sv04 - reliability solutions driving asset optimization and greater plant productivity

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

Reliability SolutionsDriving Asset Optimization and Greater Plant Productivity


Why Are We Here…

What's your Healthy and Balanced approach for Success!

Using modern technology with proven techniques… Reliability

Solutions leverage same Health & Performance Balanced approach


Asset Reliability ServicesGreater Plant Productivity = Asset Performance + Reducing Risks

3

Understanding the

Asset Baselines

Operational

Continuous

Improvement

Diagnostic

Reliability Data

Intelligence

Reliability

Professional and

Program Mgmt. Asset Tracking and

Repair Management

Storeroom

Management/

Operations

Stores and

Plant Floor

Assessment

Critical Spares/

Support Analysis

Equipment

Reliability

Analysis

KPI / Metric

Driven

Performance


Diagnostic Reliability ServiceUsing an Asset Intelligence System Enabled by The Connected Enterprise

Diagnostic Reliability ‘DR’ Service provides our clients

improved risk mitigation and control system compliance

on their most critical production assets

Asset Knowledge

Risk Reduction

Asset Performance

DRS Value Proposition

Maximizing RoA - Uptime - Compliance

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 5

Diagnostic Reliability Service implemented on 6 site locations (~500

devices per site)• Online monitoring and auditing

• Ongoing equipment health trending within dashboards

• Proactive maintenance activities driven by analysis

• Asset Management improvement plan roadmap to drive operational and

maintenance efficienciesRESULTS

• Accurate Management of Control Assets• Accuracy and completeness of control asset records

• Spares inventory correctly supports installed base

• Sustainability of enterprise system data records

• Verify asset lifecycle management

• Multiple sites within a region with many layers of

devices & systems

• Regulated & Compliance requirements

CHALLENGES SOLUTION

Large Producer & Refiner of OilReal Results: Diagnostic Reliability Service

• Implement Rockwell Automation Diagnostic

Reliability Service

• Including Network Assessment

• System Implementation to IT requirements

• User Training with specific dashboard design

• Ongoing Service contract


Agenda

Closing Comments

DRS Asset Intelligence Walk Through

DRS Use Cases

Asset Reliability Services

Industry – State of the Union


Industry Challenges for the Next Decade

• Pressure on Efficiency and Reliability

• Shrinking Expertise in Workforce

• Aging Assets

• New Assets Increasing in Complexity

• Increasing Regulatory Pressures

Manufacturers spend 40% of their time on reactive

maintenance vs. their 12% ideal (Maintenance Technology)


Industry Opportunity - Evolution

8

Asset intelligence possible from The Connected Enterprise

enables better decisions across your maintenance and production

systems creating substantial plant productivity!

How am I managing my most critical assets?

Am I leveraging smart device information to drive predictive maintenance decisions?

Are my networked devices running within known control limits and healthy?

How am I tracking asset data?

Will replacement parts meet required specifications?

How much downtime is caused by parts issues?

Do I have governing policies to manage asset change and alternative configurations?

How can I culturally evolve my maintenance program to be more predictive?

Accelerating High Performance Operations by Empowering PEOPLE to make SMARTER, more INFORMED decisions


Agenda

Closing Comments

Asset Intelligence by DRS

Scenarios- Use Cases




The Reliability Story of ‘Smokey the Bear’

“Variable Frequency drive on the Cereal Mill caused major downtime… Again!”

Customer has a major downtime event on a critical mill – drive must get powered up ASAP to get production moving

Maintenance to the rescue – all parties fire fighting

Asset Management Professional frantically trying to expedite parts –on the HOT seat

All options are on the table with multiple solutions being put into action

Maintenance device swapping, re-commissioning

Stores/ AMP calling suppliers and expediting parts

Operations rescheduling/ diverting production, shift adjustments

Time clicks on.. more People and Parts to resolve.. more issues.. finally running

Are you ready for change? Are all your heroes fire fighters?

