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Toegevoegde waarde van Asset & Life Cycle Management in de food- processing industry Marco van Veen Product Manager Services Endress+Hauser
Toegevoegde waarde van Asset & Life Cycle Management in de food-
processing industry
Marco van Veen
Product Manager Services
Endress+Hauser
Position in the Value Chain… 1 technology, multiple drivers
Yield
Value
User : Process / Energy ManagerSystem : MES, EMS (Energy)Data : Not real time (hour/day)Signal : 4-20mA, Fieldbus (digital)
Driver : Efficiency
Energy Management aM&T
Quality Value
User : Quality Assurance/MetrologySystem : CMS (Calibration)Data : Not real time (week/month)Signal : 4-20mA, Fieldbus (digital)
Driver : Quality
Quality Management
Dia
gnos
tics
Val
ueUser : MaintenanceSystems : PAM, CMMS (Asset)Data : Not real time (hour) Signal : Status (digital)
Driver : Reliability, Availability
Asset and Life Cycle Mngt.
Logistical Value
User : LogisticsSystem : ERP (Material Management)Data : Not real time (hour/day)Signal : 4-20mA, Fieldbus (digital)
Driver : Delivery, Flexibility
Inventory ManagementTan kVision
Safety Value
User : SafetySystem : SiS (Safety)Data : Real time (second)Signal : 4-20mA, Fieldbus (SiS, PROFIsafe)
Driver : Safety, ReliabilitySafety Management
Process Value
User : OperatorSystem : DCS, PLC/SCADA Data : Real time (second)Signal : 4-20mA, Fieldbus (digital)
Driver : Process, Accuracy
Process Management
Business Processes define how to satisfy customer demands
Customer Customer
Business Processes, e. g. Sales, Order Processing,
Delivery, Plant Maintenance
Various functions support Business Processes
Customer Customer
Business Processes, e. g. Sales, Order Processing,
Delivery, Plant Maintenance
Sales ProductionPlanning
Logistics Controlling Maintenance
Business Process Integration Concept Training
M. van Veen / C. Bakker Slide 5
Lack of integrated information causes business issues
Customer Customer
Business Processes, e. g. Sales, Order Processing,
Delivery, Plant Maintenance
Sales ProductionPlanning
Logistics Controlling Maintenance
Lack of integrated information may cause business issues, e. g.
Customer Customer
Business Processes, e. g. Sales, Order Processing,
Delivery, Plant Maintenance
Customer Customer
Business Processes, e. g. Sales, Order Processing,
Delivery, Plant Maintenance
Sales
ProductionPlanning
LogisticsControlling Maintenance
Limited info on sales forecast and customerdemand information increases
production cost
Lack of informationabout equipment healthincreases maintenance
cost
Missing information on customer demand and available sales stock limits customer retention andservice level
Missing of proper logisticalplanning information increaselogistic cost and reduces customer satisfaction and retention level
In-accurate, in time stock information andtransaction information increases operational costs and
bears risk of unaccounted material losses.
Our approach is to enrich the customer business systems byintegration of relevant information – Some examples
Customer Customer
Business Processes, e. g. Sales, Order Processing,
Delivery, Plant Maintenance
Customer Customer
Business Processes, e. g. Sales, Order Processing,
Delivery, Plant Maintenance
Sales
ProductionPlanning
Logistics
ControllingMaintenance
Controlling &Accounting
System
LogisticManagement
System
MaintenanceManagement
System
SalesManagement
System
ProductionPlanningSystem
Accurate, real timeinformation on raw,semi-finished andfinished material
Accurate, real timeinformation on
customer demand, raw, semi-finished and
finished material availability
Real timeinformation on
equipment health and
maintenance demand.
