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- 1. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP PM for Reliability Analysis Using SAP PM for Reliability Analysis Vince Flynn Vince Flynn E. I. DuPont deNemours & Co. Inc. E. I. DuPont deNemours & Co. Inc. Joel Barger Joel Barger Meridium Inc. Meridium Inc.
- 2. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Outline • Background DuPont and SAP • The Business Problem • A Reliability Process Model • Sources of Reliability Data in SAP • Meridium and Reliability Tools • Concluding remarks - Importance of deriving value from the data already being collected • Questions and Answers
- 3. Global operations, science based corporation • Based in Wilmington, Delaware • Consists of 14 strategic business units plus joint ventures • 2001 Sales were $27,726 (million) • Total Assets are $40,319 (million) • 79,000 Employees • 200 years young • 50+ Manufacturing Sites • $1,200 (million) in annual maintenance costs
- 4. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada DuPont SAP Update • Began using SAP in the early 1990s − PM used in Europe, Asia and Canada – R/2 − US sites remained on Legacy Business and CMMS systems • Now implementing a multi-year program to move North America onto SAP R/3 − Projects within the program are Business driven − “Go-Lives” are sequenced from 2002 thru 2004+ − Multiple cluster architecture with leveraged configuration − Utilizing most R/3 Modules, including PM (no HR) − Bolt-on applications being used to augment SAP functionality, including Meridium
- 5. The Business Problem • Maintenance optimization requires: − Efficiency – Planning & Scheduling, Materials Procurement, etc… − Effectiveness – Doing the right work − Reliability Improvement - to eliminate failures and optimize maintenance strategies. − The Stake for Reliability Improvement is BIG − The potential Uptime gain is worth 5X the maintenance cost savings • Identified a need for a Reliability Analysis Tool Set that would enhance the value of the data being collected in SAP PM
- 6. The Stable Domains of Maintenance Asset Effectiveness Reactive Reactive Planned Planned Regressive Regressive Reliability Focused Reliability Focused Manage to the budget, Let facilities deteriorate Fix it when it fails, no facilities deterioration Fix before failure, no facilities deterioration UPtime and defect elimination focus, improve the facilities Source – Winston Ledet & DuPont CMLT
- 7. Reliability Reliability is "the probability that a device will perform its intended function for a specified length of time when operated within the environment for which it was designed.“ Nachlas (1995)
- 8. What is reliability? • Elimination of failures? • Reduction in frequency & cost of repairs? • Predictable availability? • Avoidance of incidents? …All of these
- 9. A Reliability Model – with a Systems View Defect Elimination Operate/ Maintain Facilities Design & Build Analysis & Decision Support
- 10. SAP PM Business Process Routine Maint Turnaround Maint Specific Equipment Plans Work ID Prioritize Plan Schedule Execute Confirm & Document Work ID Prioritize Plan Schedule Execute Confirm & Document Operate/Maintain Operate Transactional Data (Events & History) Reliability Data from SAP • Notification Data − Functional Location − Equipment Number and Class − Breakdown Indicator − Catalog Codes • Work Order Data − Cost – Labor & Materials − Duration
- 11. PM with Defect Elimination - Reactive Reliability Routine Maint Turnaround Maint Specific Equipment Plans Operate/Maintain Operate Transactional Data (Events & History) Data Analysis for Stake Prioritize Based on Business Impact Select What to Work on Root Cause Failure Analysis Eliminate System Defect Leverage Learnings Defect Elimination • Analysis done in SAP PMIS, Excel or other tools • Impact of lost downtime not tracked in SAP • Maintenance Plans and Strategy changes not easily referenced to Root Cause Studies • Data is not well organized
- 12. PM with Analysis & Decision Support Analysis & Decision Support Strategies Maintenance Turnaround Spare Parts Training Operations Analysis Functional/ Criticality and/or Risk Based Inspection Equipment Analysis Data Routine Maint Turnaround Maint Specific Equipment Plans Leverage Learnings Defect Elimination Operate/Maintain Operate Transactional Data (Events & History)
- 13. PM with Analysis & Decision Support Analysis & Decision Support Strategies Maintenance Turnaround Spare Parts Training Operations Analysis Functional/ Criticality and/or Risk Based Inspection Equipment Analysis Data Routine Maint Turnaround Maint Specific Equipment Plans Leverage Learnings Defect Elimination Operate/Maintain Operate Transactional Data (Events & History) • Analysis tools linked to a common database in Meridium − Utilizes the SAP data structures - F/L, Equipment, Class, Catalog Codes etc… − Provides Analysis Tools not in SAP − Weibull Analysis − Risk Based Inspection − Reliability Centered Maintenance − System Reliability, etc… − SAP interfaced to Meridium • Maintenance Plan and Strategy changes linked to F/L and Equipment − Recommendations are sent to SAP as an M4 Notification Task − Replace, change inspection interval, etc..
