1. The Clear Path to Asset Excellence - Vision & Concept -
July 2006
Yokogawa Electric Corporation
(Greeting & self introduction)
In this session I would like to share with you the vision and concept of our “Asset Excellence” solutions.

2. VigilantPlant Operational Excellence model
Excellence in production, asset, and safety sustained over the life cycle of your plant
Asset Excellence: for Asset availability and utilization
Production Excellence: for operational agility and 　　　
adaptability
Safety Excellence: for health, safety, and
environmental (HSE) protection
Sustained over the life cycle of your plant
First let me position the Asset Excellence initiative in the overall VigilantPlant vision.
The Asset Excellence solutions is one of the three key components that comprise the VigilantPlant Operational Excellence model.
Safety Excellence prevents catastrophic failures and ensures HSE protection. Asset Excellence secures asset availability and utilization. Upon the firm foundation of safe and available plant, Production Excellence enables operational agility and adaptability. The life cycle perspective is firmly embedded in all three.
Asset Excellence - vision & roadmap

3. Maintenance management implications
A recent survey of maintenance management effectiveness in U.S. revealed that:
Maintenance costs can represent between 15 and 60% of the cost of goods produced
One-third of all maintenance costs is wasted as the result of unnecessary or improperly carried out maintenance
U.S. industry spends more than $200 billion each year on maintenance of plant equipment and facilities
The result of ineffective maintenance management represents a loss of more than $60 billion each year
The immediate connotation of the Asset Excellence message may probably be maintenance management, so let’s check a few background data. I’m sure I’m preaching to the choir here, but a recent survey of maintenance management effectiveness in U.S. revealed that:
As much as one-third of all maintenance costs is wasted as the result of unnecessary or improperly carried out maintenance
U.S. industry spends more than $200 billion each year on maintenance of plant equipment and facilities
The result of ineffective maintenance management represents a loss of more than $60 billion each year
This means that there is quite a room for improvement in maintenance management today, where cost-effective and well-integrated solutions are still in short supply.
Source: An Introduction to Predictive Maintenance (2002) Keith Mobley
Asset Excellence - vision & roadmap

4. Operational effectiveness implications
Plant Asset Management (PAM) Offer Solutions Beyond Maintenance to Operations
% Improvement Beyond Maintenance
Asset Performance
Workforce Efficiency
Plant Availability
Product Defects
Production Downtime
Spare Parts Inventory Costs
Furthermore, with the very high level of capacity utilization we see today in most process industries, effective plant asset management has far reaching impacts on ongoing operational aspects beyond maintenance cost reduction.
According to the ARC’s Advisory Group, effective Plant Asset Management solutions can reduce production downtime by 20%, prevent product defects by 10%, improve workforce efficiency by 20%, and improve overall asset performance by 30%.
Unplanned Breakdowns
-60
-40
-20 20 40
Source: ARC Advisory Group
Asset Excellence - vision & roadmap

5. Predictive maintenance benefits
Value Creation Potential
Growth
Increase availability 30% avg*
Improve planning
Improve product quality
Increase
Revenue
Productivity
Reduce maintenance cost >50%*
Reduce equipment failures 55 % avg*
Reduce expediting cost 60%*
Reduce insurance premium
Reduce energy cost
Reduce Costs
Improve productivity %*
Reduce spare part inventory >30%*
Increase equipment life >30%*
Optimize Assets
Again referring to a research data, we can identify multiple and ongoing benefits of predictive maintenance. Predictive maintenance contributes to both top-line growth and bottom-line enhancements as well as asset utilization.
Typical Payback: 10 times ROI or 6-12 months payback
Source:
*Mobley, R. Keith, An Introduction to Predictive Maintenance (Survey based on 500 plants of various types)
Asset Excellence - vision & roadmap

6. Asset Excellence key success factors and core building blocks
AE key components and customer benefit
Joining forces with visionary customers and fellow suppliers, Yokogawa has launched VigilantPlant Asset Excellence initiative in It is a comprehensive initiative aiming at asset availability and utilization, bringing together innovative asset related solutions into a more integrated, coherent, and evolutionary framework.
Asset Excellence - vision & roadmap

