Data and Advanced Equipment Care - OSIsoft · Data and Advanced Equipment Care Dan Riggs –Product Support Consultant Caterpillar Global Mining September 24, 2015

Data and Advanced Equipment Care

Dan Riggs – Product Support Consultant

Caterpillar Global Mining

September 24, 2015

2 / Caterpillar Confidential: GREEN / CONDITION MONITORING — ENABLED BY CAT EQUIPMENT CARE ADVISOR © Copyright 2012 OSIsoft, LLC.

A Global Reach

• Global reach and presence is unmatched

in the industry

• Serve customers in more than 180

countries around the globe

• More than half of our sales are outside the

United States

• Manufacturing, marketing, logistics,

service, R&D and related facilities along

with our dealer locations total more than

500 locations worldwideDealers • 188 worldwide with more than 126,000

employees

• Independent, locally owned

• Key competitive advantage

2


A Broad Range of Products and Industries

Cat equipment – more

than 3 million pieces

globally – is at work for

our customers on

highways, rail lines,

oceans and rivers, in

forests, quarries, mine

sites and oil fields.

3


A Great Chapter in Mining

4

5 / Caterpillar Confidential: GREEN / CONDITION MONITORING — ENABLED BY CAT EQUIPMENT CARE ADVISOR

Top Ten Proble ms

Av ailability (%)

0

5

10

15

20

25

30

1 2 3 4 5 6 7 8 9 10

Top Syste m s

Infl

ue

nc

e o

n A

va

ila

bil

ity

%

Top Ten Problems

Mean Time To Repair (MTTR)

0

5

10

15

20

25

30

1 2 3 4 5 6 7 8 9 10

Top Systems

Infl

uen

ce

on

MT

TR

Equipment Management

Equipment Management is the overall management of

site specific processes and activities involved through the

entire life cycle of the equipment.


Repair & Maintenance Process Model

Preventive

Predictive

Condition Based

Proactive Maintenance

The M&R model is based on key concepts of Preventive, Predictive or Condition

Based and Proactive Maintenance to achieve the goal of preserving the primary

function of the equipment while at optimum levels of safety, reliability & cost all

within a repair before failure strategy.


Condition Monitoring Defined

• Proactive / predictive process of evaluating equipment and

application data inputs to provide maintenance, component

replacement, application and repair recommendations

• Analyzes five data elements: electronic data, fluid analysis,

inspection data, repair history and site conditions

• Creates value-added work recommendations for a ‘repair

before failure’ approach


Condition Monitoring

Failure

Machine Alarm

Reactive Extensive Damage

High Cost

Most Downtime

PlannedSome Damage

Moderate Cost

Moderate Downtime

PredictiveMinimum Damage

Minimum Cost

Planned Downtime

Perf

orm

ance

Weeks Days Hours

Physical Indicator

Wear material

Parametric Change Prognostic

deviation

Time

Reporting Monitoring

Condition Monitoring

Customer Value Increased Planned Maintenance

‒ On time PMs, less disruption to shop

‒ Less time in shop

‒ 80/20 % scheduled work

‒ 7 hrs Mean Time To Repair (MTTR)

Lower Labor and Parts Cost

‒ Reduced contingent damage – 3X $$

‒ Reduced emergency parts ordering

Increased Component Lives

‒ Lower cost per hour

Improved Mean Time Between Shutdown (MTBS)

‒ 50-60 hrs

Increased Availability

‒ 60 MTBS and 7 MTTR = 90% PA


Cat Equipment Care Advisor

Dealer offered Condition Monitoring services

powered by Cat Equipment Care Advisor

Dealer offered Condition Monitoring services

powered by Cat Equipment Care Advisor


Machine

Conditions

Compared

to Itself

Association and Business Rules

Analytics Strategy

Machine

Conditions

Compared

to Similar

Machines

Machine

Conditions

Compared

to a

Standard

Inputs:

• Electronic Data • Repair History • Fluid Analysis • Site Conditions • Inspections


