Asset Performance Management I Maintain 2012

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presentation for breakfast master class at Imaintain 2012

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  • Welkom bij de 2e editie van de Imaintain Breakfast Masterclass.Aantalnieuwegezichten en eenaantalbekenden van vorigjaar,datgeeftaandat het de moeitewaard is omterug te komen.We hebben 1,5 uur tot 10.30 u dezesessie.De bedoeling is dat we onder het genot van eenlekkerontbijt met elkaarervaringenuitwisselen en u informeren over Analytics watwijzienalseennieuwedimensie in onderhoud. Allereerstzalik u meenemen in eenaantalstappennaarprofessionalisering van onderhoudwaarbij de stapnaar analytics in de komende 10 jaareennieuwewereldkanopenen. Vervolgenszal de andere Marc Couturier van SAS enkelevoorbeeldengeven van waardit in de praktijk al wordttoegepast en watdatkanbrengen. Maargraagwillen we dit in de tweedehelft van de ontbijtsessie met julliebesprekenomdathier net alsvorigjaarweereenindrukwekkendaantaljarenonderhoudservaringverzameld is en we zeerveel van elkaarkunnenleren.Ikwilgraagbeginnen met eenkortevoorstelrondewaarbijiedereenzijnnaam, het bedrijf en de rol in het bedrijfkanaangeven.
  • Watweetaccenturenou van onderhoud?De meeste van u zullenaccenturemisschienkennenalswereldwijdopererendadviesburo in de IT en outsourcing.Datklopt, wijzijn met 240.000 mensenwereldwijdactief consulting technology en outsourcing. We helpenmeerdan 90 van de top 100 bedrijven in de Fortune 500 om high performers te worden.Wijzijn de grootste integrator van SAP en hebbenruim 120.000 mensen in delivery centers over helewereld in near en off shoring van met name shared service activiteitenals HR, finance, payroll en andereadministratievezaken en we groeien met ca 20% per jaar.Daaromzijneenaantal business services opgezetommeer te focussen op de kernprocessen van onzeklanten. Een van deze business services in de Resources industrie (Oil & Gas, Chemie en Natural Resources en Utilities) is Accenture plant & automation solutions.In dezegroep zit eengrootaantalindustrie experts die zichrichten op optimalisatie op plant niveau (oaproductie, onderhoud, capital projects, industrial automation, supply chain en EH&S). Wijkunnenonswereldwijdekennis en delivery netwerk en diepgaandeervaring in IT combinerenomonderhoud en asset management te optimaliseren op echt global niveaumaar met lokale expertise.
  • Erwordt steeds betergebruikgemaakt van de data die beschikbaarkomtuit de operatie met real time rapportage en KPIs.Op dashboardskan de gehelebedrijfsvoeringwordenoverzien – eenvoorbeeldhiervan is olie en gas bedrijf Reliance dat de control room vooralle downstream activiteiten met alle disciplines in 1 ruimteheeftsamengebracht.
  • Analytics kanwordentoegepast op verschillendemanieren: diverse wiskundigemodellen die eenvarierendevoorspellendewaarde. De toepassing is momenteelnogbeperkt tot oil en gas upstream waarzeerhogetoegevoegdewaardewordtgehaald en wind farms met name off shore waargeldtdat door hogeinvesteringen de operationelekostenzolaagmogelijkdienenwordengehouden en minimaleinterventienoodzakelijk is omenigszinsrendabel te kunnendraaien
  • Asset Performance Management I Maintain 2012

