2012 Honeywell Users Group EMEA

Sustain.Ability.
Gary Peacock
Global Solution Marketing Manager, Asset Management
1

Agenda
1.
2.
3.
4.
5.

Industry drivers
Time for a paradigm shift
Asset Management
RAMP solution
Product overview:

Asset Manager & Field Advisor

6. Next steps

Industry Concerns and Drivers

Aging assets and infrastructure
Shrinking pool of experienced people
Robustness of Reliability System
Data and information overload

Market volatility and competition

3

Common Asset Management concerns heard within Industry

The Data and information Problem

Visual
Inspections

Control Loop
Performance
Monitoring

Process Data
(DCS, Historian,
etc.)

Smart
Instruments
(HART, FF, etc.)

Condition
Monitoring

EAM/CMMS

Corrosion
Monitoring

(SAP, Maximo,
etc.)

Reliability

Maintenance

Operations

no common understanding of true status

4

Users try to determine asset status from disparate data sources

combining data derived from disparate

sources so that the resulting information is better
than when these sources are used individually.
WISDOM
KNOWLEDGE
SENSE
MAKING

DATA
5

INFORMATION

Sensor Fusion from Wikipedia article

Data and information: Sensor Fusion

Robustness of Reliability System

One calendar year

Not
scheduled to
run

100% Maximum relevant utilization

Unplanned
Downtime

Net % UPTIME
Net % of Max Potential Rate (MPR)
(@ best consecutive period production rate)

Net % of First Time Prime Quality

Rate
Loss

Recycle or
Scrap

OEE
TEEP

Overall
Equipment
Effectiveness
7

OEE = 100% Maximum Scheduled utilization

TEEP = 100% Maximum Potential utilization

Visualization of OEE and TEEP

Planned
Downtime

Lack
of
Sales
Downtime

Lack
of
sales
derate

all TEEP Gaps are

considered, including
Scheduled Outages

Excess
capacity

Total
Effective
Equipment
Productivity

Benchmarking
Overall Equipment
Effectiveness (OEE)
OEE: Food & Beverage

Best-in-Class

Middle 50%

Bottom

78%

62%

42%

OEE: Pharmaceuticals

45%

31%

23%

OEE: Industrial Processes

Asset Downtime
Plant Floor Automation
Integrated EAM/CMMS
Standardized KPIs
across enterprise
Asset Management with
Predictive Failure Analysis

90%
3%
61%
79%

56%
13%
45%
56%

42%
34%
23%
48%

53%

40%

18%

28%

17%

6%

OEE = 100% Maximum

Scheduled utilization

Table sources: 2010 Solarsoft Manufacturing Benchmark Study and Aberdeen Group, Enterprise Asset Management

Join STAN GRABILL for OEE Seminar on FRIDAY morning

Real-Time Decision Making: A new paradigm

From

To

Reactive / Run-to-failure

Proactive / Predictive

Historical data

Real time data

Inspection Centric

Reliability Centric

Paper Operator Rounds

Online & Automated

CBM as a Point Solution

Integrated RCM, CBM &

CMMS Solution

Fire fighting

Proactive & Predictive

Asset Management with Predictive Failure Analysis

Think of Asset Management as 3 Distinct Areas

Many Data Sources
Condition Based Maintenance
(CBM)
Real-Time & Off-Line Data
Field Inspection and rounds
Wired & Wireless
Reliability Centric Maintenance
(RCM)
Enterprise Asset Management
(EAM)
Computerised Maintenance
Management Systems (CMMS)
10

Enterprise Asset Management Work-stream & Relationships

Maintenance Management: EAM and CMMS

Maintenance Management
Work Execution Management
Work Order Generation
Document Management
Financial Management
Purchasing Management
Inventory/MRO Management
Planning & Scheduling

Integration with EAM and CMMS

such as SAP and IBM Maximo

11

Enterprise Asset Management Work-stream & Relationships

Reliability: GP Allied
Alliance Partner (GP Allied)
400 Consultants Globally
Excellent Industry Reputation
Experience in all Industrial sectors
iReliability Suite of tools
Reliability Programs & Strategies
RCM / RCA
Asset Health Matrix
Equipment Maintenance Plan
KPI/Benchmarking
Change Management
Training (including craft skills)
12