- 14. Reliability for New Facilities Routine Maint Turnaround Maint Specific Equipment Plans Defect Elimination Design Procure Comission Construct Operate/Maintain Facilities Design & Build Operate Analysis & Decision Support Strategies Maintenance Turnaround Spare Parts Training Operations Analysis Functional/ Criticality and/or Risk Based Inspection Equipment Analysis Data
- 15. Reliability for New Facilities Routine Maint Turnaround Maint Specific Equipment Plans Defect Elimination Design Procure Comission Construct Operate/Maintain Facilities Design & Build Operate Analysis & Decision Support Strategies Maintenance Turnaround Spare Parts Training Operations Analysis Functional/ Criticality and/or Risk Based Inspection Equipment Analysis Data • Closing the Loop on New and Upgraded Facilities − Project Engineers can look at performance data to make Life Cycle Cost Evaluations − Mean Time Between Failures − Reliability Centered Maintenance − System Reliability, etc…
- 16. A Reliability Model – A Systems View Defect Elimination Operate/ Maintain Facilities Design & Build Analysis & Decision Support
- 17. Data Requirements for Reliability PM data enables analysis! Available Data What and Where? SAP Fields Used Functional Location, Eq Class Failure Times Malfunction Start and End Date Failure Modes Damage Code Failure Costs Total Work Order Cost Failure Effects Failure Effects Failure Causes Cause Code
- 18. Equipment Classes, Characteristics and Catalog Codes • The PM Equipment Class is a structured catalog of Equipment based on: − Legacy equipment types − Benchmarking „ What does it cost to maintain a specific class of equipment − ISA, ISO and other Standards • For DuPont over 400 Classes have been defined − Characteristics have been defined for each Class • Catalog Codes (Failure Codes) are related to an Equipment Class − Used ISO Standard 14224 as a basis for coding
- 19. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Failure Mode Code Type (Y) Rotating Equipment (PM-RTGEQ) Excessive Vibration (VIB) Object Part Code Type (B) Rotating Equipment (PM-RLH) Bearing - Radial (0450) Damage Code Code Type (C) Rotating Equipment (PM-RLH) Bent (0400) Cause Code Code Type (5) Rotating Equipment (PM-RLH) Assembly Error (0500)
- 20. Meridium Catalog Profile PM-RLH Equipment Failure Codes Caus es of Damage Follow-up Tas ks Activities Performed Component Parts Failure Modes Damage Conditions Codes Abnormal output - high Abnormal output - low Breakdown External leakage proces s Failed to Start Failed to Stop Internal leakage Minor in-s ervice problem Nois e Overheating Structural deficiency Unexpected s tart Unexpected s top Vibration Codes Acceptable Analyze trends Change PM frequency Create work reques t Evaluate probable caus es Notify Operations Notify Technical Engineer Codes Alignment Incorrect As s embly Error Clearance Incorrect Corros ion Cracking Eros ion Exces s Pres s ure Exces s Temperature Fabrication Defect Fatigue Improper Material Improper Lubrication Operation Error Welding Defect Codes Bearings - radial Bearings - thrus t Bus hings Cas ing Coupling Cylinder Liner Diaphragm Gas ket Impeller Lubrication Pis ton Pump Seals Shaft Sleeves Supports Wear Rings Codes Acceptable / OK Bent/Deformed Broken/Sheared Cavitation Corroded Cracked Crus hed Eros ion Fatigue Fouled Leaking Loos e Lubrication Plugged Seized Sticking Wrong Material Wrong Size Wrong Type Codes Adjus t Check Ins pect Modify / Relocate No Action Taken Overhaul Recondition Remove from Service Repair Replace Service / Calibrate Tes t B C A 5 Y 2
- 21. • Failure Date − Date that the equipment failed • Planning Start Date − Date that planning begins • Maintenance Start Date − Date that physical work is started • Maintenance Completion Date − Date that physical work is completed Event Date/Time Stamps
- 22. Failure Effect in SAP
- 23. Code 1: Safety “Failure causes injury or death” Code 2: Environment “Failure causes hazardous emission” Code 3: Production “Failure causes process downtime” Code 4: Quality “Failure causes off spec product” Code 5: No Effect “Failure causes no adverse effect” Failure Effect Failure Effects are defined in RCM for each Failure Mode. When captured from PM they can be used to update tasks and plans in PM
- 24. Data Requirements for Reliability How PM data enables analysis Available Data What and Where? Analysis Enabled Pareto’s and Bar Charts Failure Times Trends Failure Modes Life Distributions Failure Costs PM/Spares Optimization Failure Effects Failure Modes/Effects Analysis Failure Causes Root Cause Analysis
- 25. Where Do the Reliability Tools Fit? Equipment Complexity Æ Cost of Downtime Æ Risk Based Inspection System Reliability Reliability Centered Maintenance Weibull Analysis Root Cause Analysis
