improved availability and damage avoidance at a water ... · integrated management energy...
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1COPYRIGHT © 2016 MITSUBISHI ELECTRIC. ALL RIGHTS RESERVED. ALL TRADEMARKS ACKNOWLEDGED.Open ARC Forums 2016 (e-F@ctory Alliance partner Schaeffler) (Promo G. FA Overseas Marketing)
Improved Availability and Damage Avoidance at
a Water Treatment Plant Using Asset Analysis
Mitsubishi Electric e-F@ctory Strategy and Business Planning; Global Alliances
Joint presentation: Mitsubishi Electric,
Schaeffler GroupJuly 2016,
ARC Forum Bangalore, India
2COPYRIGHT © 2016 MITSUBISHI ELECTRIC. ALL RIGHTS RESERVED. ALL TRADEMARKS ACKNOWLEDGED.Open ARC Forums 2016 (e-F@ctory Alliance partner Schaeffler) (Promo G. FA Overseas Marketing)
Introduction
Mitsubishi Electric:
•Integrated electrical/electronics
supplier
•Established 1921
•4,394.3 billion Yen
consolidated net sales (for the year ending March 31st 2016)
3COPYRIGHT © 2016 MITSUBISHI ELECTRIC. ALL RIGHTS RESERVED. ALL TRADEMARKS ACKNOWLEDGED.Open ARC Forums 2016 (e-F@ctory Alliance partner Schaeffler) (Promo G. FA Overseas Marketing)
When it all goes wrong
Time
Ma
ch
ine
co
nd
itio
n
Minutes
Days
Weeks
Month
Smoke
Heat
Noises
Vibration
Change in
condition
Everything
was working
well
Early detection = time to plan and act
Lead time or pre-warning period
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Background
Condition
Monitoring
Systems
CMS
5COPYRIGHT © 2016 MITSUBISHI ELECTRIC. ALL RIGHTS RESERVED. ALL TRADEMARKS ACKNOWLEDGED.Open ARC Forums 2016 (e-F@ctory Alliance partner Schaeffler) (Promo G. FA Overseas Marketing)
What is the CMS measuring?
Condition
Monitoring
System
Condition
monitoring dataVibration Analysis
Energy Management
Thermography,
Oil Analysis
Environmental
dataOutside temperature, Humidity,
Atmospheric pressure, Date,
Time
Machine
process dataTemperature, Pressure,
Voltage, Current, Condition
Manufacturing
dataOrder number, Quantities,
Utilization, Material
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Sharing and analyzing
Database
Agent
Provides interfaces to different data sources
Database
Machine
process data
Manufacturing
data
Environmental
data
CMS Platform incl. visualization
"Change data into information"
Condition
monitoring
data
7COPYRIGHT © 2016 MITSUBISHI ELECTRIC. ALL RIGHTS RESERVED. ALL TRADEMARKS ACKNOWLEDGED.Open ARC Forums 2016 (e-F@ctory Alliance partner Schaeffler) (Promo G. FA Overseas Marketing)
Scalable and widely applicable
Reference Case 1 Case 2 Case 3
Customer type Public SME Multi-national
Industry Utility (water) Pulp and paper Manufacturing
Application
zoneWaste water pump Paper coating
machine
Bearing production
Device Machine Line
Process Hybrid Discrete
Local + Cloud Local + Plant cloud Local + Private cloud
Applied Condition Monitoring
8 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Schaeffler Group at a glance
• Integrated automotive and industrial supplier
• Around 84.000 employees in 50 countries
• Established 1883
• Above industry average profitability and revenue growth
• Strategic participation in Continental AG
• € 12,1 billion annual turnover
9 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Waste Water Treatment Plant
Company: Stadtwerke Rotenburg an der Fulda(Public utility company)
Application: unmanned remote waste water pumping station
Processing capacityMaximum: equivalent 34,000 peopleAverage: equivalent 20,000 people
Requirement: 1) no loss of service, 2) cope with unplanned demand3) reduce energy usage
Condition: Typical gearbox/motor breakdown within 1 – 3 years
Configuration/system
Number of pumps: 3 Archimedes screw type
Configuration: Directly mount motor on gearbox driving auger screw
Operating cycle: 24hrs/day, 7 days/week
Reference
10 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Waste Water Treatment Plant
Reference
Internet
System
All
third
pa
rty tra
de
ma
rks a
nd
/or
reg
iste
red
tra
de
ma
rks a
re t
he
pro
pe
rty o
f th
eir r
esp
ective
ow
ne
rs a
nd
are
ackn
ow
led
ge
d
11 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Waste Water Treatment Plant
Cost analysis
Overhaul the gearbox:1000 Euro
New gearbox: 5500 Euro
Solution cost
Hardware: 4700 Euro
Installation: 1000 Euro
Total 5700 Euro
Return on Investment:
Estimated: 2 gearbox failures
No CMS: Failure x2 = 5500 x2 = 11000 Euro
CMS: Solution cost + 2x gearbox overhaul
= 5700 + (2x1000) = 7700 Euro
Benefit: 3300 Euro saving on 2 failures +no loss of service
Benefit in practice:
4 months after installation a gearwheel defect was detected
Solution delivery:
Local system integrator: Willich Elektrotechnik GmbHSensor technology: SchaefflerHardware: Mitsubishi ElectricIT connectivity: eWON
Result:
Improved OEE: predictive maintenance ensures continuous services and preemptive maintenance actions reduce cost of failure
Reference
12 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Paper Mill
