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

3. 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

4. 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

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

6. 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.

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

8. Data Overload With CONTEXT With Relationships

9. 1960 to 1979

10. Eighties and Nineties

11. Humans and Computers

12. 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.”

13. Next Generation Reliability

14. 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

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

16. 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.

17. 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

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

19. 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

20. 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?

21. 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?

22. 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

23. Closed Loop Cycle

24. 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

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

26. Degradation Identified Failure Occurs T1T1 T2T2 Time to Schedule a Repair A B T3T3 Detecting Degradation

27. 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?

28. 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

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

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

31. 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

32. Integration Data is obtained from multiple sources

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

35. 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.

36. 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)

37. Measuring Performance

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

39. 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?

40. 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)