- 26. The Business Solution for DuPont • Use state of the art Reliability Analysis tools with our SAP PM solution − Utilize the Meridium ERMS System as a Bolt-on for Analysis and Decision Support • Configure SAP to capture the data for Reliability − Functional Location, Equipment Classification, Catalog Profiles, etc… • Configure Meridium to mirror the SAP data structures • Interface SAP to Meridium to push the data both ways
- 27. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada • Founded in 1993 • Focused on key process industries – refining, chemicals, power • 18 Fortune 500 corporate customers in North America, Europe, Asia • Profitable for 9 consecutive years • 100+ employees • Roanoke, VA / Houston, TX • SAP Software Partner
- 28. Metrics Manager: • Highlights problem areas • Multi-dimensional Analysis • Drill Down Analysis
- 29. Registry Allows user to: • Perform data searches • Create queries • Create reports • Create graphs • Store snapshots of data • Store analyses
- 30. Statistical Analysis - Weibull • Leverages small amounts of data • Provides an indication of how the equipment is failing: − Infant Mortality − Random − Wear-out
- 31. PM Optimization • When a PM is appropriate it calculates the optimal interval • Used to update Maintenance Plans in SAP
- 32. System Reliability • Can use stored Component Analysis or Estimated Values • Tells you what is expected to fail next and what fails the most often. • Often used to determine most cost effective re- design alternatives. • Simulation provides: − Failure Counts − Downtime − Availability − Failure Cost
- 33. Criticality Calculator • Risk Based Inspection − Failure Probability − Failure Consequence − Equipment Criticality − Inspection Priority Used to Determine the optimal inspection interval relative to the probability and consequence of failure
- 34. • Process Requires little or no historical data • RCFA business process • Fault Tree Analysis • Recommendation Tracking Root Cause Failure Analysis Used to identify and eliminate the source of a Problem
- 35. Dynamic RCM • Methodology helps determine the optimal set of operational and maintenance tasks to perform based on the functions of a system. • Can be used before a plant goes into operation. • Resulting analysis tasks can be used to update existing SAP Maintenance Plans
- 36. United Airlines Age-Reliability Analysis of Boeing 727 JT8D Engine Results of overcoming dominant failure modes by engineering improvements
- 37. Inspection Manager • Visual Inspection Data Management • Observations • Findings • Recommendations • Reports Provides for Compliance Inspection and Recommendation Tracking
- 38. Instrument Manager Tools to Manage Instruments and Calibration data
- 39. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability
- 40. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Codes are Created based on standards or RCM analysis
- 41. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability
- 42. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Notifications are Created
- 43. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability
- 44. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Work is Performed
- 45. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Failure Coding is Completed Work Order is Completed
- 46. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability
- 47. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Inspection Manager uses Component Codes as the basis of components to inspect (observations and findings)
- 48. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability
- 49. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Metrics Manager uses the codes to drill down on reliability problem areas
- 50. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability
- 51. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Component Reliability tools like Weibull Analysis use the component and failure mode data to determine failure patterns (infant mortality, wear-out and random failure)
- 52. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability
- 53. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability Root Cause Analysis is performed on chronic failures often identifying new codes that should be added.
- 54. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP for Reliability The process repeats. RCM reviews are used along with all of the other reliability tools to keep the codes current.
- 55. Conclusions • Leading companies have begun to shift to Reliability Improvement (RI) as a way to drive asset productivity • SAP PM can provide the transactional data for RI if configured to support reliability • Enterprise Reliability Management Systems (ERMS) can provide tools for managing the data and providing analysis and decision support tools • The integration of ERP and ERMS has begun • SAP and Meridium are working together to provide an integrated solution − e.g. BAPI developments that open the architecture
- 56. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Questions & Answers
- 57. Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Thank You