real-time plant availability management from a single ... · yokogawa, the netherlands • todays...
TRANSCRIPT
The power of a well designed system.
Real-time plant availability management from a single dashboard?
Introduction
• Martijn Kramer
• Senior Consultant Operational ProcessesYokogawa, The Netherlands
• Todays presentation:– Real-time plant availability management from a single dashboard?
– The power of a well designed system.
The challenge
Production lost
18days/year
Human factor
42%
Equipment
failure
36%
Process
related
22%
Age related
failure pattern
18%of the equipment
Non-age related
failure pattern
82%of the equipment
How is this with your plant
and how much money
is there involved?
Why is preventive
maintenance playing
a so dominate role for
the maintenance strategy?
When was your plant running better:
the week before or
after the turn-around?
The challenge
• IIoT has the promise to run your plant in a more optimal way.
• However:
– More data, more systems, more business requirements: How to make it a success?
The key success factors
Typical plant
Number of field
sensors
20,000
Average of
settings per field
sensor
150
Total number of
parameters to be
managed
3,000,000
75%of the plants has
several asset
management
packages
Number of PC’s
and Virtual
Machines per
plant
300
Average of health
parameters
200per item
1. Why is 10% of the field
equipment of a well maintained
plant in an unhealthy status?
2. Can we use this data for big
data management?
1. Why do we reset a PC without
check the eventlog?
2. Are we not interesting in
finding the root cause?
Number of
different software
health events
300 per application
Total number of
events to be
managed
30/hr/machine
9000
(Maintenance) data is locked up in too many different systems and applications
Technology: The reality of Digitalization
• What goes wrong?
• Do you expect that the number of parameters and events will decrease or increase using digitalization?– Network monitoring
– Threat intelligence (e.g. vulnerabilities, deep package inspection..)
– IIoT
– Predictable models
• How are you going to handle this?
Process: How is a plant run?
Process: Business ProcessBusiness performance
Operational performance
Operations management
Ensure safe operation and regulatory
compliance - license to operate
Asset management
Maximize asset deployment and avoid unplanned downtime
by ensuring equipment is healthy and
operating in the optimum mode
Production management
Clear alignment of business
and production objectives. Minimize operating cost and
improve yield
Supply chain management
Minimize disruptionto supply chain andensure committed
delivery.
Process: The reality…Business performance
Operational performance
Operations management
Shift Handover
Incident Management
Permit to Work
Management of change
Production Instruction
Etc.
Asset management
CMMS
APM
PRM
Etc.
Production management
Data historian
Data analytics
Energy management
Process optimization
Etc.
Supply chain management
Production scheduling
Production accounting
LIMS
Etc.
Process: The reality of digitalization
• Again: More systems with more information to monitor.
• How to connect ‘new’ information to your existing work flow?
• More decisions to be made in relationship to other decisions, how to manage?
• How is your staff going to effectively make use of more information to take the right decisions?
People…
Does more data and more software lead to better plant performance
all by itself?
It’s still humans that take the majority of the decisions!
People: Decision making
• When does a human take a decision:
– It must be clear there is a problem
– It is my responsibility to deal with it
• How does a human decide on the solution?
– Not clear, I will make a guess and try it (gokje)
– The problem is clear, the solution as well
The key
The true value lays in the alignment of technology with the business process, in order to prompt people to take timely and well informed decisions.
For predictable operations & sustainable profit.
One simple interface is needed!
Patch Compliance72%
Something I should knowFailure Left CPU station 0101
Backup Compliance82%
Man in the middle attackDC0101
IC00145Maintenance
Engineer
Ticket assigned toMichael
Network Compliancy72%, high
How to achieve a Real-time plant availability management?
Management dashboard (1/2)
Management dashboard (2/2)
Process integration
ITIL based service desk– Integrated helpdesk – Call management
• Customize customer dashboard, including – Dashboards covering the area’s
• Asset Availability includes condition and predictive based• Security SIEM• Process Safety Life Cycle• Operations
– Overview of call, per plant, priority, etc.– Includes strong analytics – Many interfacing tools
Important features Management Dashboard
• Open Architecture– Windows and Unix
– Covering from Sensor to Boardroom
– Virtualization platform VM or HyperV
– Any network
– Server or PC
– Many applications (300+) Oracle, SQL, VM,
– Any intelligent equipment: IOT
– Any DCS, SIS or PLC or any other OT system
– On-premise, cloud or blended
• Continually Current
• Fully Scalable
• Low implementation cost
To summarize
Only a well designed system unlocks the true potential of traditional technology & IIoT!
From ‘more data, more systems & more business requirements’ to:
✓ ‘All’ your data connected, converted into actionable insights;
✓ Aligned with your business process;
✓ Simple overview for humans to take the right action.
For more information
Contact: Martijn Kramer
yokogawa.com/nl