How Warehouse and Distribution Systems (Conveyor systems) are being designed for Maintenance

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This presentation explores how the latest conveyor and sortation hardware and control systems are being designed to anticipate or be alerted to problems quickly, maximize MTBF and uptime, and minimize MTTR. We will also examine the benefits of real time and historical data monitoring and visualization to reduce downtime, decrease maintenance and increase operational efficiency and throughput.

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  • Awareness of energy consumption by maintenance & operators is an important part of industrial energymanagement. We typically estimate 2-3% energy savings just from the increased awarenessfactor (this estimate is confirmed by the DOE's metering guidebook). Many of our customershave discovered that savings are actually higher as they discover process and equipmentproblems brought to light via monitoring.
  • Report total Operational Performance Reduce MHE system downtime – Maximize MHE performance Tie operations to energy usage – Plan for energy savings
  • An MVS also has the capability of providing energy data down to the individual device (requires sub-level metering). This data can be used to compare solutions (merge, shipping, packing, etc from one DC to another or one vendor to another vendor’s solution. This data can be rolled up to provide a yearly cost saving analysis, with newer updated features now with raw data to show true ROI based not only off thru put and error downtime, but now energy costs associated with equipment as well.Additionally, you could determine where power quality faults are occurring in the system, isolated to specific equipment, or if upstream, downstream where equipment protection should be placed to help ensure maximum uptime.Consider tracking Peak Demand in order to truly understand when is peak demand times occur, and determine where the DC is tracking in real time relevant to this information. Provide visibility of when a new peak is set, and what the cause is, with a financial feedback (dollar amount cost) to the company associated with setting this new peak demand charge. Determine options that could be implemented to help reverse the trend back downward with energy saving process improvements
  • How Warehouse and Distribution Systems (Conveyor systems) are being designed for Maintenance

    1. 1. © 2014 MHI® Copyright claimed as to audiovisual works of seminar sessions and sound recordings of seminar sessions. All rights reserved. Sponsored by: Presented by: Nathan Slider - Schneider Electric Software Solutions Specialist How Warehouse and Distribution Systems (Conveyor systems) are being designed for Maintenance
    2. 2. Maintenance Challenges for Material Handling Systems • Desire to achieve maintenance & energy savings • Reduce system downtime – while increasing reliability • Multiple equipment vendors with independent proprietary software • No means of reporting on the total facility system performance • No means of monitoring operations ability to maximize the output of the material handling solution
    3. 3. Principles of Maintenance & Operational Practices – Detection: Using preventive and predictive technologies to inspect, detect and then correct small defects before they can become costly repairs – Restoration: Restoring equipment to optimal conditions – Prevention: Preventing small defects from becoming major problems by correcting them before they become costly repairs
    4. 4. Take a Strategic Approach to Operations and Maintenance Focus on minimizing your risk and reducing downtime: • identifying potential areas of risk and ensuring that you have the necessary skills and resources to quickly address any potential events as they occur • includes developing a complete picture of all your installed automation equipment at the machine component level
    5. 5. Maintenance Methodology Steps to optimum performance • Visualization • Reporting / Analyze data • Provide real time alerts • Energy Management Actions used by Maintenance ImproveAnalyze ControlMeasureDefine
    6. 6. Visualization A complete Monitoring and Visualization Solution (MVS) provides distribution centers with real-time visibility to the plant floor You Can’t Manage What You Don’t Measure. View systems real-time such as conveyor status, lane capacity, alarm faults, energy data, etc.).
    7. 7. Visualization (Click Thru) Maintenance & Operations have drill-down data visibility with intuitive navigation
    8. 8. Reporting / Analyze data MVS also provides a very powerful set of reporting tools to help the maintenance staff analyze data Reports / Dashboard: Motor Status, Conveyor Availability, Energy, Recirculation Analysis, etc.
    9. 9. Reporting /Analyze data (Click Thru) Total Downtime Total Number of Faults E-Stop Counter Jam Counter
    10. 10. Provide Real-Time Alerts to Maintenance StaffData Alerts & Alarms on the plant floor equipment (e.g. motor statuses, jams, missing pins, etc.) Equipment Filter Alarms Correlated with Video Feed PTZ cameras to Pan Tilt Zoom to the exact location of the alarm fault (example: fire door jammed with boxes or jam due to a mechanical
    11. 11. Energy Management Visibility helps Maintenance Prioritize Visibility to the power quality and consumption of the incoming power. Motor Faults due to Power Quality Occurrence / Direction of Power Fault (Upstream / Downstream) Downtime Reporting resulting from PQ Issues.
    12. 12. All of this MHS Management Data is available at your fingertips with Mobility Solutions!
    13. 13. For More Information: Speaker email: Nathan.Slider@Schneider-Electric.com Web site: www.schneider-electric.com

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