7. Asset Excellence - vision & roadmap
Asset Reliability
Quality & Reliability
Reliable
The first key success factor of Yokogawa Asset Excellence Solutions is Asset Reliability, which is often overlooked yet is the most fundamental prerequisite for non-stop production.
Customers that put Asset Reliability firmly in place can ensure that their plant assets operate reliably day in and day out, and that production remains safe and agile.
In a plant instrumented with Yokogawa control systems and field devices, operator can focus on true process concerns, trusting in the reliability of key automation assets.
Asset Excellence - vision & roadmap

8. Asset Excellence - vision & roadmap
Asset Availability +
Maintainability
Available
Quality & Reliability
Reliable
The second key success factor, Asset Availability, is achieved by securing maintainability on top of fundamental reliability.
Customers can enhance Asset Availability by improving maintainability in the field, enabling quick engineering and efficient maintenance of field assets.
In plants deploying the new Yokogawa PC-based field maintenance solution, FieldMate, field technicians can count on this versatile and integrated tool to perform lifecycle engineering and maintenance.
Asset Excellence - vision & roadmap

9. Asset Excellence - vision & roadmap
Asset Predictability
Advanced
Diagnostics +
Predictable +
Maintainability
Available
Quality & Reliability
Reliable
The third factor, Asset Predictability, is the contribution of recent advances in online monitoring and predictive diagnosis technologies.
Customers that are early adopters of the emerging Asset Predictability solutions report both quick returns and ongoing advantages in maintenance optimization for maximum plant uptime.
In a plant where assets are centrally monitored by the Yokogawa integrated asset management solution, PRM, maintenance personnel can easily diagnose asset conditions, ensuring asset availability while optimizing maintenance.
Asset Excellence - vision & roadmap

10. Asset Excellence - vision & roadmap
Asset Performance
Continuous
improvement +
Sustainable
Asset Excellence
Advanced
Diagnostics +
Predictable +
Maintainability
Available
Quality & Reliability
Reliable
The fourth and final factor, Asset Performance, is an ongoing achievement.
It is more of a journey than a destination, demanding continuous performance improvement over the life cycle of a plant.
Customers pursuing sustainable Asset Performance need a long-term automation partner that shares in the ongoing challenge, joining forces to drive continuous improvement of asset utilization and performance.
In a plant where the customer and Yokogawa build a long-term partnership for continuous improvement, plant management can tap a wealth of diagnostic know-how and performance improvement solutions to ensure asset excellence over the entire plant life cycle.
Asset Excellence - vision & roadmap

11. The clear path to Asset Excellence
Continuous
improvement +
Sustainable
Advanced
Diagnostics +
Predictable +
Maintainability
Available
Quality & Reliability
Reliable
When added up, this is the overall framework. From the inherently reliable automation assets through maintainability solutions and diagnostics, Yokogawa helps to build our customers’ Asset Excellence from the ground up.
Now let me introduce the key solution per each step one by one.
Asset Excellence - vision & roadmap

12. Asset Excellence - vision & roadmap01
Asset Reliability
Reliability for non-stop production
The Operator can focus on true process concerns, trusting in the reliability of the integrated production control system.
The Operator Priority
Daily use of plant assets for safe and agile production
The first stage is Asset Reliability, enabled by the highly reliable systems and stable long-life sensors from Yokogawa.
The primary beneficiary of asset reliability is the Operator, who uses plant assets for safe and agile production .
Asset Excellence - vision & roadmap

13. Reliability built in our Systems
Seven-9 ( %) ultra high system reliability ensures fault avoidance and tolerance for plant operation
Duplex key components: “Pair & Spare” CPU, power, network
Hot swappable I/O module
Advanced self diagnosis
Asset Excellence - vision & roadmap

14. Reliability built in our field devices
Dramatic reduction in instruments failure.
- One-digit (10 times) difference in “mean time between failure”
Fundamental difference in performance metrics and maintenance costs.
0.1% of URL (Upper Range Limit) for 10 years, under all temperatures,
static pressure, and overpressure.
Asset Excellence - vision & roadmap

