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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. AV 04 Balancing Cost & Risk Management for Reliability Gains Photo Images From FreeDigitalPhotos.net
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Slide 3 Presentation By: Stanley Shantz Stan Shantz is Principal and Managing Partner of Meir Soft Tissue Solutions. Over the last 21 years, Stan has been assisting International Fortune 1000 companies to develop and implement cost effective and sustainable maintenance strategies - without major capital investment - based on our clients Goals, Directives, and Objectives. The focus of his work has centered on the realization of the need to create a culture that empowers managers to efficiently manage their people. Stan has developed various methodologies and software tools for: International apprenticeship programs, Troubleshooting approaches to improve equipment reliability (MTTR & MTBF), The implementation and effective use of Condition Management (CM) programs, The implementation and effective use of Equipment Reliability strategies, The determination of the effectiveness of your PM program, and How to use historical information to continuously and cost effectively improve maintenance departments. These methodologies and software tools have all been designed to lower the cost of implementation thus achieving or exceeding the Return-On-Investment, while at the same time, achieving sustainable world-class results. Direct +1-519-503-4201 email: Sshantz@MeirSTS.com Or Contact Your Invensys Sales Representative www.Preventative-Maintenance.ca
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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. CURRENT SITUATION Photo Images From FreeDigitalPhotos.net
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Slide 5 CURRENT SITUATION Over the last 10 – 15 years companies have spent millions of dollars on Asset Management tools based on the promise that these tools would continuously lower maintenance costs and sustainably improve equipment reliability. During the last 4 years companies have had to stream line their operations and curb spending to survive. Risk Management concerns have also increased. (Environmental, Legal, Image, Safety, etc.). Based on these drivers, companies are looking at ways to improve profitability while lowering risk. Most companies are looking at ways to utilize existing capital investments more efficiently without additional major capital expenditure. Photo Images From FreeDigitalPhotos.net
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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. REALITY Photo Images From FreeDigitalPhotos.net
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Slide 7 Reality All Photo Images From FreeDigitalPhotos.net Equipment Reliability Limited Budget (Fixed) Limited Resources (Fixed) Large Asset Inventory (Fixed) MAINTENANCE COST CENTER HIGH Existing Tools AVANTIS.PRO HISTORIANPREDICTIVE TECHNOLOGIE S WORK FLOW BUSINESS PROCESSES MRO INVENTORY B2B PROCUREMENT EQUIPMENT WELLNESS RISKRISK (Variable)
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Slide 8 SAME TOOLS DIFFERENT RESULTS Large Asset Inventory (Fixed) All Photo Images From FreeDigitalPhotos.net Limited Budget (Fixed) Limited Resources (Fixed) Equipment Reliability MAINTENANCE PROFIT CENTER HIGH RISKRISK Existing Tools AVANTIS.PRO HISTORIANPREDICTIVE TECHNOLOGIE S WORK FLOW BUSINESS PROCESSES MRO INVENTORY B2B PROCUREMENT EQUIPMENT WELLNESS
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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. UTILIZE HISTORY Holistically Analyze All Data & Examine For Statistical Patterns and Trends Photo Images From FreeDigitalPhotos.net
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Slide 10 Step 1 Find The Answer To These Questions: 1) Are Your Preventive Maintenance, and Predictive Maintenance Programs Effective and Adding Value? 2) Is your current Proactive Maintenance Program aligned with your corporate Risk Management concerns? Photo Images From FreeDigitalPhotos.net
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Slide 11 Reality On-going Support Planned Work Proactive Maintenance Program & Corrective work Reactive Work Emergency & Urgent Planner Supervisor Valuable Information Found in the “Free Text Fields” Trades People Fill In All Photo Images From FreeDigitalPhotos.net 1
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Slide 12 Categorize Free Text Fields + Unlimited number of Categories + Can be customized Analyze All “Free Text Fields” Using Natural Language Selection Natural Language Selection Categorizing ALL Historical Reactive and Planned Work Orders 3- 5 Years of History Natural Language Selection is the same approach Twitter, YouTube, Facebook and Google use to monitor “free text field” data, enabling them to track trends. 1
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Slide 13 Step 1 1) Are Your Preventive Maintenance, and Predictive Maintenance Programs Effective and Adding Value? 2) Is your current Proactive Maintenance Program aligned with your corporate Risk Management concerns? Match the result from the action oriented Meir PM Tree report to your goals, objectives & directives. Photo Images From FreeDigitalPhotos.net What Is Working? Can additional value be added? Can it be accomplished cheaper or faster with better results? What is Not Working?
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Slide 14 Emergency WO Labor PM (Job) WO Entity Urgent WO MRO Inventory Cost EAM / ERP Outage Duration Deficiency WO Labor MRO Inventory Cost EAM / ERP Outage Duration Routine Repair WO Reactive Labor MRO Inventory Cost Labor MRO Inventory Cost Labor MRO Inventory Cost Proactive Immediate Failure + + + EAM / ERP System (3-5 Years History) Categorized Through Natural Language Selection Reliability Vs Value True Cost Of PM Program PM Program Opportunities MRO Inventory Reliability Vs Risk Training Opportunities MRO Inventory Opportunities Meir PM Tree © Meir Soft Tissue Solutions 2009 1
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Slide 15 Step 2 For each failure you want to improve … Do you fully understand the Immediate Failure? Photo Images From FreeDigitalPhotos.net
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Slide 16 Meir Immediate Failure Analysis 2 Analyze all Additional Historical EAM data - NLS categories Inventory Design Failure Trends Failure Patterns Failure Frequency Estimated End Of Life Component Trends Etc.
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Slide 17 Step 3 For each failure you want to improve… Do you fully understand the Fundamental Failure? Photo Images From FreeDigitalPhotos.net
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Slide 18 Suggested Failure Pattern A B C D E F Historian Wonderware Historian Same Failure Pattern Over Past 25 Years Troubleshooting Window (HMI / PLC / PC / SCADA) Pattern Discovery Event Detection Software will work with all brands of historian software. Pattern Discovery Event Detection Software © Meir Soft Tissue Solutions 2009 MEIR Fundamental Failure 3
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Slide 19 Step 4 Make Adjustments to the following: Proactive Maintenance Program Troubleshooting Processes MRO Inventory & Procurement HR Trades / Technician Training Program (s) HR Hiring Standards Reliability Standards Workflow Business Processes All Photo Images From FreeDigitalPhotos.net
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Slide 20 Questions Photo Images From FreeDigitalPhotos.net
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