Tango Asset Reliability and Lifecycle Management

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TangoAsset Reliability and LifecycleManagement

• Overview Presentation
• August, 2007

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• Red light list of
• Equipment Health
• Issues
• Work Planning
• Results Accountability
• Reliability Metrics

• Manage In-house and
• Contractor Monitoring
• Reliability Analytics
• Lifecycle History

• PDM Condition
• Contractors
• Inspection Contractors
• Equipment Repair Shops

• PDM Condition Team
• Physical Inspection
• In-place Repairs
• Equipment Tracking

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Principles of Equipment Life Cycle Management

• Elimination of Failures in Service in Assets
  which disrupt production and cause high
  maintenance cost.
• Increase operating life period between failures
  by the systematic elimination of Root Causes of
  Failure.

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Reliability Program Developmental Stages
Technology, Teamwork Management Commitment
Reliability Driven
Proactive
Cost Reduction Potential
Predictive
Preventive
4-5 5-7 7-9
Reactive
Years to Develop
Source Barringer Barringer
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What Is Tango?

• Web Service providing equipment lifecycle
  reliability management.
• Focus is improving equipment reliability.
• Prevent failures in service Condition
  Management.
• Extend equipment life ( MTBF ) Equipment
  Management.
• Tango is the Information Management System
  Designed to manage a plant or corporate wide
  condition based maintenance program.
• Tango provides management of actionable results.

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Tango IS NOT

• A CMMS or EAM system but can interface to these
  systems.
• A data acquisition and analysis system but can
  interface to these systems.
• A data historian system.
• A purchasing and quote management system but
  sometimes Tango is used for that.
• A shop work flow management system.

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Tango Equipment Lifecycle Management
Multiple Repair Cycles
Reliability Analysis
Purchase

• Condition
• Failure
• Repair
• Cost

• Vendor
• Warranty
• Cost
• Design

Stores
Installation
Repair

• Incoming Inspection
• Periodic Test
• Periodic Maintenance
• Stores Management
• Search for Replacements
• Equipment Traveler

• Condition Management
• Physical Inspections
• MTBF Calculation
• Equipment Notes
• Linked Documents
• Location History
• Equipment History

• Teardown Inspection
• Quote
• Root Cause of Failure
• Repair Status
• Repair Details
• Warranty
• Cost of Repair
• Repair Documents

Equipment Inventory
Scrap

• Identification Design
• Search Design Documents

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Current State of Reliability Management

• Many separate pieces of reliability information
  in reports, databases, computer folders,
  spreadsheets.
• No Standardization.
• No Integration.
• Poor Communication.
• Poor Accountability.
• No Ability to Analyze Performance.

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Reliability Management isInformation Management

• Identification and Design data
• Design documentation
• Purchase
• Stores and stores testing/ task
• Install and location details
• Condition Test and Results
• Contractor Management
• Failure, Repair, and Warranty
• Collective analysis

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Tango Equipment Lifecycle Management
Multiple Repair Cycles
Reliability Analysis
Purchase

• Condition
• Failure
• Repair
• Cost

• Vendor
• Warranty
• Cost
• Design

Installation
Stores
Repair

• Incoming Inspection
• Periodic Test
• Periodic Maintenance
• Stores Management
• Search for Replacements
• Equipment Traveler

• Condition Management
• Physical Inspections
• MTBF Calculation
• Equipment Notes
• Linked Documents
• Location History
• Equipment History

• Teardown Inspection
• Quote
• Root Cause of Failure
• Repair Status
• Repair Details
• Warranty
• Cost of Repair
• Repair Documents

Equipment Inventory
Scrap

• Identification Design
• Search Design Documents

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Functional Locations
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Condition Assessment Task Management

• Create data collection task for work to be
  performed.
• Organizes data entry.
• Maintain a record of when a point was measured
  and what was found.
• Notification of when a task (Route ) is due.
• Assist in organizing routes that do no have a
  route based collection package, IR, MCE.