Enterprise Asset Management Work-stream & Relationships

Condition Based Monitoring

Real-Time
Condition Monitoring
Real-Time Corrosion monitoring
DCS & Historian
Simulation (UniSim)
Real-time Vibration Monitoring
Smart Instruments (FDM)
Operator Rounds (Field Advisor)
Oil Analysis
Other Condition Monitoring

13

Enterprise Asset Management Work-stream & Relationships

Integrating Real-time Asset Management

CMMS / ERP
Integration

Management
Reporting & KPIs

Maintenance &
Reliability Users

Rotating
Machinery
Monitoring

Asset Performance &

Health Assessment
DCS & Historian

Process and
Alarm Data

14

Control Loop
Monitoring

Visual
Inspections

Smart
Instruments

Corrosion
Monitoring

Equipment
Condition
Monitoring

Downtime
Reporting

Data Management Applications

Very Clear & Easy to Understand

15

Single view of Asset Performance and Health

Key Performance Information

16

Abnormal Condition Assessment

17

Downtime Dashboard

18

RAMP
Asset Manager
Notifications sent to EAM/CMMS

EAM/CMMS
Work Execution Mgmt
Maintenance Mgmt
Workflow
Document Mgmt
Financial Mgmt
Purchasing Mgmt
Inventory/MRO Mgmt
Scheduling

DATA SOURCES
Condition Monitoring
DCS & Historian
Smart Instruments
Operator Rounds
Corrosion Data
Simulation (UniSim)
Oil Analysis
Vibration Monitoring

Honeywell
Asset Manager

Programs & Strategies

19

RCM/RCA
Asset Health Matrix
Equipment Maintenance Plan
KPI/Benchmarking
Change Management
Training

Asset Manager
info used in
Reliability programs

Reliable Asset Management Performance

OUTPUTS
Alerts & Notifications
Management
Reporting & KPIs
Maintenance &
Reliability
Scorecards
Downtime Reporting
Health Assessment
Automatic Work
Order Generation

Integrating Real-time Asset Management

DCS &
Historian

Vibration
Products

Asset Health
Management

Downtime
Reporter

Equipment
Condition
Monitoring

Asset
Manager
Process
Reliability

Corrosion

Integration
with EAM

Field
Advisor

20

Downtime
Reporting

RCM

UniSim
Rotating
Machinery
Monitoring

Wireless

Smart
Instruments

RCM
Partners
and tools

Corrosion
Monitoring

Visual
Inspections

KPI /
Benchmarking
Trending

Smart
Instruments

Integration
with CMMS

Asset Manager offers a single view of performance and health

Applying RAMP
STRATEGIC

Reliability Centred
Maintenance (RCM)
Real-Time Condition Based
Maintenance (CBM)

TACTICAL

Risk Based Inspection

(RBI)

Operational Performance
Monitoring (OPM)

Abnormal Situation
Management (ASM)

Reliability Centred Design

(RCD)

Operator Driven Reliability

(ODR)

Work Execution Management

(WEM)

Asset Health Monitoring

Reliability & Maintenance
(AHM)
Engineering (RME)
Asset Manager
Enterprise Asset
Management (EAM)
TECHNOLOGY
INFRASTRUCTURE

Computerized Maintenance
Management Sys. (CMMS)
Real-Time Data Acquisition

BENCHMARKING

Overall Equipment
Effectiveness (OEE)
Total Effective Equipment
Productivity (TEEP)

21

Scalable Solutions integrated through Asset Manager

Applying RAMP: Tactical AHM

STRATEGIC

Reliability Centred
Maintenance (RCM)
Real-Time Condition Based
Maintenance (CBM)

TACTICAL

TECHNOLOGY
INFRASTRUCTURE

BENCHMARKING

22

Risk Based Inspection

(RBI)

Operational Performance
Monitoring (OPM)

Abnormal Situation
Management (ASM)

Reliability Centred Design

(RCD)

Operator Driven Reliability

(ODR)

Work Execution Management

(WEM)

Asset Health Monitoring

(AHM)

Reliability & Maintenance

Engineering (RME)

accurate view of asset health

Field Advisor
SKF Vibration
Corrosion Monitoring
Field Device Manager
OneWireless
Mobile Equipment Monitoring
..