15. Asset Reliability benefits
Minimize unplanned downtime
Mission critical control with no system failure-induced shutdown
Minimize performance deterioration
Ultra-stable process value measurement with near-zero maintenance
Better process stability, Less variability
More accurate control with better data quality
To summarize the benefits of “Asset Reliability”, the customer can minimize unplanned downtime and performance deterioration.
Only customers who secure high asset reliability upfront can enjoy non stop operation of mission critical control.
Asset Excellence - vision & roadmap

16. Asset Excellence - vision & roadmap02
Asset Availability
Maintainability in the field
The Field Technician can count on a versatile and integrated tool to perform life-cycle engineering and maintenance in the field.
The Field Technician Priority
Quick engineering and efficient maintenance of field assets
The second stage is “Asset Availability”, which is achieved by securing maintainability on top of the fundamental reliability.
The primary beneficiary of the maintainability solutions is the Field Technician, who are looking for a practical and efficient way to handle engineering and maintenance of field assets through plant life cycle.
Asset Excellence - vision & roadmap

17. Innovative new tool for maintainability in the field
World’s first portable field device engineering and maintenance tool supporting both DD & FDT/DTM
Viewer
Configuration
Setting & tuning
Log (Audit trail)
DD&FDT/DTM
Diagnostics
Maintenance is an important daily work in the plant floor. The efficiency and effectiveness of field device engineering and maintenance affect both maintenance costs and plant performance.
FieldMate is designed to support maintenance and engineering work for field devices. It is the world’s first portable field device engineering and maintenance tool which supports both FDT and DD technologies.
Asset Excellence - vision & roadmap

18. FieldMate as CAPEX saver
“One Tool for All”
Faster commissioning
and start-up
Multi presentation technologies
Multi protocols
Vendor B
Vendor A
Yokogawa
The first keyword for FieldMate is “One tool for All”, which primarily contributes as a capital expenditure saver for the customer.
FieldMate can configure and maintain all intelligent field devices regardless of their make and the field communication protocols. FieldMate can communicate via Foundation Fieldbus, HART, Profibus and the others by using FDT/DTM and DD technologies.
Furthermore, the use of the FDT/DTM technology opens a future potential that FieldMate may also be able to support devices traditionally out of our scope such as Motor Control Center, discreet automation devices, etc.
Multi vendors
・・・
Multi devices
EJX/EJA
AXF
DYF
YTA
YVP
ROTAMASS
Analyzers
Field Devices
Asset Excellence - vision & roadmap

19. FieldMate as OPEX saver
“One Tool over Device Life Cycle”
Life cycle device information management
Shutdown Maintenance
Replacement
Configuration & Setting
Loop Check, Commissioning
Daily maintenance
One D/B
Any time
Everywhere
Everyone
Maintenance
Engineer
Instrument
Operator
Field
The second key word for FieldMate is “One Tool over Device Life Cycle”, which contributes as an operating expenditure saver.
The user can use the same FiedMate from initial configuration through daily maintenance right up to device replacement.
As users perform maintenance work with FieldMate, FieldMate not only manages device parameters but also automatically generates maintenance work records and ensure audit trail.
Asset Excellence - vision & roadmap

20. Asset Availability benefits
Shorten commissioning & start-up
- One tool for All field devices
Improve maintainability
- Easy and faster tuning, calibration, and checking
- Safety remote maintenance work with less people in the field
Shorten turnaround time
- Quick replacement, Trouble-shooting
Maintenance knowledge management
- One tool over device life cycle
- Information sharing among operation & maintenance crews in one common device database
To summarize the benefits of “Asset Availability”, the customer can shorten commissioning time and start-up time, improve maintainability, shorten turnaround time, and enable maintenance knowledge management.
Asset Excellence - vision & roadmap

21. Asset Excellence - vision & roadmap03
Asset Predictability
Online monitoring and predictive diagnosis
Maintenance Personnel can easily diagnose asset conditions, ensuring asset availability while optimizing maintenance.
The Maintenance Personnel Priority
Maintenance optimization for maximum plant uptime
The third stage is “Asset Predictability”, which is achieved by the contribution of recent advances in online monitoring and predictive diagnosis technologies.
The main beneficiary of asset monitoring and diagnosis solutions is Maintenance Personnel at large, who are responsible for maintenance optimization for maximum plant uptime. Meanwhile, the Operator also benefits from Asset Predictability, if the right information is channeled to the Operator to facilitate first line of defense against performance deterioration and catastrophic failure.
Asset Excellence - vision & roadmap

