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Copyright © Ivara Corporation. All rights reserved
Delivering Customer Value through Asset Performance and ReliabilityIvara EXP – IBM Maximo Integration
Aaron Beazley, Ivara Corporation
Upgrade Maximo andImprove Asset Performance?• Why wait – the business is not stopping• Different resources are utilized• Focus on critical assets or bottlenecks• Involve Operations: it is not only a
maintenance department issue
About Ivara EXP Enterprise• Enhances IBM Maximo enterprise asset
management • Helps prevent equipment failure, increase
production and lower costs– Real-time, consolidated view of asset health.– Automates evaluation of equipment condition data
by alarming on exception– Detects onset of failure early. – Identifies PM and data collection tasks to drive
maintenance programs.
Performance Improvement
Crofton Performance Improvements:• Annual Operating performance improvement of
$1,800,000• Annual Maintenance Labour, and M & S cost reduction
of $1,350,000
Specific Annual Operating Performance Improvements:
• TMP Chip Blow System ($160,000)• TMP Pressure Screen ($50,000)• White Liquor Pressure Filter ($180,000)• 480 Refiner Mechanical Seals ($25,000)• PM3 Calendar Stack ($50,000)• Bleach Air Doctor Showers ($100,000)• Salt Cake filter performance ($150,000)
ASSETCONDITION
DATA
Inspection Data
Online Data(Data Historian,
SCADA)
PredictiveTechnologies
Asset Hierarchy
Asset Priority
Job Plans
Work Orders
ANYEAM/CMMS
Ivara EXP and Asset Performance
• The Ivara software solution ties it all together– Technology– Process & Practices– People
Strategy Development
• Set performance targets• Prioritize opportunities and
risks • Analyze assets and
develop reliability action plans– RCM2™– MTA
• Integration points:– Maximo asset priority is
updated based on Ivara risk prioritization analysis (consequence priority)
Reliability Program Implementation• Rapidly implement• Define and manage
tasks and data derived from RCM
• Define alarm points and planned response
• Collect condition data
• Integration points• Synchronize Ivara asset
hierarchy from IBM Maximo (master)
• Synchronize IBM Maximo Job Plans and Ivara tasks and jobs (bi-directional)
ASSETCONDITION
DATA
Inspection Data
Online Data(Data Historian,
SCADA)
PredictiveTechnologies
Performance Management
• Shared view of current asset health – online in real time
• Consolidated and automated analysis to make informed decisions, initiate work
• Manage by exception, priority
• KPIs
ASSETCONDITION
DATA
Inspection Data
Online Data(Data Historian,
SCADA)
PredictiveTechnologies
Work Management• Make informed decisions in
responding to alarms• Integration points:
– Create work orders in IBM Maximo
• Acknowledgement of an alarm due to a condition being out of normal range
• Use pre-planned Maximo job plans as the basis for the work triggered.
– When resulting work is completed (work order is closed in Maximo), the work order is closed in EXP.
IBM Maximo / Ivara EXP Integration
http://catalog.lotus.com/wps/portal/topal/details?catalog.label=1TW10MA1N
For details, go to:IBM Tivoli
Open Process Automation Library
(OPAL)
Benefits for IBM Maximo Customers
• Reduces integration costs, streamlines IT efforts• Accelerates the deployment of EXP Enterprise
with IBM Maximo • Accelerates IBM Maximo time-to-value • Ensures informed maintenance decision-making • Holistic approach to executing a proactive
condition-based maintenance strategy to optimize asset performance
Integrated Data SummaryItem Direction/Maximo ItemAssetsBasic information From Maximo Assets/LocationsHierarchy From MaximoConsequence priority To Maximo Asset priorityWork ordersNew work orders To Maximo work ordersStatus From MaximoStandards LibraryTasks To/from Maximo Job PlansJobs To/from Maximo PMs
Implementation Approach
Proactive Benefits:• Repair Parts Usage Reductions• Availability Improvements• Quality loss Reductions• Throughput Increases• Contractor Reductions• Overtime Reductions• Insurance Premium Reductions
Implementing Proactive work…one System at a Time…Implementing Proactive work…one System at a Time…
……replacing a replacing a Repair Culture Repair Culture with an with an Asset Management CultureAsset Management Culture
Possible Project Plan
Upgrade Upgrade PlanningPlanning
Upgrade MaximoUpgrade Maximo
Install EXP Install EXP & Interface& Interface
FeaturesFeatures to use?to use?
WeekWeek11 22 33 44 55 66 77 88 99 1010 1111 1212 1313 1414
RCMRCM MTAMTA MTAMTA
Indicator MappingIndicator Mapping
RCMRCM MTAMTA MTAMTA
1515 1616
Check Sheet Development & ValidationCheck Sheet Development & Validation
MTAMTA RCMRCM MTAMTA
EXP EXP TrainingTraining
Handheld and Online Data CollectionHandheld and Online Data Collection
Alarm Management / KPI TrackingAlarm Management / KPI Tracking
Training Implementation
Work ManagementWork Management
Process DefinitionProcess Definition Process Training Process Coaching and Adherence Monitoring
Practices TrainingPractices Training
Moving from Reactive to Proactive in less than 3 months