Lets explore same scenario with a balanced proactive strategy…


Customer Use Case - Asset Knowledge

Maintenance

ERP/ Stores

Control System

Power Devices Asset Intelligence System

Central Support Expert gets email alert from Asset Intelligence System: Red-Alert: Area

‘Mill 2’: Device ‘VFD’: Off-Line, Fault…

Support Expert goes into the system; VFD and other related system components were

down – validates with maintenance event, does data analysis (before/ after) on device,

seeks out spares situation…

No direct match for the failed parts was in inventory, so as stores was calling

suppliers the he works with maintenance technician to locate other plant equipment

with same unit using the system. Good news - part found on blower…

Mill equipment was repaired and re-commissioned. System verified what unique

VFD units are installed and tracked asset service cycle.

How can we shrink ‘mean time to restore’

on critical Assets?

• Locate/ Identify status of troubled devices early

• Obtain proactive notice of device change/ history

• Track device service cycles

• Identify device/ system firmware

• Ensure critical/ spare parts are available

WHY… Greater OEE, Reliable Uptime, Lower MRO $


Customer Use Case: Reducing Risk

Maintenance

Production

Control System


Central Support Expert has been noticing lots of minor faults. In order to get down to the

root cause more data triggers will need to be set for greater analysis/ decisions… Evaluating the situation back to VFD fault/ failure, as a detective we are asking

ourselves why, when, how, what so proper corrective action options can be created…

During maintenance repair event, the support engineer quickly identified device

firmware/ configuration relative the system compatibility to ensure work quality …Mill leadership wanted to ensure chronic/ acute problems on critical assets are

tracked in plant dashboards to ensure fixes are validated and sustained.

How can we eliminate ‘bad actors’, while

mitigating risks throughout Life Cycle?

• Proactively track/ trend potential bad actors

• Mitigate at-risk legacy equipment

• Product safety/ service advisories impact

• Improve asset life cycle mgmt. processes

• Ensure safety-security of network device changes

WHY… Safety-Security, Reliable Uptime, Lower MRO $


Customer Use Case: Performance

Maintenance

Production

Control System


Central Support Expert desires to get relevant device alerts that align to maintenance

strategy, so starting with system processors he profiles/ defines key attributes to monitor… Support Expert uses his intelligence system to package information of status changes,

condition parameter limit breaches and event instances leveraging baseline dataset…

Seeking ways to improve production processes and uptime, data decisions around

how assets are performing by area/ system is key to prioritizing projects/ activities…Central Support Expert knows it’s a team effort to drive improvements continuously

so defining enterprise, facility, area scorecards or dashboards is ideal his culture.

How can we proactively sustain asset

health, while using actionable data to

improve mfg. productivity?

• Identify status of troubled devices early

• Trend device change with impact analysis

• Track device service cycles

• Device diagnostic information

• Intelligence dashboards/ Portal

WHY… Greater OEE, Reliable Uptime, Productivity!


Agenda

Closing Comments

Asset Intelligence by DRS

Scenarios- Use Cases




Diagnostic Reliability System

Data

Platform w/

User

Interface

Process Control Network (PCN)

PLC-5

SLCControlLogix®


Addressing User Case Scenarios

What if I could simply…

Locate/ Identify status of troubled devices

Obtain proactive notice of device change/ history

Track device service cycles

Identify device/ system firmware

Determine product safety/ service advisories impact

Mitigate high-risk equipment risks

Perform a critical/ spare parts gap analysis

Verify migration plans to reduce legacy obsolescence


Diagnostic Reliability ServiceUsing an Asset Intelligence System Enabled by The Connected Enterprise

Asset Knowledge• Complete installed asset records of networked

devices (live/ historic)• Device profiles with status/ fault identification• Critical spares inventory analysis

Risk Reduction• Lifecycle obsolescence status, prioritization

and mitigation plan validation• Security/ Safety safeguards – device

monitoring, detecting threats early, MOC validation, advisory impact analysis

• Asset support strategies, firmware/ version compatibility management

Asset Performance• Device and system health diagnostics• Dynamic user interface with unified data model

provides good analytics• Simplified user tools

Diagnostic Reliability Value Proposition

Maximizing RoA - Uptime - Compliance

Our asset intelligence service is typically integrated

within our customer’s central decision support

center to drive continuous improvement outcomes:

