business industrial network
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Business Industrial Networkwww.DowntimeCentral.com
True Downtime CostTrue Downtime Cost
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Data Sources (Definition:)
TDC – True Downtime Cost
•A method of recording and analyzing all significant cost metrics associated with equipment downtime in a building or manufacturing facility. •TDC provides a way to assign time and/or monetary value to previously considered “non-tangible” cost of downtime. •Also TDC includes downtime factors commonly overlook to arrive at a more true value for the cost of downtime.
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Data Sources Overview
Data – too much of it, not enough of it, inadequate quality or the wrong sort: and what is it used for anyway?
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Considerations of best metrics: What you measure is what you’ll get! Ultimately must be able to accurately track
failure rates and allocate costs individual machines (location, asset) machine categories (motors, pumps) components (bearings, seals)
Major benefits can be attained with current technology -- more effectively applied lower cost data collectors
Digging for dataequipment histories, CMMS reports, life cycle cost analyses, financial records, production schedules.
These are the recommended sources to build a cost justification report to be presented to the bean counters.A maintenance manager would need a full time research assistant to run a productive department.
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Measurement effectiveness:Do measures such as maintenance cost /
RAV show contribution to real objectives? age of equipment, process intensity
MTBF; total population / total repairs or equipment specific statistics which, what, how often
PM compliance and PM backlog, % overtime, % PM compared to % reactive don’t measure whether activity is required or
how much value is produced
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What do all these data sources have in common?
They all build on downtime cost estimates that are only 10% or less of the True Downtime Cost. (10%TDC)
Cost justification requires analysis of several of these areas by management.
Often you have to justify the validity of the data source.
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Where does valid data come from?
all computer systems and networksplant automation systems
distributed control systems programmable logic controllers diagnostic monitoring systems.
asset management software
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How to bring it all togetherWonderwareVersacall
The new millennium focus is on bringing the valid data from various sources back to the management software and technique of your choice.
Will this full circle of data management bring us close to 100% management efficiency?
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Versacall.comVersaCall Facility Communications
System. capture and document downtime monitoring response time communicating an alarm occurrence
"5% of cost in a sites production capability from downtime is a fairly safe number. It does vary by
industry ~ mostly going up from the 5%." "80% of the manufacturing operations I have
interacted with have no idea what they are losing in true dollars with downtime."
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Not even close You will see a 200%
to 300% increase in efficiency, but that’s only 30%TDC, will that give you the required ROI?
Why settle for 300% when you can easily have 800%?
“LEAN”TPM, RCM, PM
ERP,CMMS,EDI,DCS,PLC
OEE,RAV
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The Answer, TDC Actually a combination
of two methods are used to bridge the gap between data collection and management technique. Strict usage of TDC
metrics And data sharing
standards like MIMOSA
“LEAN”TPM, RCM, PM
ERP,CMMS,EDI,DCS,PLC
TDC
MIMOSAEquipment ManagementInformation Modelthanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Control System - DCS
Decision Support
Data
Maintenance ManagementCondition Measurements
Information
MIMOSAEquipment ManagementInformation Modelthanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Control System - DCS
Decision Support
Data
Maintenance ManagementCondition Measurements
Start/Stop timesSpeedfluid (lube oil) conditionvibration (on and off-line)operating measurements (on-line and operating logs)motor characteristicsthermographyanodic/cathodic voltageultrasonic (leak detection)corrosion thickness
Information
MIMOSAEquipment ManagementInformation Modelthanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Control System - DCS
Maintenance Management
Data:ID’s: Plant / Location / Equipment EventsNumerical values (measurements)True Downtime Cost MetricsMeasurement trendsArray / Image:
•Vectors•Time Waveforms•Orbits•Spectra (frequency, order, CPB)•Lube oil particle•Temperature images
Data:ID’s: Plant / Location / Equipment EventsNumerical values (measurements)True Downtime Cost MetricsMeasurement trendsArray / Image:
•Vectors•Time Waveforms•Orbits•Spectra (frequency, order, CPB)•Lube oil particle•Temperature images
Condition Measurements
Information
Data
MIMOSAEquipment ManagementInformation Modelthanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Control System - DCS
Maintenance ManagementCondition Measurements
Information
Data
asset management (inc. spare parts)workforce managementscheduled maintenance (inc. PM)work managementMRO inventory managementtool and rental equipmentcost accounting
MIMOSAEquipment ManagementInformation Modelthanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Control System - DCS
Maintenance ManagementCondition Measurements
Information
Data
