iamkp-b-a040 copyright © yokogawa electric corporation july 2006 the clear path to asset excellence...
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IAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
The Clear Path to Asset Excellence - Vision & Concept -
July 2006Yokogawa Electric Corporation
Page 2Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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
Page 3Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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
Source: An Introduction to Predictive Maintenance (2002) Keith Mobley
Page 4Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Operational effectiveness implications
-60 -40 -20 0 20 40
Unplanned Breakdowns
Spare Parts Inventory Costs
Production Downtime
Product Defects
Plant Availability
Workforce Efficiency
Asset Performance
% Improvement Beyond Maintenance
Source: ARC Advisory Group
P lant A sset Management (PAM) Offer Solutions Beyond Maintenance to Operations
Page 5Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
• Reduce maintenance cost >50%*
• Reduce equipment failures 55 % avg*• Reduce expediting cost 60%*• Reduce insurance premium• Reduce energy cost
• Improve productivity 20-30%*
• Reduce spare part inventory >30%*• Increase equipment life >30%*
• Increase availability 30% avg*• Improve planning• Improve product quality
Value Creation Potential
Source:*Mobley, R. Keith, An Introduction to Predictive Maintenance (Survey based on 500 plants of various types)
Typical Payback: 10 times ROI or 6-12 months payback
Predictive maintenance benefits
IncreaseRevenue
Reduce Costs
Optimize Assets
ProductivityProductivity
GrowthGrowth
Page 6Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
AE key components and customer benefit
Asset Excellence key success factors and core building blocks
Page 7Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Quality & Reliability
Reliable
Asset Reliability
Page 8Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Quality & Reliability
Reliable
Asset Availability
+Maintainability
Available
Page 9Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Quality & Reliability
Reliable
Asset Predictability
+Maintainability
Available
AdvancedDiagnostics+
Predictable
Page 10Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Quality & Reliability
Reliable
Asset Performance
+Maintainability
Available
AdvancedDiagnostics+
Predictable
Continuous improvement+
Sustainable
Asset Excellence
Page 11Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Quality & Reliability
Reliable
+Maintainability
Available
AdvancedDiagnostics+
Predictable
Continuous improvement+
Sustainable
The clear path to Asset Excellence
Asset Excellence
Page 12Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
01
Asset ReliabilityReliability for non-stop production
The Operator PriorityDaily use of plant assets for safe and agile production
The Operator can focus on true process concerns, trusting in the reliability of the integrated production control system.
Page 13Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Reliability built in our Systems
Seven-9 (99.99999%) 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
Page 14Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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.
Page 15Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Asset Reliability benefits
Minimize unplanned downtimeMission critical control with no system failure-induced shutdown
Minimize performance deteriorationUltra-stable process value measurement with near-zero
maintenanceBetter process stability, Less variabilityMore accurate control with better data quality
Page 16Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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Asset AvailabilityMaintainability in the field
The Field Technician PriorityQuick engineering and efficient maintenance of field assets
The Field Technician can count on a versatile and integrated tool to perform life-cycle engineering and maintenance in the field.
Page 17Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
World’s first portable field device engineering and maintenance tool supporting both DD & FDT/DTM
Innovative new tool for maintainability in the field
Viewer
Configuration
Setting & tuning
Log (Audit trail)
DD&FDT/DTM
Diagnostics
Page 18Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Faster commissioning and start-up
FieldMate as CAPEX saver
Field Devices
Yokogawa
Vendor A
Vendor B
EJX/EJA DYFAXF ROTAMASS
Multi devices
Multi vendors
Multi protocols
Multi presentationtechnologies
YTA Analyzers
・・・YVP
“One Tool for All”
Page 19Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Life cycle device
information management
FieldMate as OPEX saver
“One Tool over Device Life Cycle”
Shutdown Maintenance
Replacement
Configuration & Setting
Loop Check, Commissioning
Daily maintenance
One D/BOne D/B
Any timeAny time
EverywhereEverywhere
EveryoneEveryone
Maintenance Engineer
Instrument Engineer
Field Operator
Page 20Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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
Page 21Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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Asset PredictabilityOnline monitoring and predictive diagnosis
The Maintenance Personnel PriorityMaintenance optimization for maximum plant uptime
Maintenance Personnel can easily diagnose asset conditions, ensuring asset availability while optimizing maintenance.