Accurate, real time information on material movement and availability
Accurate, real timeinformation on customer
demand and own material available for
Sale
M. van Veen / C. Bakker Slide 8
Enrich business systems by field information
Business Processes Sales Logistics Maintenance
IT System to supportBusiness Process
IT Integration usingMiddleware
Other
SalesManagement
System
LogisticManagement
System
MaintenanceManagement
System
Other
Plant, equipment, assets
Integration platform
Information examples:Information examples:• Available goods• Storage capacity• Production forecast• Customer demand• Equipment health• Transfer volumes• …
M. van Veen / C. Bakker Slide 9
Enrich business systems by field information – example SAP
Business Processes Sales Logistics Maintenance
IT System to supportBusiness Process
IT Integration usinge. g. Web services
Other
Plant, equipment, assets
Examples:Examples:• Available goods• Storage capacity• Production forecast• Customer demand• Equipment health• Transfer volumes• …
SD MM PM
Other
XI/PI, RFC/BAPI, IDoc
“Simple” Data Integration in Logistics
RFCLogistics
MM
Maintenance
PMSD
Sales
Tank Vision Plant Level
BAPI
RFC
BPI Middleware
M. van Veen / C. Bakker11
“Advanced” SAP Data Integration
RFCLogistics
MM
Maintenance
PMSD
Sales
BPI Middleware
- Work order exchange with CompuCal- Sending Corrective Maintenance
Data to Dashboard- Integration to W@M Portal to get
detailed instrument information
Calibrations executed& Managed by E+H
CompuCal
W@M showing:- Detailed device information- Calibration certificates from CompuCal
KPI Monitoring on:- Amount of Corrective Maintenance � From SAP + CompuCal- Amount of instruments out of spec � From CompuCal
- Send work order results to SAP-PM- Send Calibration Certificate to W@M- Send Calibration data to Dashboard
A challenge… Comply to directives, legislations, quality systems, etc…. in the food processing industry
Calibration Data
COKZ
Who, what, where?
Fragmented Asset Information
Documentation
IFS 5.0
Logbook
Audit trail
FDA
How to deal withThis?
“Information is key but documentation is pain”
� User manuals
� Technical information
� Asset Condition
� Safety statements
� Product Status
� Supplier specific events
� Calibration data
� Certificates
� Software versions
� Process data – spec sheet
� Maintenance frequency
� Spare part information
� Standard Operation Procedures
� Spec sheet
� Drawings…..
How do you keep your Asset Information up-to-date?
M. van Veen Slide 14
Which strategy do you apply?
Corrective MaintenanceActions when failure occurs(Failure = risk, minimized by plant design)
Preventive MaintenanceActions to prevent failures(focus Plant Asset Management)
Time basedMaintenanceCalibration
Condition basedInitiated based on a condition(basal diagnosis: diagnostic values 1 instrument
Pro-ActiveStatistical analysis‘Reference value’• evaluation: <,>, =, hyst.,…
PredictiveDynamical analysis ‘Reference trend’• extrapolation, time derived,…
Condition basedInitiated based on a condition(advanced diagnosis: correlation diagnostic values)
Pro-ActiveStatistical analysis‘Reference value’
• evaluation: <, >, =, hyst., .…• boolean logic (AND, OR, …)• methods, algoritm,…
PredictiveDynamical analysis ‘Reference trend’
• evaluation: <, >, =, hyst., .…• boolean logic (AND, OR, …)• methods, algoritm,…
Condition basedInitiated based on a condition(process diagnose: correlation multiple instruments)
Pro-ActiveStatic analysis‘Reference value’
• evaluation: <, >, =, hyst., .…• Boolean logic (AND, OR, …)• correlation, algorithm,…
PredictiveDynamic analysis ‘Reference trend’
• evaluation: <, >, =, hyst., .…• Boolean logic (AND, OR, …)• correlation, algorithm,…
ValueB-E-F
ValueB-E-F
ValueB-E-F
ValueB-E-F
ValueB-E-F
ValueB-E-F
Asset Information integrated in your business process
W@M Life Cycle Management
PC= Product CenterSC= Service & Sales Center
CER�Serial#
Work order / Maintenance information
Endress+Hauser Product center• Tag number• Serial number• Order code• Manuals• Certificates• Purchase infoEvents:• Production info• Calibration info• Repair info
Flow
Pressure
Level
Temperature
Analysis
Endress+HauserSales center• Maintenance reports• Calibration reports• Service reports• Repair reports• Inspection reports
within maintenance orcalibration contracts
Webservices
Business Process Integration
Our information
Your applications
M. van Veen Slide 16
SAP-PM integration
Internet
W@Mportal
SAP-PM
A dream… 1 central Asset Management system
Calibration Management
Work orders
Reporting
Asset Information
Documentation
Instrument Configuration
Logbook
Loop diagrams
Engineering data
Is this possible?Is it needed?
