Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP PM for Reliability AnalysisUsing SAP PM for Reliability Analysis
Vince FlynnVince FlynnE. I. DuPont deNemours & Co. Inc.E. I. DuPont deNemours & Co. Inc.
Joel BargerJoel BargerMeridium Inc.Meridium Inc.
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
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
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
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
The Stable Domains of MaintenanceA
sset
Eff
ecti
vene
ss
ReactiveReactive
PlannedPlanned
RegressiveRegressive
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
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)
What is reliability?
• Elimination of failures?
• Reduction in frequency & cost of repairs?
• Predictableavailability?
• Avoidanceof incidents?
…All of these
A Reliability Model – with a Systems View
DefectElimination
Operate/Maintain
FacilitiesDesign & Build
Analysis &DecisionSupport
SAP PM Business Process
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Work ID
Prioritize
Plan
Schedule
Execute
Confirm &Document
Work ID
Prioritize
Plan
Schedule
Execute
Confirm &Document
Operate/Maintain
Operate
TransactionalData
(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
PM with Defect Elimination - Reactive Reliability
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Operate/Maintain
Operate
TransactionalData
(Events &History)
DataAnalysis for
Stake
Prioritize Basedon Business
Impact
SelectWhat toWork on
Root CauseFailure
Analysis
EliminateSystemDefect
LeverageLearnings
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
PM with Analysis & Decision Support
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
Equipment Analysis Data
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
LeverageLearnings
Defect Elimination
Operate/Maintain
Operate
TransactionalData
(Events &History)
PM with Analysis & Decision Support
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
Equipment Analysis Data
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
LeverageLearnings
Defect Elimination
Operate/Maintain
Operate
TransactionalData
(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..
Reliability for New Facilities
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Defect Elimination
Design Procure
ComissionConstruct
Operate/MaintainFacilities Design & Build
Operate
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
Equipment Analysis Data
Reliability for New Facilities
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Defect Elimination
Design Procure
ComissionConstruct
Operate/MaintainFacilities Design & Build
Operate
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
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…
A Reliability Model – A Systems View
DefectElimination
Operate/Maintain
FacilitiesDesign & Build
Analysis &DecisionSupport
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
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
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Failure ModeCode Type (Y)
Rotating Equipment (PM-RTGEQ)Excessive Vibration (VIB)
Object PartCode Type (B)
Rotating Equipment (PM-RLH)Bearing - Radial (0450)
Damage CodeCode Type (C)
Rotating Equipment (PM-RLH)Bent (0400)
Cause CodeCode Type (5)
Rotating Equipment (PM-RLH)Assembly Error (0500)
Meridium
Catalog ProfilePM-RLH Equipment
Failure Codes
Caus esof Damage
Follow-upTas ks
ActivitiesPerformed
ComponentParts
FailureModes
DamageConditions
Codes
Abnormaloutput - high
Abnormaloutput - lowBreakdown
External leakageproces s
Failed to StartFailed to Stop
Internal leakageMinor in-s ervice
problemNois e
OverheatingStructuraldefic iency
Unexpecteds tart
Unexpecteds top
Vibration
Codes
AcceptableAnalyze trends
Change PMfrequency
Create workreques tEvaluate
probable caus esNotify
OperationsNotify Technical
Engineer
Codes
AlignmentIncorrect
As s embly ErrorClearanceIncorrectCorros ionCrackingEros ionExces s
Pres s ureExces s
TemperatureFabrication
DefectFatigue
ImproperMaterial
ImproperLubrication
Operation ErrorWelding Defect
Codes
Bearings - radialBearings - thrus t
Bus hingsCas ing
CouplingCylinder Liner
DiaphragmGas ket
ImpellerLubrication
Pis tonPumpSealsShaft
SleevesSupports
Wear Rings
Codes
Acceptable / OKBent/Deformed
Broken/ShearedCavitationCorrodedCrackedCrus hedEros ionFatigueFouledLeakingLoos e
LubricationPluggedSeized
StickingWrong Material
Wrong SizeWrong Type
Codes
Adjus tCheck
Ins pectModify /Relocate
No Action TakenOverhaul
ReconditionRemove from
ServiceRepair
ReplaceService /Calibrate
Tes t
B C A 5 Y 2
• 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
Failure Effect in SAP
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 EffectFailure Effects are defined in RCM for each Failure Mode. Whencaptured from PM they can be used to update tasks and plans in PM
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
Where Do the Reliability Tools Fit?
Equ
ipm
ent C
ompl
exity
Cost of Downtime
Risk BasedInspection
System ReliabilityReliability
Centered Maintenance
Weibull Analysis
Root CauseAnalysis
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
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
Metrics Manager:
• Highlights problem areas
• Multi-dimensional Analysis
• Drill Down Analysis
Registry
Allows user to:• Perform data
searches• Create queries• Create reports• Create graphs• Store
snapshots of data
• Store analyses
Statistical Analysis - Weibull
• Leverages small amounts of data
• Provides an indication of how the equipment is failing:− Infant Mortality− Random− Wear-out
PM Optimization
• When a PM is appropriate it calculates the optimal interval
• Used to update Maintenance Plans in SAP
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
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
• Process Requires little or no historical data
• RCFA business process• Fault Tree Analysis• Recommendation
Tracking
Root Cause Failure AnalysisUsed to identify and eliminate the source of a Problem
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
United AirlinesAge-Reliability Analysis of Boeing 727 JT8D Engine
Results of overcoming dominant failure modes by engineering improvements
Inspection Manager
• Visual Inspection Data Management
• Observations• Findings• Recommendations• Reports
Provides for Compliance Inspection and Recommendation Tracking
Instrument ManagerTools to Manage Instruments and Calibration data
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
Codes are Created based on standards or RCM analysis
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
Notifications are Created
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
Work is Performed
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
Failure Coding is Completed
Work Order is Completed
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
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)
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
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
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
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)
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP for Reliability
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.
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.
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
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Questions & Answers
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Thank You