Page 22Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
The positioning of PRM
Operation Maintenance
Plant Floor
Page 23Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
The positioning of PRM
Board OperatorBoard Operator
quantum
Plant Floor
Maintenance EngineerMaintenance Engineer
Control System
Process DataServer Device
Master
Dashboard Solution
Cxx
Operation Maintenance
Control Diagnostics
Page 24Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Device status viewing
Audit Trail
Tuning, Adjustment & Calibration
Maintenance Information Management
Maintenance Alarm
Advanced Diagnostics
Integrated platform for maintenance & diagnosis
Core Integrated Maintenance Platform
Online Maintenance Core
Predictive Diagnostics Core
Page 25Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
PRM as open asset management core
Integrated Device Management DB
On-line, remote maintenance from workshop
Full access to overall plant asset
Web enabled
Instruments & valves
Equipment & Process
•Rotating•Machiner
y
quantum
ERP
CMMS
Engineering
Web
MaintenanceEnterprise
Production
Safety
Device management
tool
Open interfaceOpen interface
Page 26Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
PRM integrates predictive asset intelligence all over the plant
PerformanceDiagnostics
Loop & Equipment Diagnostics
DeviceDiagnostics
Process interface Diagnostics
PRM as predictive diagnosis core
•Sensor•CPU, Memory•Amplifier•A/D converter•Ambient temp
•Impulse line blocking•Steam tracing•Electrode adhesion•pH electrode•Valve signature
•Heat exchanger•Pump•Compressor•Control valve
•Control area monitoring•Valve total works•Device & process abnormality
PRM Advanced DiagnosticApplication Tool (PAA)
Page 27Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Classification
Interpretation
Notification
Predictive intelligence collection
Maintenance work prioritization
Alarm & guidance for actions
Alerting the right people with the right information
Board OperatorBoard Operator Field OperatorField OperatorMaintenance EngineerMaintenance Engineer
Predictive Diagnostics InformationOnline Maintenance Information
Collaboration between Operation and Maintenance
Central Diagnosis Engine
Page 28Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Asset Predictability benefits
Shorten commissioning & start-up- Quick online diagnosis- Efficient design and configuration by standardization
Eliminate unnecessary site trips- Quick online diagnosis
Minimize planned downtime- Optimize maintenance w/ predictive diagnostics
Shorten turnaround timeGenerate collaboration between Operation
and Maintenance- Maintenance function as a Reliability Team, not a Repair Team- Shift maintenance paradigm as a Process, not an Event
Page 29Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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Plant Management can tap the wealth of diagnosis know-how and performance improvement solutions to ensure asset excellence over plant life cycle.
Asset PerformanceContinuous performance improvement
The Plant Management PriorityContinuous improvement of asset utilization and performance
Page 30Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
InsightSuiteAE maximizes Asset Performance
The Yokogawa InsightSuite™AE Asset Excellence Services is a suite of consultancy, diagnosis, and optimization services that maximizes asset performance.
Sustainability
Reliability
Quality
Predictability
Availability
Maintainability
Yokogawa GLOBAL Response Center
Page 31Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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
Asset Performance benefits
Page 32Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
The Vigilant Integration Partner (VIP ) Initiative and other collaborative efforts
Open and Best-in-Class Collaboration
Page 33Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Open & best-in-class collaborations
CENTUM CS 3000 & PRM Plant Resource Manager
CENTUM CS 3000 & PRM Plant Resource Manager
Control Valves FieldInstruments
Condition Monitoring
Open Standards(FDT&EDDL)
Operators and Maintenance Personnel
Operators and Maintenance Personnel
VIP InitiativeVIP Initiative an open non-exclusive standard-based interoperability-driven partnership
(OPC)
Collaboration with:Collaboration with:
Page 34Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Yokogawa value propositions with Asset Excellence
Conclusion
Page 35Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
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
Asset Excellence key success factors summary
Page 36Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
With openness & interoperability...
Open & Interoperable solutions enable plant-wide collaboration for Asset Excellence
Condition Monitoring
For Maintenance Engineers
For Plant Managemen
t
• Process• Unit
And Operators as well
For Field Technicians
Instruments & valvesInstruments & valves
Page 37Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Yokogawa helps you achieve Asset Excellence
Minimum plant downtime, maximum asset utilization
Reduce blind spotsMonitor plant-wide asset conditions
Preempt bottlenecksOptimize operation and maintenance
Avoid surprisesPredict asset conditions and avoid downtime
Page 38Asset Excellence - vision & roadmapIAMKP-B-A040Copyright © Yokogawa Electric CorporationJuly 2006
Asset Excellence Solutions that maximize performance of assets and productivity of
production.