22. Asset Excellence - vision & roadmap
The positioning of PRM
Operation
Maintenance
Plant Floor
Our key platform for asset predictability is PRM. Before talking about our direction with PRM, let’s first put its position into perspective.
For a plant to operate optimally and produce the right amount of on-spec products in a cost competitive manner, both Operation and Maintenance must do their respective jobs right. Operation uses the plant assets kept in good condition by Maintenance. In other words, Maintenance ensures asset availability so that Operations can achieve maximum asset utilization and profitable plant operations.
Automation solutions in the past were primarily concerned with the Operation side. DCS and other advanced solutions have enabled our customers to highly automate their operations. The key technology on this side is of course Control.
Meanwhile, a number of promising new technologies have emerged in the past decade or so which are opening up new possibilities for automating the Maintenance side. Here, the key technology is Diagnostics.
Asset Excellence - vision & roadmap

23. Asset Excellence - vision & roadmap
The positioning of PRM
Dashboard Solution
Maintenance Engineer
Cxx
Board Operator
Process Data
Server
Device
Master
Operation
Maintenance
Control System
Control
Diagnostics
Applying this framework to our solutions helps to clarify the positioning of PRM.
PRM occupies this position on the ride side, serving the Maintenance needs as an integrated plant asset management platform. This position is roughly equivalent to Exaquantum as PIMS on the left side, serving the Operations needs as an integrated process data server.
Both sides must have a good link to the enterprise systems to enable effective performance dashboard solutions.
Plant Floor
Asset Excellence - vision & roadmap

24. Integrated platform for maintenance & diagnosis
Core Integrated Maintenance Platform
Online Maintenance Core
Predictive Diagnostics Core
Device status viewing
Advanced
Diagnostics
Maintenance Information
Management
Maintenance Alarm
Audit Trail
Tuning, Adjustment
& Calibration
Therefore PRM is the flagship software package in the Asset Maintenance area. PRM is designed to cover every functionality necessary to optimize plant maintenance work.
Here you might also want to note that FieldMate is an off-line and handy tool for Field Technicians and Field Operators. PRM is online and provides centralized solutions for maintenance management.
The core of PRM is “Device Master Database”. Once a device is defined on PRM, its information such as device name, model name, supplier name, the parameters, etc are recorded as “Device Master” record. Moreover dynamic information like maintenance history, audit trail record, alarm history, etc are also recorded.
And PRM expands its capability to device diagnostics area. Once a device diagnostics is defined, the diagnostic data, alert, predictive alarm etc are supported by PRM.
So far PRM covers only automation assets such as field instruments and valves. In the future PRM will expand its capability to production assets such as rotating and reciprocating machinery, as well as discreet automation devices such as MCC.
Furthermore, process units such as heat exchanger, boiler, etc will be supported by the same “Device Master Database” manner followed by some diagnostics.
Asset Excellence - vision & roadmap

25. PRM as open asset management core
Web enabled
Instruments
& valves
Equipment & Process
Rotating
Machinery
ERP
CMMS
Engineering
Web
Maintenance
Enterprise
Production
Safety
Device management tool
Open interface
Integrated Device Management DB
On-line, remote maintenance
from workshop
Full access to
overall plant asset
Just as Exaquantum is the Yokogawa process data server that gathers process data from CENTUM, Prosafe, Stardom, etc and provides process data to MES solutions and ERP solutions, so is PRM the Yokogawa asset management data sever that supports asset information of CENTUM, Prosafe, Stardom, etc. and provides asset information to MES and ERP solutions in a suitable manner.
Some of the integration and data exchange implied in this slide require more work, but this is the way we’d like to build the capabilities of PRM.
Asset Excellence - vision & roadmap

