trapac, llc - xcelerate · 2018. 11. 12. · maintenance and reliability training, innovation and...

Maintenance and reliability training, innovation and education

Mark JensenAssistant Vice President - Equipment and

Facility Maintenance

TraPac, LLC

2© 2018 | Fluke Corporation.Company Confidential.

How to develop a team built for reliability

Connecting reliability and operational excellence utilizing technology and digitization

3© 2018 | Fluke Corporation.Company Confidential.

● Container terminal operator and vessel stevedore that provides port terminal services to the West Coast of USA

● Leading edge in container-terminal automation in North America● Among the first to implement and combine:

○ Automated straddle carriers supporting automated stacking cranes and semi-automated on-dock rail system

○ Terminal-wide Pi Historian System

About TraPac

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About TraPac - Corporate Video

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● Maintenance organization relied on tribal knowledge and very simple record keeping● Management on instinct and past practice● Silos of automation and technology● Simple key productivity metric

○ Gross Moves per Hour

The Past

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● Bringing data and information together● Need a single source of truth● Drive towards data-centric decision making and identification of optimization opportunities● Complex automation solution that involves multiple systems from different vendors● Inadequate data-acquisition tools for in-depth analysis of additional metrics

The Challenge

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● Implement site wide Historian system● Define asset hierarchy and master data library● Capture and organize data via Historian system● Visualize, summarize and distribute data via Historian or related reporting tools● The Historian is the single source of truth● Implement eMaint CMMS to leverage Historian data and to manage maintenance of assets

The Solution

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The Implementation

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Three use cases that demonstrate how TraPac has benefited from the digitization and technology:● Accelerated issue resolution● Improved PM Schedule Compliance● Reduced downtime

The Gains

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● Objective: Leverage technology to expedite troubleshooting● Issue seen where significant reduction in ARMG throughput due to increase in equipment exception

handing and faults● Problem was intermittent and visual inspection was inconclusive● Initial suspicions pointed to recent control-system update

Accelerating Issue Resolution

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Results● Quick visual recognition of typical hoist height

profile versus bad in the telemetry data● Without data, would be guessing at issue● Worked with mechanics to pinpoint issue – focus

on Pick Attempt part of cycle● After detail check of target shapes moved to

flippers. Found slightly bent spreader flipper, with a distortion visually undetectable at about 10mm over 0.7m.

● “Unless we went out there with a straight edge, we may still be searching for the cause!”

Accelerating Issue Resolution

GOOD

BAD

Pick AttemptMoving to Pick Location

Smooth change in hoist direction

Hoist is “bouncing” to pick container

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● Objective: Leverage technology to digitalize maintenance workflows and improve maintenance interval compliance

● PI AF configured to send email to third-party eMaint CMMS daily using PI Analysis, PI Event Frames and PI Notifications

Improving PM Schedule Compliance

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Automated Straddle Carrier● Automated container transport vehicle● Travels freely between equipment● Operates in fenced-off automated area● Breakdowns may not be addressed until work stoppage

Improving PM Schedule Compliance

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Results: Timely and accurate data has resulted in a significant shift in compliance to PM schedules

● AutostradPM is typically based on a 200 hrsinspection and a hierarchical 1,000 hrsservice interval.● Actual intervals against this target have been tracked for gauging PM Schedule Compliance.● PM Scheduling compliance:

○ -0/+10%: on target.○ -0/+5%: considered hitting the bullseye.

● Daily availability of meter reading data allows for daily determination of priorities

Improving PM Schedule Compliance

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The data trend is indicating very favorable to improving PM Schedule Compliance

● The new method supported by Pi sees good accuracy and repeatability for the 200hrs inspections interval. The previous method never captured 200hrs inspection data for comparison.

Improving PM Schedule Compliance

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● Objective: Leverage technology to boost analytical capabilities● Use technology to capture, organize, visualize and help interpret data for operating metrics and

performance● Direct maintenance effort and priorities to equipment to get best value for effort invested

Reducing Downtime

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● Using Pareto Charts to analyze fault data -> Target efforts to bad performers

Reducing Downtime

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● New focus on getting the basics right.● Step change in driving and completing PMs on Automated Stacking Cranes through April 2018

Reducing Downtime

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● Automated Stacking Crane Downtime (h) –Measured by rolling 7 day period

Reducing Downtime

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Closing

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● Mark Jensen● mark.jensen@trapac.com● Assistant VP - Equipment & Facility Maintenance● TraPac, LLC

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Maintenance and reliability training, innovation and education

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