Company: Mitsubishi HiTec Paper Europe GmbH
Application: cooling system for paper mill producing coatedthermo-sensitive paper
Processing Speed: 1730m/min
(103.8 km/hr)Paper roll: 9000kg per roll (2.9m wide)
(150,000,000 kg/yr)Machine height: 4 stories (floors)
Requirement: 1) no loss of service, 2) aid planned maintenance3) no machine damage
Configuration/system
Number of cooling fans: 26 Weight of 1 fan impeller: 100kgImpeller speed: 1500rpmTarget temperature: below 68 deg C
(starting temp. 250 deg C)
Reference
13 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Paper Mill
Reference
System
26 smartcheck
vibration
sensors
All
third
pa
rty tra
de
ma
rks a
nd
/or
reg
iste
red
tra
de
ma
rks a
re t
he
pro
pe
rty o
f th
eir r
esp
ective
ow
ne
rs a
nd
are
ackn
ow
led
ge
d
14 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Paper Mill
Cost analysis
Cost of 1 roll: 12000 Euro
Solution cost
Hardware: 19500 Euro
Installation: 6000 Euro
Total 25500 Euro
Return on Investment:
Estimated: 3 rolls of paper
No CMS: Failure x3 = 12000 x3 = 36000 Euro
CMS: Solution cost = 25500 Euro
Benefit: 10500 Euro saving on 3 failures +no loss of service, no machine damage
Solution delivery:
Local system integrator: Carl Werthenbach
Konstruktionsteile GmbH & Co. KG
Sensor technology: SchaefflerHardware: Mitsubishi Electric
Result:
Achieved continuous running process, no machine damage, now utilizing planned maintenance/service
Solution rolled out to second plant.
Reference
15 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Manufacturing line
Company: Schaeffler GmbH
Application: bearing production (stamping, pressing, turning, welding, coating of bearings and bearing components)
Processing Products per year: 840millionMaterial input: 65,000 tons of steelWork space: 77,000m²Operations: 3500 employees
working 24/7
Requirement: 1) no loss of service, 2) aid planned maintenance3) no machine damage
Configuration/system
Reference
16 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Manufacturing line
Reference
Internet
SCADAz.B.Iconics o. WinCC
Ethernet
Ethernet
ERP
Level
MES
Level
Controller
Level
Field
Level SL
MP
SL
MP
Modbus TCP
Analog/
Digital
In/Out
TC
P/I
P
PLC (e.g. SIEMENS, Schneider, Rockwell, Beckhoff, …)
ERP = Enterprise Resource Planning
MES = Manufacturing Execution System
SCADA = Supervisory Control and Data Acquisition
Gateway = Connection to other industrial protocol with
converting modules possible
Analog/
Digital
In/Out
Cloud/
Internet**** Profibus
Profinet
CANopen
CC-Link
DeviceNet
EtherCAT
DB
Agent
TC
P/I
P
FAG
SmartVisual
Gateway
All trade
All
third
pa
rty tra
de
ma
rks a
nd
/or
reg
iste
red
tra
de
ma
rks a
re t
he
pro
pe
rty o
f th
eir r
esp
ective
ow
ne
rs a
nd
are
ackn
ow
led
ge
d
17 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Manufacturing line
Result: Accumulated knowledge
Deeper appreciation and understanding
Preparation for the future
Return on Investment:
Priceless!We will be implementing at our other factories
Reference
18 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
And the future?
19 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
SmartGuard
Plattform
System
(Schaeffler/
Customer)
SmartCheck
communicate
directly with Cloud
Smart Products and Services HMI 2016 (available for pilots)
SmartGuard
Link
Customer Schaeffler Service
Infrastructure
Internet and
LAN/WLAN
Access to own
data, no local
Software installation
Access to
all data
Administration
Plattform
Expert tools for
CM Service
Views and Reports,
Layouts, Usability
RULRemaining
Useable Lifetime
20 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
Overview
Condition Monitoring System for Railway Applications
Overview of the condition monitoring system
implemented on bogies, with signal
detection, data processing and diagnosis
which delivers bearing health status.
21 Predictive Condition Monitoring by Schaeffler: ARC Forum Japan/India 2016
22COPYRIGHT © 2016 MITSUBISHI ELECTRIC. ALL RIGHTS RESERVED. ALL TRADEMARKS ACKNOWLEDGED.Open ARC Forums 2016 (e-F@ctory Alliance partner Schaeffler) (Promo G. FA Overseas Marketing)
Collaboration and “know-how”
IIoT, Industrie 4.0 are complex
manufacturing environments – to
maximize the opportunity
collaboration is required
23COPYRIGHT © 2016 MITSUBISHI ELECTRIC. ALL RIGHTS RESERVED. ALL TRADEMARKS ACKNOWLEDGED.Open ARC Forums 2016 (e-F@ctory Alliance partner Schaeffler) (Promo G. FA Overseas Marketing)
Together we make solutions!
PC-Less
connection
directly to
MES/ERP
Process
managementIntegrated
energy
management
From receipt of order,
manufacturing and
delivery
Live production
reporting
Increased
quality; produce
right first time
Small or large
batch flexibility
Pre-emptive
maintenance
Renewable
energy
managementTraceability and
tracking control
Empowering customer
to make the
right decisions!
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THANK YOU!