Cat Equipment Care Advisor

Know More.• Practical knowledge from

worldwide fleets

• Global Caterpillar and Cat

dealer knowledge and expertise

Get More.• Advanced analytics

• Maintenance and repair

recommendations

• Value tracking

Do More.• Higher availability

• Increased productivity

• Improved operator performance


Customer Value

• Condition Monitoring more effective

– Percent Scheduled Work improvement of 5% - 30%

– Mean Time Between Stoppage improvement of 10% - 50%

– Physical Availability Improvement of 1%-5%

• Recommendation value – based on “saves”

– Real examples range from $5,000 to $500,000


Recommendation Value: $53,600 Risk Avoidance: $73,200

Repair Cost: $19,600

Cat ECA was used to monitor a fleet of 797Fs at a MARC site in Australia. A new C175 engine had just

been installed. Ten days after installation, the “Compare to Self” analytical model indicated engine oil

pressure was dropping rapidly. The Dealer Condition Monitoring Analyst sent a recommendation to site

suggesting a possible turbo failure and/or possible fuel dilution. Recommended boost test and cylinder cut

out test be performed, as well as another engine oil sample.

Value examples

Result: Boost pressure test indicated no issue, technician pulled oil sample and did on site viscosity test

and determined the root cause to be a leaking upper injector seal that was causing fuel dilution and

engine oil pressure degradation.


Recommendation Value: $33,907 Risk Avoidance: $45,322

Repair Cost: $11,415

Value examples

Result: Inspection revealed an injector damaged by a misaligned pushrod. The pushrod was replaced

along with the damaged injector and rocker on the LH bank causing higher RH exhaust temperatures.

A 793D at a site in South America experienced 3 different

exceptions that were all related: engine fluid result with high

soot and iron, exhaust temperature differential trend and

exhaust temperature compared to self. Possible causes were

dead injector, wiring harness fault, or boost leak. Condition

monitoring analyst sent a recommendation with two

knowledge articles, one for inspecting for harness fault and

one for inspecting for lash on valves and injectors.


Recommendation Value: $465 Risk Avoidance: $592,479

There was an engine oil filter pressure differential on an off-highway truck that was not enough to trigger on board

alert, but was discovered by Cat ECA because the rate of change was abnormal. Dealer Condition Monitoring

Analyst looked at fluid sample results, which were good, and saw last PM was done less than a few hours before

this issue was flagged. Dealer sent recommendation to site to pull engine oil filters and look for blockage. Local

technician inspected filter and found plastic covering for the filter inside the filter housing. Inaction would have

eventually restricted enough oil flow to scuff a bearing, potentially leading to engine failure.

Recommendation Value: $576.16 Risk Avoidance: $5,500

There was a brake pressure low exception found by Cat ECA from a comparison of the local fleets’ rear brake

system pressures. Cat ECA also noted an exception in this truck’s rear brake pressure from a long term trend

analysis. In these situations, the normal course of action by maintenance is to reseal the hydraulic slack

adjuster. However, the Dealer Condition Monitoring Analyst looked at data logger information and discovered

erratic pressure sensor signals. He instead told the site to replace the sensor and not the slack adjuster. This

avoided unneeded additional downtime , repair labor, and parts.

Value examples


Caterpillar Value

• True VOC on how equipment is being utilized

• Seamless transition of product improvement into

Engineering

• More efficient CPI and NPI process


Taking Equipment Management Solutions to Market

• Supplying the Customer his data of equipment location and what it’s doing with

remote, real-time information

• Supplying the Customer the ability to manage his equipment with health and

utilization trends compared to benchmarks via automated reporting.

• Supplying the Customer condition based recommendations to make informed

decisions about managing and maintaining machines.

• Supplying the Customer PM Planning / Scheduling and Repair Execution based

on the M&R processes, Component tracking and planning, Parts execution

planning, Operation application consulting, Operator training, and CI support

• Supplying the Customer empowerment of Cat Dealers to proactively manage

equipment so they can focus on their business.


Cat_ECA_ShowMe_CUST_Full_v3_720_May2015.mp4

Cat_ECA_ShowMe_CUST_Full_v3_720_May2015.mp4


Documents

Data and Advanced Equipment Care - OSIsoft · Data and Advanced Equipment Care Dan Riggs –Product Support Consultant Caterpillar Global Mining September 24, 2015