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RELIABILITY ONLINE ROCKWELL AUTOMATION PREDICTIVE MAINTENANCE TECHNOLOGY

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WHEN DOWNTIME IS NOT AN OPTION


PREDICTIVE MAINTENANCE TECHNOLOGY

From the maintenance department through to the boardroom, companies are now recognising the requirement for a proactive maintenance strategy.
Condition Monitoring (CM) is a broad name for evaluating maintenance requirements based on specific performance indicators of a plant. Adopting a CM programme will minimise maintenance actions without sacrificing integrity or reliability of the system. Understanding why assets fail is key, and identifying and measuring the failure mode is vital to the strategy. Failure modes can be defined from operational history, industry knowledge or from the equipment manufacturer.

DEFINE THE AFFECT RELIABILITY ONLINE


Rockwell Automations Reliability Online (ROL) is a unique service designed to provide costeffective results for CM programmes. It provides the advantage of an in-house integrated CM programme, but managed remotely, and without the capital investment. Reliability Online delivers results with minimal investment in equipment, training and personnel. It uses the internet or e-mail to access a central team of highly skilled engineers, providing timely maintenance recommendations.

RELIABILITY ONLINE IN REALITY


Following a plant audit, data collection intervals are set, measurement points defined, and if required, transducers are installed. A web link is provided to connect the plant to Rockwell Automations skilled engineers. The data is then collected and transferred to the secure website. An analysis will lead to a prompt report on the status of the assets, allowing appropriate maintenance activities to be planned in a timely manner.

MEASURE THE CAUSE


To measure the failure mode, a number of common CM methods can be adopted. These include: Vibration Analysis Thermography Oil Analysis Ultrasonic Testing Routine Inspections Magnetic Particle Testing Electrical Tests

THE IMPORTANCE OF UPTIME


A recent ARC Advisory Group study estimated that in the US more than $20 billion is lost each year due to unscheduled downtime clearly fail and fix maintenance is not a viable maintenance strategy. Rockwell Automations Reliability Online provides a cost-effective Predict and Prevent strategy. The CM services offered by Rockwell Automation are flexible and reliability driven. Our goals are to reduce unplanned downtime and improve plant availability. These services can be offered as part of an Asset Management Support Contract providing commercial benefits in terms of preferential pricing, as well as an all encompassing support structure, ensuring customers gain maximum benefit from the full range of services.

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RELIABILITY ONLINE SERVICE DESCRIPTION


Reliability Online (ROL) is a unique service designed to protect your plant assets from failure mode. Any equipments failure mode can be defined from operational history, industry knowledge, or the equipment manufacturer. To protect your equipment against failure mode, Reliability Online monitors your equipment for impending problems so that it can be repaired at first notification. Reliability Online includes programmes ranging from portable/periodic data collection to online protection/continuous data collection. Data is analysed by Rockwell Automation engineers for continuity of equipment functionality. This programme shows results with minimal investment in equipment, training, and personnel.

Improve your Overall Equipment Efficiency (OEE):


Improve Availability Experience increased equipment availability, reliability and life, through machine monitoring for repair at first notification. Repairs made quickly when outof-specification is captured, extends the life of your equipment and reduces downtime Improve Performance Equipment reliability can generate improved productivity

RELIABILITY ONLINE THE PROCESS Programme Objectives


Reliability Online consultants meet with you to review the objectives of the programme

Plant Audit
A plant audit will be performed to identify which assets are to be monitored

Improve your Return On Net Assets (RONA):


Improve Revenue via Increased Uptime Continuous or periodic equipment monitoring and analysis of the data will alert you to critical maintenance needs early, and will prevent extended downtime Reduce Costs and Improve Cash Management Effectively manage maintenance costs with this customised solution, based on your needs, by data collection interval and method Decrease Assets Reliability Online delivers results with minimal investment in equipment, training, and personnel. Equipment life is extended through timely maintenance notification

Data Collection
Based on safety and environmental concerns, data collection locations are recommended Based on machine criticality, the best intervals for data collection are set, either periodic or continuous Based on the intervals set, data collection will be performed by surveillance, walk-around, or a combination of both

Web Link
A web link is provided to connect your plant to skilled engineers at Rockwell Automation. Data is uploaded from the data collector to the secure website

Analysis and Maintenance Recommendation


Reliability Online engineers analyse your data and promptly report to you the status of your assets. This report will alert you to the need to take appropriate maintenance action

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Rockwell Automation Services & Support


Assessment Services Baseline evaluations of plant floor technical skills, procedures, equipment operation, spare parts inventory, risk, safety and securityas well as other automation-related assessments. PREDICT PREVENT REACT Condition Monitoring Predictive Maintenance products and services for rotating equipment. Asset Management Services Maintenance Repair Operations (MRO) process and Spare Parts Management for automation assets. Remote Support Services Real-time troubleshooting and monitoring* of automation equipment and systems by off-site automation specialists. Safety, Network & Security Services Network design and evaluation, security policy development/deployment, and machine safety services. Training Services Instructor-led training, self-paced training and competency testing on automation and related topics. On-Site Support Services Startup, troubleshooting, repair, conversions and Preventive Maintenance for automation equipment and systems by Rockwell Automation Field Support Engineers. Repair Services & Renewal Parts Remanufacturing and exchange services for automation products and build-to-order legacy automation products.
*System monitoring not available at all service levels

Allen-Bradley, ControlLogix and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication No. GMSA40-BR006B-EN-P March 2007

Copyright 2006 Rockwell Automation, Inc. All Rights Reserved. Printed in UK.