Scalable Solutions integrated through Asset Manager

Applying RAMP: Tactical OPM

STRATEGIC

Reliability Centred
Maintenance (RCM)
Real-Time Condition Based
Maintenance (CBM)

TACTICAL

TECHNOLOGY
INFRASTRUCTURE

BENCHMARKING

23

Risk Based Inspection

(RBI)

Operational Performance
Monitoring (OPM)

Abnormal Situation
Management (ASM)

Reliability Centred Design

(RCD)

Operator Driven Reliability

(ODR)

Work Execution Management

(WEM)

Asset Health Monitoring

(AHM)

Reliability & Maintenance

Engineering (RME)

one view of the truth

UniSim Design
Downtime Reporter
Corrosion Monitoring
Well Performance
Monitoring
OMPro
.

Scalable Solutions integrated through Asset Manager

RAMP Underlying Principles

1. Relentless integration of all aspects of people,
processes, and technology
2. Applied across the entire asset life cycle:

Capital Delivery (CapX)

Operations (OpX)
Maintenance (MaintX)

3. Includes the management of all assets

mechanical, electrical, stationary, process automation and

control assets

4. Modular and scalable

5. Change Management is woven into the deployment
24

Integration of People, Processes and Technology

Asset Manager R410

Built on the Intuition Platform
Single Location for Asset Management
Wired & Wireless Vibration Monitoring
Real-time Corrosion management
Control System & Instrumentation Monitoring
Inputs from OPC, PHD, any Experion site, ..

Integration with Honeywell and 3rd Party Products & Solutions

Aptitude Analyst & DMx (SKF Corp)
iReliability Suite; including a fault model library (GP Applied)
Integrate
information

Fault Models

Multiple
sources
Future proof

25

Based on
integrated
information

Alerts
Based on the
fault model
execution

Alert-based
Automatic Actions
Operator
notifications
E-mail
notification

See these in the

demo room!!
Problem Solving
Collaboration
between teams
Historical
information
Link to relevant
documentation

Another bridge between Operations and Maintenance

Field Advisor R200 and R201 (2012 releases)

Technology Refresh
Honeywell Intuition framework and modernized handheld user interface
Microsoft SQL Server Standard edition

Updated configuration tools with graphical configuration

New rounds scheduling, tracking and reporting calendar
Efficient Installation/Migration and Integrated Security
Automatically trigger and track operator tasks

Select Work

26

Execute Tasks
Enter
comments

Review
Consequences
When limits
are exceeded

Review
History

Corrective
Actions
Execute
reconditioning
tasks

Upload Work

Tremendous Benefits Received

Improve Safety
Reduce incidents by up to 40%
Increase operator competency
Support continuous improvement

Improve Efficiency
Reduce

off-spec material up to 50%

Reduce transition material up to 30%
Catalyst consumption down by 1%
Improve throughput 2-8%
Reduce energy use 5-10%
Improve forecast accuracy 4-20%
Reduce inventory 15-30 %

27

Improve Reliability
Improve plant availability 3-8%
Preserve and extend asset life
Reduce maintenance costs 3-5%
Improve customer service 5-15%

Improve Sustainability
Green house gas emissions

reduced by 25%
Ensure compliance standards
Reduced total cost of ownership
Reduce energy consumption
>$5B US in measurable benefits has been
added to our customers bottom-line
*Results based on past customer experience

Typical Return on Investments are 3 Months to 1 Year

Recommended Next Steps (At HUG)

Visit the demo room
Honeywell

Asset Management and RAMP

Asset Manager R410
Field Advisor
Corrosion

SKF
Vibration

GPAllied
iReliability
RCM

Attend the OEE Seminar

Friday 16th November, 09:00 12:00
Presenter: Stan Grabill
28

Recommended Next Steps (When you get back)

Ask for an assessment at your
site
Start small if needed
Solutions are scalable

Be a champion for your company

Must get operations and
management involved
Do something

29

Questions?

30

GARY.PEACOCK@HONEYWELL.COM