26. PRM as predictive diagnosis core
PRM Advanced Diagnostic
Application Tool (PAA)
PRM integrates predictive asset intelligence
all over the plant
Device
Diagnostics
Process interface
Diagnostics
Loop & Equipment
Diagnostics
Performance
Diagnostics
Sensor
CPU, Memory
Amplifier
A/D converter
Ambient temp
Impulse line blocking
Steam tracing
Electrode adhesion
pH electrode
Valve signature
Control area monitoring
Valve total works
Device & process abnormality
Heat exchanger
Pump
Compressor
Control valve
Again, “diagnostics” is the key technology that enables automation suppliers to contribute to better Asset Management. Condition based maintenance leveraging predictive intelligence of diagnostics technologies is much more effective in both minimizing maintenance costs and maximizing plant uptime as compared to time based preventive maintenance, not to mention run-to-failure breakdown maintenance.
Now, diagnosis itself can be classified into a few different levels.
Device Diagnostics are very basic. All devices must have the capability to diagnose their own health.
More challenging but also more valuable are Process Interface Diagnostics, such as ILBD, steam trace diagnostics, and so on. Yokogawa is working on a number of such Process Interface Diagnostics, as will be explained in more detail in the PRM session later.
Yokogawa is also working on the next level, developing Loop & Equipment Diagnostics solutions in cooperation with key customers. For this level, we will be using the new and powerful PRM Advanced Diagnostics Application environment which will be released with PRM R3.0
Down the road we also envision Performance Diagnostics using model-based technologies.
These multi-level diagnostics solutions are provided through PRM, which work as the Yokogawa Asset management data sever.
Asset Excellence - vision & roadmap

27. Alerting the right people with the right information
Collaboration between Operation and Maintenance
Board Operator
Maintenance Engineer
Field Operator
Classification
Interpretation
Notification
Predictive intelligence collection
Maintenance work prioritization
Alarm & guidance for actions
Central Diagnosis Engine
Earlier, I mentioned that Asset Predictability can also benefit the Operator as well as Maintenance Personnel.
To do so, PRM must have the capability to channel the right alarms to the right people.
Urgent process-related alarms detected by PRM should be handled by the Board Operator.
Alarms related to field devices should be notified to the Field Operator.
And if the alarms are from predictive diagnostics, that is, not exactly alarms but predictive alerts, they should be handled by the Maintenance Personnel.
PRM supports these classifications, channeling the right information to the right people.
Online Maintenance Information
Predictive Diagnostics Information
Asset Excellence - vision & roadmap

28. Asset Predictability benefits
Shorten commissioning & start-up
- Quick online diagnosis
- Efficient design and configuration by standardization
Eliminate unnecessary site trips
Minimize planned downtime
- Optimize maintenance w/ predictive diagnostics
Shorten turnaround time
Generate collaboration between Operation and Maintenance
- Maintenance function as a Reliability Team, not a Repair Team
- Shift maintenance paradigm as a Process, not an Event
To summarize the benefits of “Asset predictability”, the customer can shorten commissioning time and start-up time, eliminate of unnecessary site trips, minimize planned downtime, shorten turnaround time, and generate collaboration between Operation and Maintenance.
Asset Excellence - vision & roadmap

29. Asset Excellence - vision & roadmap04
Asset Performance
Continuous performance improvement
Plant Management can tap the wealth of diagnosis know-how and performance improvement solutions to ensure asset excellence over plant life cycle.
The Plant Management Priority
Continuous improvement of asset utilization and performance
The fourth and final stage is “Asset Performance”, which is more of a journey than a destination.
Everybody benefits from sustainable Asset Performance, but most likely it is the responsibility of Plant Management to enable continuous improvement to ensure world class asset performance over the plant life cycle.
The Yokogawa solution for this stage is a new service program named InsightSuteAE.
Asset Excellence - vision & roadmap

30. InsightSuiteAE maximizes Asset Performance
Reliability
Sustainability
Quality
The Yokogawa InsightSuite™AE Asset Excellence Services is a suite of consultancy, diagnosis, and optimization services that maximizes asset performance.
Predictability
Maintainability
Availability
Yokogawa GLOBAL Response Center
The quick definition of Yokogawa InsightSuite™AE Asset Excellence Services is a suite of consultancy, diagnosis, and optimization services using FieldMate and PRM functionalities.
FieldMate and PRM will be available as very good tools for the customer; however not all customers will be able to use these tools to their full benefits on their own.
Many customers will introduce the tools but only use their basic functions in a very limited manner, not knowing how to fully utilize the tools for continuous improvement of their asset performance. That’s where Yokogawa service can add value, offering consultancy and value added services to help customers improve their asset performance using these innovative tools.
Asset Excellence - vision & roadmap

