65% can be reduced by better diagnostics !


Diagnostics – Technical Solutions today/tomorrow


Needs of enduser / EUReduce machine downtime► Identification of defective

components a.s.a.p.► Data collection and storage► …

Enhance reliability/safety► Diagnosis of crucial drives ► New safety concepts

using diagnostic …

Improve productivity ► Leakage detection► Recording of Energy

consumption data► Preventive maintenance

Benefits from additional machine functionality►New components : easily integrated into machine►Increasing performance of pneumatic

Improve customer service► Remote service by

specialist in pneumatics► Support of local

maintenance teams …► Productivity garantuees

Basis for new business models► Operating, maintenance,

repair of systems, Leasing,► Pay-per-use, …

Needs of machine builder/ OEM

Requirements of EU/OEM and contribution of the pneumatics

SM-K3/Dipl. Ing. Eberhard Klotz, MBA Diagnostics Management F-NL - F&P Seminar 6. November 2007 geändert: 6. November 2007, EKZ 14

Requirements out of a typical F&P application?►Example: A manufacturer of packaging

machinery►Striving to increase reliability and quality of

their blister production process through new diagnostic concepts

► 5% of total cost of a machinary** will be accepted by customers!

Air amount for blister process

Monitoring of positioning time of cylinders for the transportation unit

Detailed fault-diagnostics for servo controlled cylinder

2

3

4

1Condition Monitoring of whole pneumatics system i.e. fingerprint of pneumatics by pressure and flow monitoring

** Pneumatics are often less than 7% of machine costs


Festo Solutions for maximum Diagnostics: Valve Terminal CPX/MPA

CPX/MPA offers max. possible diagnostics and condition monitoring in the market.• Single channel diagn.

(or module oriented) • Analogue values:upper/lower limits

• Pilot valve diagnostics• Pressure sensors int./ext.• Operating voltages

according to 3 tolerances• SMS-/E-Mail Alarm• Web-Monitor • Integr. Controller for

pre-processing of diagn.• ….


CPX Web-Monitor as an integrated IT solution

Web-Monitor within CPX/MPA – remote Diagnostics & Services

è START Live-Demoè click


Festo Diagnostics Solutions bottom-up - and Pricing Example---------------------------------------------------------------------

------CPX/MPA 24IN, 12 M/J-Valves: € 1770,--Module oriented diagnosticsOrder code 1: 50E-F13GFQSERERER-D

Order code 2: 32P-SGL-R-MAABB-8M4J

dto. with single channel-oriented € 1930,--

Price premium: € 160,-- oder 9%---------------------------------------------------------------------

------

High Quality Compact Camera or High Speed Camera:

below € 3000,--


Festo - Components for Diagnostics provided now!

► Sensors:Pressure, flow rate, position, optical

► Compact camera “high speed” and “quality”

► Controller:“Embedded“ and “standalone“

► Intelligent components:- Valve terminals - Air supply units - Drives with sensors and controllers

► Software for simulation and engineering

► HMI elements, SCADA systems


Festo - System approach for customer specified diagnostic solution tomorrow

Service products (engineering, assem

bly, operation

System diagnostics(fault localisation)• valve or cylinder• Leakage detection

Monitoring(fault notification)► Counting functions, monitoring of cycle times and Basic units: pressure, flow rate, temperature►Energy management►Electrical parameters (voltage, wiring)

Component diagnostics(fault identification)

•Load, friction• int./external leakage• switching error

Integration in standard autom

ation structures(controller, H

MI, SC

ADA system

s)

Realised by a assembling kit for diagnostics• Existing products with

advanced diagnostic features

• New product solutions: Controller and Software for diagnostics


Diagnostics – Projects with customers


Co-operation with Partners - Example

Common project Condition Monitoring of packaging machines

Focus points:

►Analysing faults for downtime, critical process conditions!

►Development of diagnostic methods, defenition for sensors

►Development of an interdisciplinaire system plattform(MECHANICS-ELECTRICS-PNEUMATICS ---)

►Test on different types pf packaging machines

http:\\www. zupack.de


Packaging machine


Packaging machine: pneumatic functions with monitored values

Draw down• Cylinder for

pressing of draw down(force + wear of belt)

Knife• Cylinder for cutting

(cutting time, cutting force)

Cooling air• Valve – type

MPA(sum of cooling air)

Vertical sealing• Cylinder for pressing

(positioning times, stroke counter)

Generally:

• Air consumption, energy monitoring

• Monitoring of supply pressure

• Monitoring of valves


Packaging machine

Siemens - PLC

Additional sensors

Valve terminal MPA with CPX, fieldbus module, controller FEC

HMI, Visualizing(Machine panel or additional FED)

Diagnostic results via Fieldbus

E/A via Fieldbus(End switches-/ control signals)

calculation at the CPX-FEC


Integration of pneumatics und sensors

CPX-fieldbus-module + controller

MPA-valve terminal

Pressure sensor SDE1force of belt

Pressure sensor SDE1 supply pressure

Flow sensor MS6 supply (total air consumption)

SMAT Sensor wear of belt

Analog/digital input -modules

Pressure and flow sensors for monitoring of cooling air


Diagnostics Management for maximum Process Reliability

Conclusions• Advanced diagnostic systems reduce downtime (65%)• Condition Monitoring Systems avoid downtime (35%)• Critical success factors in the application have to be well known• End users significantly increase productivity• OEMs can differentiate & reduce service costs • Considering the life cycle costs and the potential risk

of downtime, pay-back on advanced diagnostics is very short, especially in fast running machines of F&P businesses.

Win-Win for OEM and EU possibleThank you for your kind attention

Dipl. Ing. Eberhard Klotz, MBA


Thank you for your attention!

Documents

Diagnostics Management for maximum Process Reliability · SM-K3/Dipl. Ing. Eberhard Klo tz, MBA Diagnostics Management F-NL -F&P Seminar 6. ... November 2007 geändert: 6. November