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CONDITION BASED MAINTENANCE Leverage Operational Data in SAP Plant Maintenance

Robert Pascal

12 September 2013

Real. World. Experience.

AGENDA

Introduction of Vesta Partners

Condition Based Maintenance

System landscape

Vesta CBM tool

Veros

Real. World. Experience.

AGENDA

Introduction of Vesta Partners

Condition Based Maintenance

System landscape

Vesta CBM tool

Veros

Real. World. Experience.

VESTA OVERVIEW

Headquartered in Connecticut USA and with offices in Europe,

Canada, Australia and Singapore, Vesta is an SAP Services and Gold

Consulting Partner focused on delivering measurable results in

Enterprise Asset Management (EAM) globally.

We help our customers build solid business practices that are enabled

by the right technology applications.

Real. World. Experience.

VESTA SERVICES

As an SAP Services and Gold Consulting Partner, Vesta has the depth and experience to meet all of your SAP EAM needs. Through our propriety VTEAM methodology, Vesta’s services and products can address your industry specific needs and meet your unique business requirements.

Our services are positioned as follows:

Enterprise Asset Management Services

• SAP Enterprise Asset Management

• Maintenance Work Process

• Training and Workshops

• Strategy and KPI’s

Real. World. Experience.

VESTA SERVICES

Specialty and Technical Services

• SAP MII

• SAP MRS

• SAP EPC

• SAP PPM

• NRX Asset Hub

• Business Intelligence

• Mobility for EAM

• SAP Work Clearance Management

• Custom Developments

Software Products

• Vesta PMX

• Vesta MAC

• Vesta QMC

• Vesta CBM

YOUR

Real. World. Experience.

AGENDA

Introduction of Vesta Partners

Condition Based Maintenance

System landscape

Vesta CBM tool

Veros

Real. World. Experience.

CONDITION-BASED MAINTENANCE

From Wikipedia, the free encyclopedia

Condition-based maintenance (CBM), shortly described, is maintenance when need arises. This maintenance is performed after one or more indicators show that equipment is going to fail or that equipment performance is deteriorating.

Real. World. Experience.

POTENTIAL FAILURE P-F CURVE

Co

nd

itio

n

Time

Point where

failure can first

be detected P

Point of failure

F

Point where

failure starts

John Moubray, Reliability Centered Maintenance II

Real. World. Experience.

No preventive Maintenance

Preventive/ Scheduled

Maintenance

Mobile Rounds populating

measurement documents

Sensors automatically

populating measurement

documents

Sensors feeding

Rule engine to make

decisions about

maintenance necessary

THE CONDITION BASED MAINTENANCE EVOLUTION

Real. World. Experience.

CONDITION BASED MAINTENANCE

Real. World. Experience.

CONDITION BASED MAINTENANCE

So why is it not common use yet?

• No data available or just to much data?

• Hard to collect the data, only programmers can get it?

• High initial costs?

Real. World. Experience.

Foundational elements in place?

• Master Data

• Work Process Standardization

• SAP EAM Solution – enhanced technical capability

Availability of Tools

• Manufacturing Integration and Intelligence (Mii)

• CBM Applications (e.g. Vesta)

• New technology tools for monitoring / low cost installation (e.g. Veros)

• Large Quantity Data analysis (HANA)

• Ease of sharing data (UI / Syclo)

• Remote Data capture

SAP RELATED CBM – NOW THE TIME IS RIGHT!

Real. World. Experience.

AGENDA

Introduction of Vesta Partners

Condition Based Maintenance

System landscape

Vesta CBM tool

Veros

Real. World. Experience.

Web pagesWeb pages

Process/ Equipment

PLC

Scada,

Data Historian

SAP ERP

SAP EAM

NotificationsWork Orders

Measurement PtsEquipment Records

MII

Web pages

Applets

MII Event Scheduler

SAP ServerSAP

Actions

Data

Actions

Process

Operations

MII Business

Process

Logic

Sensor

Plant

Connectivity

(Pco)

Monitoring

Applications

Web Service

ConnectorURL-based web

service calls

AUTOMATED MONITORING WITH MII

1. Data Event or

Condition Occurs

2. MII Capture Details

through Polling or

Event detection

3. Condition or Event interpretation

4. Present to End User for Action or

Alert

5. Build notification or work order for

posting to SAP ERP

6. Post into SAP PM

7. View results, history and current

conditions

Event & Condition Management

2a. Posts event &

details to MII

6a. Sends email/text alerts

1a. Data Event or

Condition Occurs

and detected by

monitoring

software

Real. World. Experience.

AGENDA

Introduction of Vesta Partners

Condition Based Maintenance

System landscape

Vesta CBM tool

Veros

Real. World. Experience.

VESTA CBM

Web pagesWeb pages

Process/ Equipment

PLC

Scada,

Data Historian

SAP ERP

SAP EAM

NotificationsWork Orders

Measurement PtsEquipment Records

MII

Web pages

Applets

MII Event Scheduler

SAP ServerSAP

Actions

Data

Actions

Process

Operations

MII Business

Process

Logic

Sensor

Plant

Connectivity

(Pco)

Monitoring

Applications

Web Service

ConnectorURL-based web

service calls

Vesta CBM

Configurable Application to Accelerate Implementation

Real. World. Experience.

VESTA CBM / MAIN FUNCTIONALITY

Map process parameters to SAP objects

Predefined checking rules

Monitor alerts

Monitor readings

Manual entry of readings

Standard creation of Measuring documents, Notification, Order, Order

with task list

Real. World. Experience.

BROWSER-BASED SCREENS FOR GENERAL USERS

CMP View

Real. World. Experience.

BROWSER-BASED SCREENS FOR GENERAL USERS

Alert View

Real. World. Experience.

BROWSER-BASED SCREENS FOR GENERAL USERS

Reading View

Real. World. Experience.

BROWSER-BASED SCREENS FOR GENERAL USERS

Graphed Readings

Real. World. Experience.

BROWSER-BASED SCREENS FOR GENERAL USERS

Manual Entry

Real. World. Experience.

AGENDA

Introduction of Vesta Partners

Condition Based Maintenance

System landscape

Vesta CBM tool

Veros

Real. World. Experience.

VEROS – INTERFACE BY VESTA CBM C

on

ditio

n (

no

t to

sca

le)

Lead Time to Functional Failure (not to scale)

Good

Bad

On-set of fault

Protective

RelaysGE Multilin

Relay

Excessive

heat by

touching

Audible

noise or

IR

Portable

Data

Loggers

Temperature

Probes

Lube

Analysis

Continuous

Vibration/

Electrical

On-line

Partial

Discharge

12+ months1-12 months

1-6 months

6-8 weeks

4-8 weeks

1-4 weeks

1-5 days

Veros Predictive

Intelligence Monitor

(PIM)

Real. World. Experience.

CONTACT

Robert Pascal Practice Manager Europe

Vesta Partners Regentesselaan 69

2562 CP The Hague The Netherlands

T +31 70 220 9720 M + 31 6 11169728

rpascal@vestapartners.com www.vestapartners.com