From Maintenance Management:Conditions foundSpare parts availabilityWork accomplished -- Action takenMaintenance history: work performed, cost, process downtimeNameplate dataManufacturers specificationsWork order issued: Work order number, requirements: parts, resources, tools, peopleWork schedule
From Maintenance Management:Conditions foundSpare parts availabilityWork accomplished -- Action takenMaintenance history: work performed, cost, process downtimeNameplate dataManufacturers specificationsWork order issued: Work order number, requirements: parts, resources, tools, peopleWork schedule
MIMOSAEquipment ManagementInformation Modelthanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Control System - DCS
Maintenance ManagementCondition Measurements
Information
Data
mechanical diagnostics inc. rolling bearingperformance/efficiencyreciprocating analysisoperating deflection shape (ODS)root causereliability centered maintenance (RCM)risk prognosis
mechanical diagnostics inc. rolling bearingperformance/efficiencyreciprocating analysisoperating deflection shape (ODS)root causereliability centered maintenance (RCM)risk prognosis
MIMOSAEquipment ManagementInformation Modelthanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Control System - DCS
Maintenance ManagementCondition Measurements
Information
Data
InformationStatus -- something happened, eventState of health -- numerical condition indexRate of change (health/severity) -- numericalTime to action -- predicted date under current conditionsProblem identification -- descriptionComponents affected -- descriptionRecommendations -- operating and maintenanceRemarks/Comments -- explanatory informationWork request -- yes or noConfidence -- numerical
InformationStatus -- something happened, eventState of health -- numerical condition indexRate of change (health/severity) -- numericalTime to action -- predicted date under current conditionsProblem identification -- descriptionComponents affected -- descriptionRecommendations -- operating and maintenanceRemarks/Comments -- explanatory informationWork request -- yes or noConfidence -- numerical
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MTBF Example Average 2 year MTBF on 2,000 pumps
(compared to world class -- 6 to 7 year) Average cost of repair $5,000 Double MTBF to 4 years
saves $2.5 million!! 6 year MTBF
saves $3.3 million That’s at the profit level!!
how much product must be produced to deliver $2.5 million profit at 10% pretax??
PROFIT CENTERED MENTALITY
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Information required for equipment management is optimally developed within specialty systems: condition monitoring / assessment
Start/Stop, speed, vibration, fluid analysis, thermography, motor electrical, ultrasound
control (DCS) performance, efficiency Calculated with TDC
maintenance management (CMMS) manufacturers specifications, task instructions,
history, parts, costs
Information Sources
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Information must be:Readily available, easily exchanged and
clearly understandable for everyone with requirements throughout the enterprise
MIMOSA!Machinery Information Management Open Systems Alliance
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TDC MetricsEquipment MetricsLabor ConstantsDowntime DataOutsourcing Information
TDC DetailsEquipment
Categories
People
Product
Start-Up
Bottleneck
Sales Exp
Labor
LPP/M
QC
Maintenance
EngineeringManagement
Downtime
Time
Reduced
Scrap
Band-Aid
OEM
Tooling
Part / Ship
Overhead
TDC, a closer look at Equipment
Categories Use MIMOSA, machine, priority, type, cell, line, Notes, etc.
People Number of Direct and in-direct idle workers
Product Cost per unit at that stage in production Units per hour
Start-Up Electrical surge cost, Set up, % reduced till start/stop Equipment fatigue Scrap produced, is it recycle able
Bottleneck List other downstream equipment, and % effected
Expected Sales % effect on product out the door.
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LPP / Equipment Contribution Not as accurate, use if not items below
QC wages Extra inspections, Rework
Management wagesEngineeringMaintenanceSupportEquipment operators
TDC, a closer look at Labor
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Time Down Reduced
% reduced, for how long Scrap
Number of units, % recovered by recycling Band-aid
Is a sub category of several, value in %TDC OEM
Annual fee/ est. hours used per year, or T&M + Expenses Tooling
Replacement, reworking, recycling Parts
Actual repair, and band-aid
TDC, a closer look at Downtime
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TDC-Warning Data Overload!Too many variables, Too complicated, Too much change!
Equipment These are all one time entry of constants, updated annually, exported from your existing computer systems.
Labor
DowntimeThese are per downtime occurrence entries,
but most can be exported from your CMMS.
Overhead You can use a percentage of existing numbers depending on amount of TDC
metrics they are made up of
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Is using TDC too much change ?
Not really. You just need to require up front that your vendors adhere to MIMOSA
standards and TDC metrics.
Your vendors being data collection equipment vendors, and software vendors such as
CMMS.
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Let’s put Downtime in it’s own bucket and make sound decisions.
DT veiwed now WITH TDC
2% 1%0%
1%
6%
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TDC represents the final bottlenecks to a fully integrated and auditable approach to maintenance strategy development / justification.
“LEAN”TPM, RCM, PM
ERP,CMMS,EDI,DCS,PLC
TDC
Click the link to learn more about•TDC Data Source•TDC Cost Factors
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