PREVENTATIVE MAINTENANCE SOLUTIONS Presented by : Brian Kroning
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DIGITAL TRANSFORMATIONEnabling…
Faster time to market
Lower total costof ownership
Improved assetutilization
Enterprise riskmanagement
This session will focus on Lower Total Cost of Ownership &
Improve Asset Utilization
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At least 60 percent of preventive maintenance tasks performed in today’s plants are considered unnecessary.2 A reliability-centered approach that aims to maximize equipment performance by applying the right task to the right asset at the right stage in its lifecycle can reverse this trend.
2 Reducing the Cost of Preventive Maintenance, Plant Maintenance Resource Center (www.plant-maintenance.com/articles/PMCostReduction.pdf )
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Problems
We have a PM program but still experience down time
Line 1 has a component failure
Our support staff is stretched thin
We can’t find people to fill a second shift of production
We don’t have the bandwidth to address production performance - OEE
PROBLEMS FACING TODAYS MANUFACTURING
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• Why does Preventative Maintenance matter?
• Preventative Maintenance Solutions
• Process Efficiency
• Outcomes
• Call to Action
AGENDA
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• Reduce downtime that impacts production output
• Determine what parts need to be replace during next PM
• Shrinking workforce makes it difficult to keep on top of Preventative Maintenance schedules
WHY DOES PREVENTATIVE MAINTENANCE MATTER ?
Typical PM programs focus on the mechanical aspects of production equipment
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The cost of downtime is increasing as processes get more optimized and lean.
•Automotive OEM Stamping Machine: $43,000/hour of lost revenue. That is $720/minute.
•Food Packaging Line: $15,000/hour of lost revenue for a typical packaged food or consumer item. That is $25/minute.
•Pharmaceutical Batch: $500,000/batch when interruption of a batch causes the entire batch to be scrapped. This is approximately $8,300/minute.
•Paper Drying Line: $31,000/hour of lost revenue for a typical bottleneck in paper production. That is $516/minute.
Source: Rockwell Automation/ARC Advisory Group
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PREVENTATIVE MAINTENANCE SOLUTIONS
Predictive Maintenance for: Drives PLC Communication Modules Ethernet Switches Distributed I/O Control I/O Modules Servos Motors
What if your controls could inform you of a pending issue?
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FactoryTalk® Analytics™ for Devices
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WHAT DOES IT DO?
Automation Devices
Analytics Appliance
Browser + Mobile Access
• Communicates with Ethernet/IP devices automatically
• Performs analysis on device data
• Catalogs when devices change health state
• Learns what issues are important for specific users
• Diagnoses hard-to-discover intermittent issues
FactoryTalk® Analytics™ for Devices
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FactoryTalk® Analytics™ for Devices
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FactoryTalk® Analytics™ for Devices
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FactoryTalk® Analytics™ for Devices
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FactoryTalk® TeamONE™
Action Cards on mobile device
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Process Efficiency
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PROCESS EFFICIENCY
• Are your lines running at peak performance.
• Has your production output dropped
• Does anyone know WHY?
What if you can improve production output without extensive labor investment?
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FactoryTalk® Analytics™ LogixAI™
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Operations / System focused improvements!
• Targeting one key source of data / the controller code
• Target key control variables / stability issues.
• Definition of key metrics – i.e. Quality / Scrap %
• Capture baseline for measuring success.
• Hypothesize the benefit
FactoryTalk® Analytics™ LogixAI™
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FactoryTalk® Analytics™ LogixAI™Descriptive | Diagnostic | Predictive | Prescriptive
Configure• Install module
in ControlLogix chassis
Identify Data• What to
predict• Related inputs
Model• Automatically
thin data• Automatically
build model
Monitor• Use auto-
quality• Continue
learning
Integrate your
Predictions!
N o d a t a s c i e n t i s t r e q u i r e d
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Developing and Using Analytics
A u to ma t i o n / P ro c e s s
E n g in e e rs
IT / P ro c e s s E n g in e e rs /
IT / D a ta S c ie n t i s t s
UseDevelop / Deploy
DIGITAL TRANSFORMATIONENABLING A CONNECTED ENTERPRISE
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Problem Strategy Solution
We have a PM program but still experience down time
Know about equipment issues before catastrophic failure
FactoryTalk Analytics for Devices
Line 1 has a component failure Obtain a replacement and replace when production is not impacted.
Our support staff is stretched thin Oversee operations and alert your team to abnormal situations Team One Mobile App
We can’t find people to fill a second shift of production Leverage your data to increase
capacity, reduce energy and improve quality
FactoryTalk Analytics Logix AI
We don’t have the bandwidth to improve production performance
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• Anomaly Detection — Early detection and alarm on abnormal operations
• Production Optimization — Drive operations to stable peak performance
• Predictive KPIs — Predict performance and quality issues early and identify key influences
OUTCOMES
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• Assess what your company is doing for Preventative Maintenance
• Determine if all your production processes running efficiently
• Engage with Werner Electric for further discussions and explore
• Ask your Werner Electric team about a Digital Transformation readiness assessment
CALL TO ACTION
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DIGITAL TRANSFORMATIONEnabling…
Faster time to market
Lower total costof ownership
Improved assetutilization
Enterprise riskmanagement
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DISCOVER MOREChallenge us
Thank you for attending!Questions?