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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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Agenda 1276551

Technology to Support the Increasing Focus on Asset Reliability

January 29, 2004


Agenda
Agenda

  • About Ivara

  • Case study of focusing on reliability

  • Industry trends

  • Technology for improved reliability


About ivara
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


Customers

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


Case study dofasco
Case Study - Dofasco

  • North American Manufacturer

  • $3 Billion / Year in Revenue

  • Manufacturing Equipment Replacement Value of $5 Billion


Motivation to improve
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


Motivation to improve1
Motivation to Improve

  • Equipment Reliability identified as the key to improvements in:

    • Product quality

    • Production output

    • Costs

    • Shareholder return


The results
The Results

100 %

Proactive Maintenance

30%

80%

% Total Maintenance Hours

70%

Reactive Maintenance

20%

Then

Now


The results1
The Results

100 %

9%

Unavailable

22%

Average

Equipment

Availability

78%

91%

Available

Then

Now


The results2
The Results

Quality increased from 76% yield to 91%

90

85

% Prime Yield

80

75

70

Then

Now


The results3
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


The payoff
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


Industry trends

Changing Demands

Better Understanding

of Equipment Behavior

New Technologies & Practices

Industry Trends

  • Leaders are Focusing on Reliability

    • After 20 years of CMMS experience


The traditional view of failure

Age

The Traditional View of Failure

Assumed most items

wear out at about the same age

Conditional

Probability

of Failure

Preventive Maintenance

(time based)


The view of failure evolved

Age

The View of Failure Evolved

The PM itself could

cause failure

Probability

of Failure


The reality of failure
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


Technology for improved reliability
Technology for improved reliability

  • How is work identification software (such as Ivara EXP) different from a traditional CMMS?

  • Where does it fit in?


Cmms focus on efficient work execution
CMMS: Focus on Efficient Work Execution

The Maintenance Function

Crafts / Trades people

Shutdowns

Schedules

Areas


Exp focus on work identification doing the right work

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


Leverage existing technologies

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


Leverage existing technologies1

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


Leverage existing technologies2

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


Leverage existing technologies3

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


Leverage existing technologies4

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


How work identification software works

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


Set up indicators

Set up Indicators

  • Define equipment performance targets

    • Normal

    • Non-normal

Set Up Indicators



Set up indicators2
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


Define performance targets
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






Collect input readings

Collect & Input Readings

Set up Indicators

  • Manual checksheets

  • Electronic checksheets

  • On-line data

  • Define equipment performance targets

    • Normal

    • Non-normal

Collect & Input Readings


Collect input readings1
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




Work identification software analyses presents results

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


Analyses presents results

Compares current asset condition to performance targets

Analysis is automated

No manpower needed

Results are presented graphically

Analyses & Presents Results






Right work sent to cmms

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


Cmms executes the right work at the right time
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