Asset Lifecycle Management

Automation Controls Network Compliance

Asset Reliability and Performance Improvement

Maintenance efficiency towards uptime goals

Optimal storeroom critical spares management

“The Rockwell Automation Diagnostic and

Reliability Manager is like an EKG heart

monitor for process control equipment.”- Reliability Services Customer


Solution Summary Part I

DR Solution provides a health monitoring system and engineering services to improve reliability of your critical

PLC infrastructure that includes PLC/PAC processors, I/O and comms, system networks and connected power

control field assets. DR Solution for your Central Decision Support Center will be packaged to perform the

following capabilities:

User interface with analytical triggers and central information HUB

Serve data in structured central database including all plants

Data agent/ collection schema (weekly, daily, near real time), while remaining non-intrusive

Configurable device profile/ criteria for rule triggers by system

Device data by type, record health dataset: state, health indicator, diagnostics


Solution Summary Part II

19

System interface will serve pertinent information to users, empowering them with data analysis, reporting and

information dashboard screens sharing the health of PLC/PAC system devices. Our DR system will provide data

collection, processing and information management layers across your vast device infrastructure using safe and

secure methods; resulting in a unified data model that is centrally viewed and managed.

System engineers – both database and device specialists – will configure analytical triggers and device data

management rules by type, ensuring health data context is rich. Our DR engineering services will not only be

validating, testing and deploying system across selected facilities/ IT environments, but will be supporting/ training

users, periodic maintenance and fine-tuning management packs/ criteria over time with users as asset/ devices

change.

Program managers will be versed in your culture, policies and procedures to effectively execute the project well

within your program structure. Streamlining processes, while handling unique characteristics of each plant, is the

program manager’s role.


Central Decision Center PLC Health Monitoring Requirements

20

In Scope:

DR system with following dataset

Identification attributes - general

Manufacturer

Device Name

Device Type

Serial Number

Firmware

Node/ IP

Status

Health attributes/ Diagnostic data by category

[PLC/ PAC processors]

Status description (online/ offline)

Fault state description (major/ minor)

Fault code on minor/ major if available

Battery status

Key switch position

Chassis rack/ slot location (processor/ IO/ Comms in racks)

CPU performance data (memory, connections, task scan time)

[PLC/ PAC in chassis I/O]

I/O model status

I/O channel status

I/O performance data

[PLC/ PAC communication cards]

Ethernet network performance data (ports, connections, link status,

media counters)

ControlNet performance data (node status, network parameters/

configuration, counters)

DeviceNet performance data (node, scanner status, configuration)

[PLC/PAC distributed/ non-chassis I/O]

Communication protocol

I/O model status

I/O channel status

I/O performance data

[VFD/ AC-DC Drives]

Parameter/ attribute data for diagnostics

Frequency (Output, Command)

Power (Current, Voltage, Power factor)

DC bus voltage

Speed feedback

IGBT temperature

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 22

Explore the DRS interfaces

Database – Backend Information Portal – Frontend Data Diagnostics – Frontend

SQL Light switch Interface FTVantagePoint Interface FTViewSE Interface


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36

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40

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26

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Plant A Plant B Plant C Plant D Plant E Plant F

Dev

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Fau

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ou

nt

Plant PCN Device Faults per date

9/30/2014 9/29/2014 9/28/2014 9/27/2014 9/26/2014 9/25/2014 9/24/2014

PCN Device Alerts


Why Are We Here…

Using modern technology with proven

techniques… Reliability Solutions leverage same

Health & Performance Balanced approach

Accelerating High Performance Operations by Empowering PEOPLE to make SMARTER, more INFORMED decisions

sv04 - reliability solutions driving asset optimization and greater plant productivity

Technology

rockwell automation

rokteched agenda

asset tracking

asset optimization

asset intelligence system

rokteched industry challenges

control system compliance

site locations