PREVENTATIVE MAINTENANCE SOLUTIONS · Reducing the Cost of Preventive Maintenance, Plant Maintenance Resource Center ... of lost revenue for a typical packaged food or consumer item

PREVENTATIVE MAINTENANCE SOLUTIONS Presented by : Brian Kroning

WERNERMN.comDiscover more

DIGITAL TRANSFORMATIONEnabling…

Faster time to market

Lower total costof ownership

Improved assetutilization

Enterprise riskmanagement

This session will focus on Lower Total Cost of Ownership &

Improve Asset Utilization


At least 60 percent of preventive maintenance tasks performed in today’s plants are considered unnecessary.2 A reliability-centered approach that aims to maximize equipment performance by applying the right task to the right asset at the right stage in its lifecycle can reverse this trend.

2 Reducing the Cost of Preventive Maintenance, Plant Maintenance Resource Center (www.plant-maintenance.com/articles/PMCostReduction.pdf )


Problems

We have a PM program but still experience down time

Line 1 has a component failure

Our support staff is stretched thin

We can’t find people to fill a second shift of production

We don’t have the bandwidth to address production performance - OEE

PROBLEMS FACING TODAYS MANUFACTURING


• Why does Preventative Maintenance matter?

• Preventative Maintenance Solutions

• Process Efficiency

• Outcomes

• Call to Action

AGENDA


• Reduce downtime that impacts production output

• Determine what parts need to be replace during next PM

• Shrinking workforce makes it difficult to keep on top of Preventative Maintenance schedules

WHY DOES PREVENTATIVE MAINTENANCE MATTER ?

Typical PM programs focus on the mechanical aspects of production equipment


The cost of downtime is increasing as processes get more optimized and lean.

•Automotive OEM Stamping Machine: $43,000/hour of lost revenue. That is $720/minute.

•Food Packaging Line: $15,000/hour of lost revenue for a typical packaged food or consumer item. That is $25/minute.

•Pharmaceutical Batch: $500,000/batch when interruption of a batch causes the entire batch to be scrapped. This is approximately $8,300/minute.

•Paper Drying Line: $31,000/hour of lost revenue for a typical bottleneck in paper production. That is $516/minute.

Source: Rockwell Automation/ARC Advisory Group


PREVENTATIVE MAINTENANCE SOLUTIONS

Predictive Maintenance for: Drives PLC Communication Modules Ethernet Switches Distributed I/O Control I/O Modules Servos Motors

What if your controls could inform you of a pending issue?


FactoryTalk® Analytics™ for Devices


WHAT DOES IT DO?

Automation Devices

Analytics Appliance

Browser + Mobile Access

• Communicates with Ethernet/IP devices automatically

• Performs analysis on device data

• Catalogs when devices change health state

• Learns what issues are important for specific users

• Diagnoses hard-to-discover intermittent issues









FactoryTalk® TeamONE™

Action Cards on mobile device


Process Efficiency


PROCESS EFFICIENCY

• Are your lines running at peak performance.

• Has your production output dropped

• Does anyone know WHY?

What if you can improve production output without extensive labor investment?


FactoryTalk® Analytics™ LogixAI™


Operations / System focused improvements!

• Targeting one key source of data / the controller code

• Target key control variables / stability issues.

• Definition of key metrics – i.e. Quality / Scrap %

• Capture baseline for measuring success.

• Hypothesize the benefit

FactoryTalk® Analytics™ LogixAI™


FactoryTalk® Analytics™ LogixAI™Descriptive | Diagnostic | Predictive | Prescriptive

Configure• Install module

in ControlLogix chassis

Identify Data• What to

predict• Related inputs

Model• Automatically

thin data• Automatically

build model

Monitor• Use auto-

quality• Continue

learning

Integrate your

Predictions!

N o d a t a s c i e n t i s t r e q u i r e d


Developing and Using Analytics

A u to ma t i o n / P ro c e s s

E n g in e e rs

IT / P ro c e s s E n g in e e rs /

IT / D a ta S c ie n t i s t s

UseDevelop / Deploy

DIGITAL TRANSFORMATIONENABLING A CONNECTED ENTERPRISE


Problem Strategy Solution

We have a PM program but still experience down time

Know about equipment issues before catastrophic failure

FactoryTalk Analytics for Devices

Line 1 has a component failure Obtain a replacement and replace when production is not impacted.

Our support staff is stretched thin Oversee operations and alert your team to abnormal situations Team One Mobile App

We can’t find people to fill a second shift of production Leverage your data to increase

capacity, reduce energy and improve quality

FactoryTalk Analytics Logix AI

We don’t have the bandwidth to improve production performance


• Anomaly Detection — Early detection and alarm on abnormal operations

• Production Optimization — Drive operations to stable peak performance

• Predictive KPIs — Predict performance and quality issues early and identify key influences

OUTCOMES


• Assess what your company is doing for Preventative Maintenance

• Determine if all your production processes running efficiently

• Engage with Werner Electric for further discussions and explore

• Ask your Werner Electric team about a Digital Transformation readiness assessment

CALL TO ACTION


DIGITAL TRANSFORMATIONEnabling…

Faster time to market

Lower total costof ownership

Improved assetutilization

Enterprise riskmanagement


DISCOVER MOREChallenge us

Thank you for attending!Questions?

Documents

PREVENTATIVE MAINTENANCE SOLUTIONS · Reducing the Cost of Preventive Maintenance, Plant Maintenance Resource Center ... of lost revenue for a typical packaged food or consumer item