leveraging sap to support reliability analytics

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Leveraging SAP to Support Reliability Analytics

Chris Zawislak & Mike PolandConAgra Foods, Inc Life Cycle Engineering, Inc.

• ConAgra Overview

• Taxonomy

• Criticality

• Workflows

• Key points to take home

• Questions

What I’ll Cover

ConAgra Foods overview

Slide 3

ConAgra Foods started in 1919 as Nebraska Consolidated Mills. In 1971 it was renamed ConAgra, Inc., and the company became ConAgra Foods in 2000.

ConAgra Foods is a Fortune 500 company with more than 24,000 employees, with the company’s world headquarters located in Omaha, Neb.

ConAgra Foods is one of North America’s leading food companies, with brands in 97 percent of America’s households.

In fiscal year 2010, ConAgra Foods brought in $12+ billion in net sales.

“From the earth” to food you love

ConAgra Foods Brands

Introduction & Overview

Executive Vision

• Leverage CPS to improve performance

• Leverage SAP to drive cost down

Situation

• 2007 PM Pillar established• Working to establish foundation (PM Step 1) • Implemented SAP across consumer plants• Currently working to develop reliability competencies• SAP configuration was adequate to support foundation

but requires optimization to support reliability analytics and other continuous improvement activities

SAP PM

Risk Analysis

Failure Mode and Effect Analysis

Severity of Failure

Likelihood of Occurrence

Delectability of Failure

Risk Ranking Control Plans Reliability Analysis

Asset Module of EAM

Continuous Improvement

FunctionalHierarchy

Criticality Analysis

Reliability Maturity

Action

Create a Reliability Center of Excellence• Reliability Action Team• Reliability Focus Team• Reliability Engineering function and resource

development• Reliability Infrastructure – SAP Configuration

Taxonomy Criticality Workflows

•Learning to See

Process Flow DiagramValue Stream MappingRelationship Models

Equipment CriticalityFailure Analysis

Risk AnalysisRisk Ranking

Standard WorkOperating Procedures

PreventivePredictive

Condition MonitoringRemote Monitoring

Operator CareCritical Spares

OEETCO

Asset UtilizationMTBFMTTR

OPERATIONAL STABILITY

MeasureControlAnalyzeClassify

Continuous ImprovementPlan Do Check Act

Reliability Infrastructure

Taxonomy

“Systematic classification of items into generic groups based on factors possibly common to several of the items”

ISO 14224, Petroleum and natural gas industries — Collection and exchange of reliability and maintenance data for equipment

Hierarchy(1)

BusinessCategory

(2)Installation/

Business Unit

(3)Cost Center/ Op Unit

(4)Function

(5)System/ Process Line

(6)Sub system/Asset/Equipment

(7)Component/Maintainable Item

(8)Part/ BOM

Use

/ Loc

atio

n D

ata

Equ

ipm

ent S

ubdi

visi

on

Taxonomy per ISO 14224:2006

Functional Block Diagram

In Feed Assembly Out feed AssemblyFill Table

Shaker

VFD

Drive Unit

PLC

Rotary Filler – Technical Object

Objects

FMEA to SAP

Slide 14

FAILURE MODE(FUNCTIONAL FAILURE) POTENTIAL CAUSE(S) CURRENT CONTROL(S) SE

VERI

TYPR

OBA

BILITY

DET

ECTI

ON

RISK

PRI

ORI

TY N

UM

BER STRATEGY:

CM ‐ Corrective (RTF)PM ‐ Time BasedCBM ‐ Condition BasedMOD ‐ Modification TH

ERM

OGRA

PHY

VIBR

ATIO

N A

NAL

YSIS

ULT

RASO

UND

OIL

ANAL

YSIS

MOTO

R CI

RCUIT

ANAL

YSIS

TEM

PERA

TURE

REA

DIN

GIN

SPEC

TION

LUBR

ICAT

ION

SCHED

ULE

D R

EBUILD

SCHED

ULE

D R

EPLA

CEM

ENT

ROUTI

NE CL

EANIN

GAM

D C

LEAN

ING

AMD IN

SPEC

TION

AMD LUBR

ICAT

ION

CSD V

ALID

ATIO

NRU

N TO

FAI

LURE

DINNER OUT OF POSITION AND OR DOES NOT TRANSFER LUG MISALIGNMENT DAILY PM INSPECTION 3 2 2 12 CBM DCHAIN STRETCH DAILY PM INSPECTION, AUTO LUBE 8 2 1 16 CBM DRAIL MISALIGNMENT DAILY PM INSPECTION 3 2 2 12 CBM DSERVO MOTOR FAILURE 1W PM INSPECTION (VISUAL) 5 4 9 180 CBM 1M 1WPHOTO EYE FAILURE (2) NONE 3 5 7 105 PM 1MDRIVE CHAIN FAILURE 1W PM INSPECTION (VISUAL) 4 2 3 24 CBM 1WDRIVE SPROCKET WORN 1W PM INSPECTION (VISUAL) 4 2 3 24 CBM 1WLUG CHAIN CONTAMINATION (PRODUCT FALLING) NONE 2 5 9 90 MOD

DINNER NOT IN 4 X 5 MATRIX RAIL MISALIGNMENT INFORMAL PM DAILY INSPECTION 3 2 4 24 MODBELT CONTAMINATION NONE 3 8 8 192 MODSERVO MOTOR FAILURE NONE 5 4 9 180 CM, POSSIBLE MODBELT DRIVE GEAR(2) FAILURE (ONE PLASTIC, ONE METAL) DAILY PM INSPECTION 4 2 2 16 CBM DBELT TORN OR EXCESSIVELY WORN INFORMAL PM DAILY INSPECTION 3 3 3 27 CBM D

Damage Codes Cause Codes

Task Codes

Rotary Filler Catalog Profile

CodeComponent

Description In feed Fill Table Out Feed Shaker Drive Unit VFD PLC

1001 Rail Misalignment X X1002 Failed Bearing X X1003 Worn Gear X X X X1004 Air Leak X1005 Failed Electrical Circuit X X X1006 Failed Belt X X1007 Programming Error1008 Failed Belt X1009 Failed Chain X1010 Failed eye X X

Cause Code Catalog

CodeComponent

Description In feed Fill Table Out Feed Shaker Drive Unit VFD PLC

2001 Process Stopped X X X X X X2002 Process Slow X X X X X X2003 Process Fast X X2004 Over fill X X X X X2005 Under fill X X

Damage Code Catalog

Rotary Filler Cause Code Group

Rotary Filler Task Code Group

Rotary Filler Damage Code Group

Maintenance Plan

Finding: ABC Indicator does provide adequate granularity for equipment criticalityResult: Insufficient indicators provide requisite separation of assets for prioritizing the application of corporate resources Recommendation: Develop a criticality business process and RACI to at least Base-10

There are 36 characters available in ABC Indicator which provide considerable granularity but often only 3 are used….


Slide 16


• Single point failure• Impact to value stream• Impact to corporate objectives• Replacement asset value• Impact on reputation• Impact on EHS


Slide 18

RIME Index

Slide 19

Work Order Type

Equi

pmen

t Crit

ical

ity

10 9 8 7 6 5 4 3 2 1

10 100 90 80 70 60 50 40 30 20 10

9 90 81 72 63 54 45 36 27 18 9

8 80 72 64 56 48 40 32 24 16 8

7 70 63 56 49 42 35 28 21 14 7

6 60 54 48 42 36 30 24 18 12 6

5 50 45 40 35 30 25 20 15 10 5

4 40 36 32 28 24 20 16 12 8 4

3 30 27 24 21 18 15 12 9 6 3

2 20 18 16 14 12 10 8 6 4 2

1 10 9 8 7 6 5 4 3 2 1

Workflow Optimization

Slide 20

Key Points to Take Home

• SAP configuration needs to mature along with your organization• Collaboration between reliability, maintenance, and IT professionals is key• Control strategy performance indicators should depend on work order accuracy • Leverage FMEA for development of technical object catalogs as well as overall

control strategy• FMEA and technical object catalogs are living documents and should be updated

when appropriate• Criticality needs to be granular enough to support reliability analytics and backlog

management• Task, damage, and cause codes are linked to equipment class for ease of

replication across the enterprise

Build or MigrateDatabase

Risk Analysis

Failure Mode and Effect Analysis

Severity of Failure

Likelihood of Occurrence

Detectability of Failure

Risk Ranking Control Plans Reliability Analysis

Asset Module of EAM

Continuous Improvement

Functional Hierarchy


Close the Loop


Chris Zawislak, CMRPConAgra Foods, Inc.

[email protected]

Mike Poland, CMRPLife Cycle Engineering, Inc.

[email protected]


March 27 – 30, 2011Hyatt Regency Huntington Beach Resort and Spa

Huntington Beach, California