Business Industrial Network

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Business Industrial Network

• www.DowntimeCentral.com

True Downtime Cost
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Data Sources (Definition)

• TDC True Downtime Cost

• A method of recording and analyzing all
  significant cost metrics associated with
  equipment downtime in a building or manufacturing
  facility.
• TDC provides a way to assign time and/or monetary
  value to previously considered non-tangible
  cost of downtime.
• Also TDC includes downtime factors commonly
  overlook to arrive at a more true value for the
  cost of downtime.

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Data Sources Overview

• Data too much of it, not enough of it,
  inadequate quality or the wrong sort and what is
  it used for anyway?

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Considerations of best metrics

• What you measure is what youll get!
• Ultimately must be able to accurately track
  failure rates and allocate costs
• individual machines (location, asset)
• machine categories (motors, pumps)
• components (bearings, seals)
• Major benefits can be attained with current
  technology -- more effectively applied
• lower cost data collectors

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Digging for data

• equipment histories,
• CMMS reports,
• life cycle cost analyses,
• financial records,
• production schedules.

These are the recommended sources to build a cost
justification report to be presented to the bean
counters. A maintenance manager would need a full
time research assistant to run a productive
department.
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Measurement effectiveness

• Do measures such as maintenance cost / RAV show
  contribution to real objectives?
• age of equipment, process intensity
• MTBF total population / total repairs or
  equipment specific statistics
• which, what, how often
• PM compliance and PM backlog, overtime, PM
  compared to reactive
• dont measure whether activity is required or how
  much value is produced

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What do all these data sources have in common?

• They all build on downtime cost estimates that
  are only 10 or less of the True Downtime Cost.
  (10TDC)
• Cost justification requires analysis of several
  of these areas by management.
• Often you have to justify the validity of the
  data source.

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Where does valid data come from?

• all computer systems and networks
• plant automation systems
• distributed control systems
• programmable logic controllers
• diagnostic monitoring systems.
• asset management software

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How to bring it all together

• Wonderware
• Versacall

The new millennium focus is on bringing the
valid data from various sources back to the
management software and technique of your
choice. Will this full circle of data management
bring us close to 100 management efficiency?
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Versacall.com

• VersaCall Facility Communications System.
• capture and document  downtime
• monitoring response time
• communicating an alarm occurrence

"5 of cost in a sites production capability from
downtime is a fairly safe number. It does vary by
industry mostly going up from the 5."  "80
of the manufacturing operations I have interacted
with have no idea what they are losing in true
dollars with downtime."
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Not even close

• You will see a 200 to 300 increase in
  efficiency, but thats only 30TDC, will that
  give you the required ROI?
• Why settle for 300 when you can easily have 800?

OEE,RAV
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The Answer, TDC

• Actually a combination of two methods are used to
  bridge the gap between data collection and
  management technique.
• Strict usage of TDC metrics
• And data sharing standards like MIMOSA

TDC
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Maintenance Management
Condition Measurements
Decision Support
Data
Information
MIMOSA Equipment Management Information
Model thanks to Ken Bever, John Hawkins, Alan
Johnston, Art Jones, Peter Morgan
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Maintenance Management
Condition Measurements

• Start/Stop times
• Speed
• fluid (lube oil) condition
• vibration (on and off-line)
• operating measurements (on-line and operating
  logs)
• motor characteristics
• thermography
• anodic/cathodic voltage
• ultrasonic (leak detection)
• corrosion thickness

Decision Support
Data
Information
MIMOSA Equipment Management Information
Model thanks to Ken Bever, John Hawkins, Alan
Johnston, Art Jones, Peter Morgan
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Maintenance Management
Condition Measurements

• Data
• IDs Plant / Location / Equipment
• Events
• Numerical values (measurements)
• True Downtime Cost Metrics
• Measurement trends
• Array / Image
• Vectors
• Time Waveforms
• Orbits
• Spectra (frequency, order, CPB)
• Lube oil particle
• Temperature images

Data
Information
MIMOSA Equipment Management Information
Model thanks to Ken Bever, John Hawkins, Alan
Johnston, Art Jones, Peter Morgan
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Maintenance Management
Condition Measurements
Data
Information
MIMOSA Equipment Management Information
Model thanks to Ken Bever, John Hawkins, Alan
Johnston, Art Jones, Peter Morgan
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Maintenance Management
Condition Measurements