    1. 1. Analytics open a new dimension in maintenance I-Maintain Breakfast Masterclass 22 March 2012 Marc Hoppenbrouwers - Accenture Marc Couturier - SASCopyright © 2012 Accenture All Rights Reserved. 1
    2. 2. Introducing AccentureCopyright © 2012 Accenture All Rights Reserved. 2
    3. 3. Production and manufacturing companies all face similar strategic and tactical challenges... Sustainable Small developments, Increase Reduce • Due to decreasing margins margins rules and Operational the revenues need to Reliability regulations Expenses increase and expenditure has to reduce • Yet the western industry are facing cost reductions in CAPEX and OPEX, an aging workforce are limiting the ability to handover Knowledge knowledge and experienceLow Capital Aging Aging Management & to new skilled workersInvestments Equipments Workforce Transfer • Additionally new regulations (environmental, energy trading, ISO/PAS/OSHA) demand to change to more sustainable operationsCopyright © 2012 Accenture All Rights Reserved. 3
    4. 4. Asset Performance Management requires continuous improvement in two dimensions... Asset Performance Management requires continuous improvement in efficiency; increase process performance; and effectiveness; increase plant performance. effective Right maintenance Right maintenance poorly executed Excellent executed Plant Performance Wrong maintenance Wrong maintenance Poorly executed Excellent executed ineffective inefficient Process Performance efficientCopyright © 2012 Accenture All Rights Reserved. 4
    5. 5. Maintenance maturity: efficiency Maintenance maturity roadmap focus on execution efficiency Basic levels of maintenance Maintenance best practices Performance based maintenance D Condition based MaintenanceBenefits • Define root causes of failures • Monitor asset condition Risk based 5 • Set warning and alarm levels • Determine p-f interval maintenance C Usage based Maintenance 4 • Introduce timers e.g. runhours, mileage Condition based maintenance • Logical meters • Nesting of tasks Preventive maintenance B 3 Basic preventive maintenance Planned • Time based maintenance maintenance D • Regulatory tasks Breakdown • Vendor recommended actions maintenance 2 • Operator Asset Care C B A Work initiation & prioritizing 1 • Clear notifications A 0 • Gatekeeping on work requests • Work Request Prioritization Capability • Equipment Criticality maturity Copyright © 2012 Accenture All Rights Reserved. 5
    6. 6. Maintenance maturity: effectiveness Maintenance maturity roadmap focus on asset performance Advanced levels of maintenance Maintenance best practices Performance based maintenance H Predictive Asset MaintenanceBenefits • Integrate data sources 5 • Data driven models to generate early Risk based warnings maintenance • Simulate maintenance scenarios H • Optimise maintenance planning G G Performance monitoring 4 • Define performance KPIs Condition based maintenance • Assure data quality & integrity F • Monitor plant performance in real time • Combine operating and decision Preventive E functions in one operations centre maintenance F 3 Living reliability centred maintenance Planned • Criticality Ranking on value drivers maintenance • Define failure modes and assess risks • Optimize maintenance intervals Breakdown maintenance 2 • Close improvement loop using failure codes E Preventive Maintenance Optimisation 1 • Optimise maintenance strategy based on bad actor Pareto analysis Preventative 0 • Reduce consequences Maintenance Planning Maintenance Optimization Maintenance Execution Capability • Schedule compliance maturity Copyright © 2012 Accenture All Rights Reserved. 6
    7. 7. Technology enablers EAM landscape Integrated Best practice EAM Software solution overview Performance Analytics & Predictive Master Data Document management monitoring Asset Maintenance management system (Historians/MES) Control systems Maintenance management (EAM/CMMS) Performance (DCS/SCADA) Dashboards Condition Monitoring Maintenance strategy Spare part Planning/Scheduling (CBM) (RCM / RBI) managementCopyright © 2012 Accenture All Rights Reserved. 7
    8. 8. EAM issue Current EAM system Issue: integration with operations The best-in-class enterprise asset management (EAM) systems fail to make this crucial connection to operations, focusing instead on measures like number of work orders outstanding, task completion against standards and norms, or MRO inventory costs Smarter Assets Require Smarter EAM 18 February 2010Copyright © 2012 Accenture All Rights Reserved. 8
    9. 9. EAM trends The main driver for EAM systems is to increase reliability, analytics will play an important role in achieving thisCopyright © 2012 Accenture All Rights Reserved. Source: ARC best practices – February 2012 9
    10. 10. Analytics Analytics define a new dimension in the industry Analytics Definition “What’s the best that can Optimization happen?” Predictive “What will happen next?” Predictive Modeling Competitive Advantage Analytics Forecasting/ “What if these trends (the “so what”) Analytics will Extrapolation continue?” help our clients become more Statistical “Why is this happening?” insightful decision makers Analysis who implement more Alerts “What actions are needed?” impactful interventions to Query/ improve business outcomes, “What exactly is the problem?” Drill down i.e. the “now what!” Descriptive “How many, how often, Analytics Ad hoc Reports where?” (the “what”) Standard “What happened?” Reports Sophistication of Intelligence Source: Competing on Analytics: The New Science of Winning (Davenport / Harris)Copyright © 2012 Accenture All Rights Reserved. 10
    11. 11. Analytics: the data challenge The challenge – Too many surprises Collect Analyze Decide Act Maint. $ AvailabilityCopyright © 2012 Accenture All Rights Reserved. 11
    12. 12. Analytics: informed decision making Analytics offer the solution to reduce surprises Collect Analyze Decide Act Maint. $ Availability Data Strategy & Socialization Infrastructure policy Intelligence Descriptive Organization Analytics Predictive AnalyticsCopyright © 2012 Accenture All Rights Reserved. 12
    13. 13. Analytics: integration of data sources Analytics - better cooperation based on better data Reliance has one control room for their entire downstream operations in IndiaCopyright © 2012 Accenture All Rights Reserved. 13
    14. 14. Analytics: industryPredictive Asset Maintenance (PAM) –Different industries and time horizons require different predictivemethodologies and that defines the business value gained value created based on predictive asset maintenance analytical methods applied Predictive Asset Maintenance High  Similarity –Based Models Petroleum Petroleum Power Up stream Power Down stream  Proportional  Markov Models Medium Hazard Models Hydro Wind Farm off-shore  Bayesian Models Wind Farm Natural Gas on-shore Nuclear  Condition Monitoring Power  Regression models  Survivor Analysis Chemicals Industry Low  Expert Systems Short term Mid Term Long Term Time Horizon Copyright © 2012 Accenture All Rights Reserved. 14
    15. 15. Analytics: @ work The value of Analytics APPS BI AnalyticsCopyright © 2012 Accenture All Rights Reserved. 15

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