31. Asset Performance benefits
Maximize asset life time
- Installation environment diagnosis
Prevent performance deterioration
- Monitor and diagnose asset performance
Maximize ROI
- Maximum productivity (ROA)
- Minimum operation, maintenance, and safety costs
- Reduced manning
Quick and right decision making
- Fact-based
- Proactive
To summarize the benefits of “Asset Performance”, the customer can maximize asset life time, prevent performance deterioration, maximize ROI, and enable quick and right decision making.
Asset Excellence - vision & roadmap

32. Asset Excellence - vision & roadmap
Open and Best-in-Class Collaboration
The Vigilant Integration Partner (VIP ) Initiative and other collaborative efforts
Beyond our own in-house deliverables, the Asset Excellence initiative also encompasses open and best-in-class collaborations with our fellow suppliers to address a wider cross section of plant assets.
So let me touch on these alliance initiatives before I conclude this Asset Excellence framework session.
Asset Excellence - vision & roadmap

33. Open & best-in-class collaborations
CENTUM CS 3000
&
PRM Plant
Resource Manager
Operators and Maintenance Personnel
(OPC)
Collaboration with:
VIP Initiative
an open
non-exclusive
standard-based
interoperability-driven
partnership
Open Standards
(FDT&EDDL)
Field
Instruments
Control Valves
Condition Monitoring
For control valves, we have launched the Vigilant Integration Partners Initiative, VIP for short, which enables open, non-exclusive, standard-based and interoperability-driven alliances with leading control valve suppliers. The initial VIP member companies are Dresser, Flowserve, Metso and Samson, all agreed to participate in the FDT Group.
For production assets such as compressors, pumps, motors, etc., we have already started a collaboration work with GE Energy, the leading supplier of condition monitoring solutions for rotating and reciprocating equipment. The first step is to ensure smooth data exchange between our PRM and their Bently Nevada System 1 platforms. Here again, we will use open standard such as OPC.
Furthermore, we ensure integration of our plant-level asset management solutions with best-in-class business level asset management solutions such as SAP and MAXIMO.
Asset Excellence - vision & roadmap

34. Asset Excellence - vision & roadmap
Conclusion
Yokogawa value propositions with Asset Excellence
Now that I have covered all the major subsets of Asset Excellence, let me conclude this session by a quick summary of our value proposition.
Asset Excellence - vision & roadmap

35. Asset Excellence key success factors summary
Asset Reliability
Daily use of plant assets for safe and agile production
Asset Availability
Quick engineering and efficient maintenance of field assets
Asset Predictability
Maintenance optimization for maximum plant uptime
Asset Performance
Continuous improvement of asset utilization and performance
Key success factors for Asset Excellence are Asset Reliability, Asset Availability, Asset Predictability and Asset Performance.
Asset Excellence - vision & roadmap

36. With openness & interoperability...
Open & Interoperable solutions enable plant-wide collaboration for Asset Excellence
For Plant
Management
And Operators
as well
For Maintenance
Engineers
Process
Unit
Condition
Monitoring
Yokogawa starts delivering solutions that address all the key success factors in a collaborative manner so that the various types of users in our customer plants can work together more efficiently and effectively for plant-wide asset excellence.
For Field Technicians
Instruments & valves
Instruments & valves
Asset Excellence - vision & roadmap

37. Yokogawa helps you achieve Asset Excellence
Minimum plant downtime, maximum asset utilization
Reduce blind spots
Monitor plant-wide asset conditions
Avoid surprises
Predict asset conditions and avoid downtime
Preempt bottlenecks
Optimize operation and maintenance
The ultimate goal is minimum plant downtime, maximum asset utilization. We help our customers achieve this goal by reducing blind spots, avoiding surprises, and preempting bottlenecks.
Asset Excellence - vision & roadmap

38. Asset Excellence - vision & roadmap
Asset Excellence Solutions that maximize performance of assets and productivity of production.
Asset Excellence - vision & roadmap