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January 29, 2004

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

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January 29, 2004

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  1. Technology to Support the Increasing Focus on Asset Reliability January 29, 2004

  2. Agenda • About Ivara • Case study of focusing on reliability • Industry trends • Technology for improved reliability

  3. About Ivara • Ivara provides solutions to maximize asset reliability • Unique reliability software • Unparalleled reliability expertise • Our solution helps customers to • Optimize asset performance • Improve quality and customer service (in manufacturing) • Ensure safety and environmental integrity • Identify The Right Work at the Right Time

  4. Oil and Gas Terasen Pipelines Citgo Global Sante Fe Helmerich & Payne Drilling Noble Drilling Parker Drilling Rio Alto Exploration Syncrude Chevron Canada Utilities & Power Generation EPCOR New Brunswick Power Southern California Edison Pacific Gas & Electric Brighton Beach Food and Beverage Kraft Molson Breweries Pulp & Paper Domtar Alberta-Pacific Forest Products Slave Lake Pulp The Price Company Metals and Mining 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 Gibson Petroleum Transportation TSI Delta Port Customers

  5. Case Study - Dofasco • North American Manufacturer • $3 Billion / Year in Revenue • Manufacturing Equipment Replacement Value of $5 Billion

  6. 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

  7. Motivation to Improve • Equipment Reliability identified as the key to improvements in: • Product quality • Production output • Costs • Shareholder return

  8. The Results 100 % Proactive Maintenance 30% 80% % Total Maintenance Hours 70% Reactive Maintenance 20% Then Now

  9. The Results 100 % 9% Unavailable 22% Average Equipment Availability 78% 91% Available Then Now

  10. The Results Quality increased from 76% yield to 91% 90 85 % Prime Yield 80 75 70 Then Now

  11. The Results Market pressures to reduce costs demanded significant downsizing 12,500 # of Employees 7,000 3,460 Maintenance employees 1,700 Maintenance employees Then Now

  12. 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

  13. Changing Demands Better Understanding of Equipment Behavior New Technologies & Practices Industry Trends • Leaders are Focusing on Reliability • After 20 years of CMMS experience

  14. Age The Traditional View of Failure Assumed most items wear out at about the same age Conditional Probability of Failure Preventive Maintenance (time based)

  15. Age The View of Failure Evolved The PM itself could cause failure Probability of Failure

  16. The Reality of Failure • There are six failure patterns >80% random <20% time based 4% 7% Bathtub Condition Related 2% 14% Age Related Random Failure 5% 68% Fatigue Related Infant Mortality The majority of failures are random, not time-based

  17. Technology for improved reliability • How is work identification software (such as Ivara EXP) different from a traditional CMMS? • Where does it fit in?

  18. CMMS: Focus on Efficient Work Execution The Maintenance Function Crafts / Trades people Shutdowns Schedules Areas

  19. Crafts / Trades people Shutdowns Schedules Areas EXP: Focus on Work Identification – Doing the Right Work The Maintenance Function Asset 1 Asset 2 Asset 3 Asset 4

  20. CMMS • Asset Management • Work Order Management • Planning & Scheduling • MRO Materials • Procurement • Tasks and Jobs • Personnel & Trades Leverage Existing Technologies Process Control Tools • SCADA • Data historians Predictive Maintenance Tools • Check sheets • Hand held devices • PdM/CBM technology

  21. CMMS • Asset Management • Work Order Management • Planning & Scheduling • MRO Materials • Procurement • Tasks and Jobs • Personnel & Trades Leverage Existing Technologies Process Control Tools • SCADA • Data historians Predictive Maintenance Tools • Check sheets • Hand held devices • PdM/CBM technology

  22. Work identification software Leverage Existing Technologies Doble analysis Infrared thermography Oil analysis • Applied RCM • Condition-based management • Rules-based diagnostic engine • Indicator-based job triggers • Performance analysis and tracking The Right Work at the Right Time Circuit breaker analyser results Relay calibration tests RCM analysis Aladon tool kit Operator rounds Visual inspections Electrical/Mechanical inspections

  23. CMMS • Asset Management • Work Order Management • Planning & Scheduling • MRO Materials • Procurement • Tasks and Jobs • Personnel & Trades Leverage Existing Technologies Process Control Tools • SCADA • Data historians Predictive Maintenance Tools • Check sheets • Hand held devices • PdM/CBM technology

  24. Work identification software CMMS • Applied RCM • Condition-based management • Rules-based diagnostic engine • Indicator-based job triggers • Performance analysis and tracking • Asset Management • Work Order Management • Planning & Scheduling • MRO Materials • Procurement • Tasks and Jobs • Personnel & Trades Leverage Existing Technologies Process Control Tools • SCADA • Data historians Predictive Maintenance Tools • Check sheets • Hand held devices • PdM/CBM technology

  25. Collect & Input Readings EXP Analyses & Presents Results Right Work sent to CMMS Set up Indicators • Manual checksheets • Electronic checksheets • On-line data • CMMS executes The Right Work at the Right Time • Define equipment performance targets • Normal • Non-normal • One place to view the health of all equipment • Draws attention where needed How Work Identification Software Works

  26. Set up Indicators • Define equipment performance targets • Normal • Non-normal Set Up Indicators

  27. Set Up Indicators

  28. 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

  29. Define Performance Targets • Normal and non-normal indicator values • specific to asset operating context • Assign alarm severity to non-normal values Oil Viscosity Critical Warning Normal 10 50 100

  30. Descriptive Indicators

  31. Numeric Indicators

  32. Calculated Indicators

  33. Rules-Based Indicators

  34. Collect & Input Readings Set up Indicators • Manual checksheets • Electronic checksheets • On-line data • Define equipment performance targets • Normal • Non-normal Collect & Input Readings

  35. 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

  36. Handheld Data Collection

  37. Integration to Online Data

  38. Collect & Input Readings EXP Analyses & Presents Results Set up Indicators • Manual checksheets • Electronic checksheets • On-line data • Define equipment performance targets • Normal • Non-normal • One place to view the health of all equipment • Draws attention where needed Work Identification Software Analyses & Presents Results

  39. Compares current asset condition to performance targets Analysis is automated No manpower needed Results are presented graphically Analyses & Presents Results

  40. Analyses & Presents Results

  41. Analyses & Presents Results

  42. Analyses & Presents Results

  43. Analyses & Presents Results

  44. Collect & Input Readings EXP Analyses & Presents Results Right Work sent to CMMS Set up Indicators • Manual checksheets • Electronic checksheets • On-line data • CMMS executes The Right Work at the Right Time • Define equipment performance targets • Normal • Non-normal • One place to view the health of all equipment • Draws attention where needed Right Work Sent to CMMS

  45. 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

  46. Right Work Sent to CMMS

  47. Software demonstration

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