proficy* maintenance gateway close-the-loop between your plant floor and plant maintenance systems

Proficy* Maintenance GatewayClose-the-loop Between Your Plant Floor and Plant Maintenance Systems

©2008 GE Fanuc Intelligent PlatformsAll Rights Reserved

What are the challenges today when applying maintenance practices….


Current Practices: NOT State-of-the-Art• Reactive Maintenance

(Run the assets to failure then fix them!)– Causes UNPLANNED downtime – On average, unplanned downtime

exceeds 20% of the total downtime in a plant

• -OR-

• Calendar-based Preventive Maintenance (Ex: “first Monday of every quarter”)– Will underestimate need – leading

to unplanned downtime– Or, will overestimate need –

leading to unnecessary costs


How to Increase Plant Reliability

• Strategy should include being PROACTIVE! – Critical maintenance

actions should be focused on PREVENTING unplanned downtime

• Establish an “agile” infrastructure between the plant and the enterprise – prevent any delays in

the implementation of the chosen strategy

Move Away from Being Only REACTIVE to Asset Failures!


What is a Proactive Strategy?

• PREVENTING failures by scheduling maintenance at appropriate intervals

– based on asset criticality and failure histories of components (MTTF,MTTR, etc.)

• -AND/OR-• PREDICTING imminent failures based on “symptoms” and attending

to them BEFORE they occur– especially, to eliminate downtime of critical, capacity-

constraining assets!


How to increase Plant Production Readiness

MaintenancePractices

Reduced Failure Rate

IncreasedPlant

AvailabilityIncreased

Plant ProductionReadiness

IncreasedAsset

ReliabilityReduced

Downtime

Start Here


“Appropriate” Preventive Maintenance

• Step 1: Set a threshold for USAGE to drive Preventive Maintenance based on prior failure histories

• Step 2: Collect data from the machines regularly to compute USAGE

• Step 3: Order Preventive Maintenance when the actual USAGE exceeds the threshold

Schedule Maintenance Based on the USAGE of the Assets to Avoid“Under” or “Over” Maintaining Assets


Predicting Failures

• If the trend is undesirable (“emerging failure symptoms”), there is a potential for a failure

• Prevent such failures by ordering maintenance and executing the maintenance activity with agility – even while the

machines are still producing!

Understand the “Health” of Critical Machines by ContinuouslyMonitoring the Trend of Key Process Variables and Derivatives


“Real-Time” is of the Essence!Your “Right Mix” of Strategies Must be Implemented withMinimal Latency for Maximum Agility

Agile Infrastructure: Minimize Forward-Loop Latency through real-time plant integration to Enterprise Asset Management Systems and

Reverse-Loop Latency through real-time tracking of MTTR

Forward-Loop Latency – the loop starting from data collection in the plant to generation of a maintenance WorkOrder in the Enterprise Asset Management System

Reverse-Loop Latency – the loop starting from the generation of a maintenance Work Order in the Enterprise Asset Management System to the closure of that order


How do we help you do this …….


Proficy Maintenance GatewayMonitors the Health of All Your Assets – All the Time

Raw Process Data Stored and

Contextualized by Equipment & Events

Maintenance Work Orders Created,

Viewed and Closed

Data Flow

Data Flow


Proficy Maintenance Gateway

System maps GE Fanuc Software to your Maintenance System

Configuration wizards walk you through building your rules

– Rules can be time or event-based and can be edited at any time

Rules configured and maintained by maintenance or production personnel in the plant

Allows You – in the Plant – to Configure Your Maintenance Rules


Proficy Maintenance Gateway

Leverage the Plant Model in GE Fanuc software to navigate the complexity of Maintenance Work Orders (WO)

Access all the information you need for each asset

– Operating locations of equipment

– Stores, repair shops and vendors for equipment

– Equipment-related costs, histories, failures, etc…

– Un/stocked spare parts– WO-related information

Your Window to All Asset Maintenance and ProductionPerformance Information


Proficy* Maintenance Gateway

Machine downtime, states, cycle timesCycle countsMachine process variablesEtc.

List of open work orders, PMs, Job Plans, failure history, MBTF

Maintenance Work orders

Proficy Portal

Reports•Preventive Maintenance•Work Orders•Job Plans•Failure History

Maximo EAM

Proficy Maintenance

Gateway

Plant Floor Data(CBM, Sensors, PLC, HMI

SCADA, etc.)

Proficy Historian

Proficy Plant Applications

Harbor Statement

• The information presented is intended to be an outline of general product direction and it should not be relied on in making a purchasing decision. The information on the roadmap is for information purposes only, and may not be incorporated into any contract and is not a commitment, promise or legal obligation to deliver any material, code, or functionality. The development, release, and timing of any features or functionality described for our products remains at our sole discretion.

• The information presented is intended to be an outline of general product direction and it should not be relied on in making a purchasing decision. The information on the roadmap is for information purposes only, and may not be incorporated into any contract and is not a commitment, promise or legal obligation to deliver any material, code, or functionality. The development, release, and timing of any features or functionality described for our products remains at our sole discretion.


Plant AdaptorsPMG 1.0

PMG Architecture

PMG Database

PMG Database

MAXIMOMAXIMO

PMG ServerPMG Server

MAXIMO Adaptor

MAXIMO Adaptor

SAP Adaptor

SAP Adaptor

Infor.Adaptor

Infor.Adaptor

Proficy ListenerProficy Listener

OPC DAListenerOPC DAListener

Plant X ListenerPlant X Listener

Proficy ServerProficy Server

PMG Intelligence Engines

Data MSMQData MSMQ Action MSMQAction MSMQ

PMG ActionAgent

PMG ActionAgent

PMG MonitorPMG

Monitor

PMG BusinessPMG Business PMX ViewerPMX ViewerPMG AdministratorPMG Administrator

PMG Control PanelPMG Control Panel

Enterprise AdaptorsPlant Adaptors

Note 1: The green boxes represent the adaptations for PMG 1.0.

Note 2: The dotted lines in the diagram refer to a data exchange between components, against continuous lines which refer to direct interaction.

Note 1: The green boxes represent the adaptations for PMG 1.0.

Note 2: The dotted lines in the diagram refer to a data exchange between components, against continuous lines which refer to direct interaction.


Summarizing Your Steps to Transformation

• Formulate the “Right Mix” of Reliability-Centered strategies that is appropriate for YOUR plant – Will include, Preventive, Predictive

and Reactive Maintenance – Focus to minimize unplanned

downtime

• Implement the “Right Mix” by MAXIMIZING AGILITY in the forward and reverse loops – Use real-time integration from the

Plant to the Maintenance System and real-time tracking of MTTR

• Continuously monitor and improve the “Right Mix” to optimize the Cost of Reliability, maximize Plant Availability and increase Plant Production Readiness!

Move away from a “Reactive-Only” Maintenance Strategy

proficy* maintenance gateway close-the-loop between your plant floor and plant maintenance systems

Documents

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