CMMS: Integration With Other Information Sources

1. CMMS: Integration With Other Information Sources Operations/Maintenance Partnership: The Road to Process Reliability Specialty Conference March 9-11, 2005 Steve Shores, Vice President Asset Management Solutions The DEI Group

2. 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

3. 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

4. Business Case: Why You Want It to Work • Financial Incentive • Company Reason – make more money • Maintenance and Operations Folks – Weekends off

5. 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.

6. Data to Information to Knowledge Office of Naval Research (ONR) Workshop hosted by the CAD Research Center Quantico, VA, June 5-7, 2001.

7. Data Overload With Relationships With CONTEXT

8. 1960 to 1979

9. Eighties and Nineties

10. Humans and Computers

11. Dr. Pohl’s Conclusions “While the capabilities of present day computer-based agent systems are certainly a major advancement over data-processing systems, we are only at the threshold of a paradigm shift of major proportions. Over the next several decades, the context circle shown in Fig.17 will progressively move upward into the computer domain, increasing the sector of "relevant immediate knowledge" shared at the intersection of the human, computer, data, and context domains.”

12. Next Generation Reliability

13. 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

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

15. 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.

16. 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

17. Equipment Failure Knowledge • How do you get it? • What do you do with it? • RCM Analysis

18. 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

19. 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?

20. 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?

21. 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

22. Closed Loop Cycle

23. 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

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

25. Detecting Degradation Time to Schedule a Repair A B Degradation Identified Failure Occurs T1 T3 T2

26. 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?

27. 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

28. Sensors • Traditional and wireless • Current and future expectations • more and more data available • How do fewer people review more and more data?

29. A Culture Change • People using an integrated computer system • People doing the right maintenance activities at the right time.

30. 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

31. Integration Data is obtained from multiple sources

33. Culture Change Software solutions alone are not enough. You have to want to have WEEKENDS OFF!

34. 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.

35. 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)

36. Measuring Performance

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

38. 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?

39. 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)