• From Maintenance Management
• Conditions found
• Spare parts availability
• Work accomplished -- Action taken
• Maintenance history work performed, cost,
  process downtime
• Nameplate data
• Manufacturers specifications
• Work order issued Work order number,
  requirements parts, resources, tools, people
• Work schedule

Data
Information
MIMOSA Equipment Management Information
Model thanks to Ken Bever, John Hawkins, Alan
Johnston, Art Jones, Peter Morgan
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Maintenance Management
Condition Measurements

• mechanical diagnostics inc. rolling bearing
• performance/efficiency
• reciprocating analysis
• operating deflection shape (ODS)
• root cause
• reliability centered maintenance (RCM)
• risk
• prognosis

Data
Information
MIMOSA Equipment Management Information
Model thanks to Ken Bever, John Hawkins, Alan
Johnston, Art Jones, Peter Morgan
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Maintenance Management
Condition Measurements

• Information
• Status -- something happened, event
• State of health -- numerical condition index
• Rate of change (health/severity) -- numerical
• Time to action -- predicted date under current
  conditions
• Problem identification -- description
• Components affected -- description
• Recommendations -- operating and maintenance
• Remarks/Comments -- explanatory information
• Work request -- yes or no
• Confidence -- numerical

Data
Information
MIMOSA Equipment Management Information
Model thanks to Ken Bever, John Hawkins, Alan
Johnston, Art Jones, Peter Morgan
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MTBF Example

• Average 2 year MTBF on 2,000 pumps (compared to
  world class -- 6 to 7 year)
• Average cost of repair 5,000
• Double MTBF to 4 years
• saves 2.5 million!!
• 6 year MTBF
• saves 3.3 million
• Thats at the profit level!!
• how much product must be produced to deliver 2.5
  million profit at 10 pretax??
• PROFIT CENTERED MENTALITY

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Information Sources

• Information required for equipment management is
  optimally developed within specialty systems
• condition monitoring / assessment
• Start/Stop, speed, vibration, fluid analysis,
  thermography, motor electrical, ultrasound
• control (DCS)
• performance, efficiency Calculated with TDC
• maintenance management (CMMS)
• manufacturers specifications, task instructions,
  history, parts, costs

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Information must be

• Readily available, easily exchanged and clearly
  understandable for everyone with requirements
  throughout the enterprise
• MIMOSA!
• Machinery Information Management Open Systems
  Alliance

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TDC Metrics

• Equipment Metrics
• Labor Constants
• Downtime Data
• Outsourcing Information

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TDC Details
Overhead
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TDC, a closer look at
Equipment

• Categories
• Use MIMOSA, machine, priority, type, cell, line,
  Notes, etc.
• People
• Number of Direct and in-direct idle workers
• Product
• Cost per unit at that stage in production
• Units per hour
• Start-Up
• Electrical surge cost, Set up, reduced till
  start/stop
• Equipment fatigue
• Scrap produced, is it recycle able
• Bottleneck
• List other downstream equipment, and effected
• Expected Sales
• effect on product out the door.

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TDC, a closer look at
Labor

• LPP / Equipment Contribution
• Not as accurate, use if not items below
• QC wages
• Extra inspections, Rework
• Management wages
• Engineering
• Maintenance
• Support
• Equipment operators

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TDC, a closer look at
Downtime

• Time Down
• Reduced
• reduced, for how long
• Scrap
• Number of units, recovered by recycling
• Band-aid
• Is a sub category of several, value in TDC
• OEM
• Annual fee/ est. hours used per year, or TM
  Expenses
• Tooling
• Replacement, reworking, recycling
• Parts
• Actual repair, and band-aid

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TDC-Warning Data Overload!
Too many variables, Too complicated, Too much
change!
Equipment
These are all one time entry of constants,
updated annually, exported from your existing
computer systems.

Labor
These are per downtime occurrence entries, but
most can be exported from your CMMS.
Downtime
You can use a percentage of existing numbers
depending on amount of TDC metrics they are made
up of
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Is using TDC too much change ?
Not really. You just need to require up front
that your vendors adhere to MIMOSA standards and
TDC metrics.
Your vendors being data collection equipment
vendors, and software vendors such as CMMS.
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Lets put Downtime in its own bucket and make
sound decisions.
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TDC represents the final bottlenecks to a fully
integrated and auditable approach to maintenance
strategy development / justification.
TDC

• Click the link to learn more about
• TDC Data Source
• TDC Cost Factors

www.BIN95.com