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Condition Assessment Task
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Rounds Logging of Parameters Observations

• Measurements
• Gauge Readings
• Observations
• Barcode Point ID

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Integrated Condition Report
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Condition Entry Details
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Equipment History Report
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Location History Report
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Repair Tracking
Multiple Repair Cycles
Reliability Analysis
Purchase

• Condition
• Failure
• Repair
• Cost

• Vendor
• Warranty
• Cost
• Design

Repair
Stores
Installation

• Teardown Inspection
• Quote
• Root Cause of Failure
• Repair Status
• Repair Details
• Warranty
• Cost of Repair
• Repair Documents

• Incoming Inspection
• Periodic Test
• Periodic Maintenance
• Stores Management
• Search for Replacements
• Equipment Traveler

• Condition Management
• Physical Inspections
• MTBF Calculation
• Equipment Notes
• Linked Documents
• Location History
• Equipment History

Equipment Inventory
Scrap

• Identification Design
• Search Design Documents

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Repair Tracker Start Page
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Repair Business Info
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Status History and Failure Info
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Linked Documents
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Cost and Warranty
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Design and Information Documents
Multiple Repair Cycles
Reliability Analysis
Purchase

• Condition
• Failure
• Repair
• Cost

• Vendor
• Warranty
• Cost
• Design

Stores
Installation
Repair

• Incoming Inspection
• Periodic Test
• Periodic Maintenance
• Stores Management
• Search for Replacements
• Equipment Traveler

• Condition Management
• Physical Inspections
• MTBF Calculation
• Equipment Notes
• Linked Documents
• Location History
• Equipment History

• Teardown Inspection
• Quote
• Root Cause of Failure
• Repair Status
• Repair Details
• Warranty
• Cost of Repair
• Repair Documents

Equipment Inventory
Scrap

• Identification Design
• Search Design Documents

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Equipment ID Tag and Nameplate
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Design Data for Tag E-14405
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Detailed Search
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Search Options
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Stores Management
Stores Management
Multiple Repair Cycles
Reliability Analysis
Purchase

• Condition
• Failure
• Repair
• Cost

• Vendor
• Warranty
• Cost
• Design

Stores
Installation
Repair

• Incoming Inspection
• Periodic Test
• Periodic Maintenance
• Stores Management
• Search for Replacements
• Equipment Traveler

• Condition Management
• Physical Inspections
• MTBF Calculation
• Equipment Notes
• Linked Documents
• Location History
• Equipment History

• Teardown Inspection
• Quote
• Root Cause of Failure
• Repair Status
• Repair Details
• Warranty
• Cost of Repair
• Repair Documents

Equipment Inventory
Scrap

• Identification Design
• Search Design Documents

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Stores Management
Plant Receiving Stores
Repair Shop
Production Area
Functional Location
Rack/Bin
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Stores Motor Management Functions

• Receive Motor from repair shop
• Incoming inspection / test
• Are accessories Installed?
• Check Info in Tango and release to pay Invoice
• Place in stores rack, track in Tango
• Periodic inspection/ test/ rotate
• Ship to production area and designate action in
  Tango

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Stores Structure
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Equipment Traveler
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Tango Equipment Lifecycle Management
Reliability Analysis
Multiple Repair Cycles
Purchase

• Condition
• Failure
• Repair
• Cost

• Vendor
• Warranty
• Cost
• Design

Stores
Installation
Repair

• Incoming Inspection
• Periodic Test
• Periodic Maintenance
• Stores Management
• Search for Replacements
• Equipment Traveler

• Condition Management
• Physical Inspections
• MTBF Calculation
• Equipment Notes
• Linked Documents
• Location History
• Equipment History

• Teardown Inspection
• Quote
• Root Cause of Failure
• Repair Status
• Repair Details
• Warranty
• Cost of Repair
• Repair Documents

Equipment Inventory
Scrap

• Identification Design
• Search Design Documents

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Condition Analysis
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Faults by Fault Type
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Faults by Equipment Type
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Program Metrics
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Program Metrics
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Equipment Analysis
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Repairs by Equipment Type
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Repair Cost by Equipment Type
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Average Cost by Equipment Type
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MTBF
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Failures by Failure Type
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Vendor Analysis
Shop 1 Shop 2
Shop 1 Shop 2
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Repairs per Month
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Repair Cost by Month
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Tango Summary

• Tango Works it is in use at over 200
  facilities.
• Tango may be implemented incrementally starting
  with the plants top priorities.
• Tango Provides the next step in advancing from
  predictive maintenance to reliability based
  maintenance.