How can José have all created Calibration Information available in the correct systems without manual data transfer
Calibration Management
CompuCalMobile
Service results from:- Customer (CMMS)- E+H (CompuCal)
Manual Field Calibration
BeamexMC5
Automated Field Calibration
IntegrationMiddleware
Calibration executed& Managed (by E+H)
AnySystem
IntegrationMiddleware
Middleware
SAP-PM/Maximo/Infor
CompuCal
W@MPortal/Enterprise
Instrument specific Central Asset information
Asset updatefor audit trail
KPI updateIn dashboard
Update Work orderdata
CalibrationWork order
How is José’s plant condition and how is it supportedwhen it needs attention?
OSIPi
Service results from:- Customer (CMMS)
Data Historian
BeamexMC5
Automated Field Calibration
Inspection executed& Managed by E+H
ConditionMonitoring
OPC UA Middleware
SAP-PM/Maximo/Infor
E+H SMP via Netviewer
W@MPortal/Enterprise
Instrument specific Central Asset information
Workflow
Send notificationto Service supplier
Store datain historian
Update statusin Asset Logbook
What are the benefits when applying Asset & Life Cycle Management in the Value Chain?
• Enriching the information systems with neededinformation in the Business Processes to:• Create overview in Logistics, Energy, Maintenance &
Quality area• Based on this information we help to increase the
performance levels of our customers… e.g.• Margin & Volume up • Energy waste down --> cost• Stock levels down to JIT --> cost
Conclusion for Asset & Life Cycle Management in the food processing industry
• Choose jointly your strategy during project phase to support your MRO phase
• Follow up on a step plan to implement Asset Information Management according to pre-determined workflows
• Don’t try to search for 1 system to handle all your Asset Information tasks…
• …but enrich with the best possible solution landscape by using standardized interfacing tools which fit the chosen strategy
• As part of these steps we can consult you to come to the correct Asset Information strategy
• Asset Information Management is needed to sustain your strategy
Thank you for your attention!
Questions?
Customer Council Canada
M. van Veen Slide 23
Logbook update
Customer Council Canada
M. van Veen Slide 24
Main View - Condition Monitoring Overview• Provide a way to view Status Monitors
of different machines in one place.
Customer Council Canada
M. van Veen Slide 25
How can I be Compliant?
CalibrationManagement andNotification
TraceableReference Standards
Defined CriticalityClassificationand Tolerance
CompetentCalibrationPersonnel
Technically Valid Calibration
Procedures
The cornerstones of valid plant instrument calibrations are:
1 2
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Customer Council Canada
M. van Veen Slide 26
Calibration Certificate upload to W@M via Middleware
- Creation of calibration certificate
- Upload of calibration certificate to W@M Portal
Customer Council Canada
M. van Veen Slide 27
Improve quality to optimize the assets over time
Customer Council Canada
M. van Veen Slide 28
Information to be assured in Data historian – OSI AF2
CompuCal FieldCare
Calibrationinformation
W@MAsset Information
Device configuration information+Device Performance monitoringinformation
To be used interface standards:- DDE- ODBC- WebServices
BPI Middleware
OSI PI AF2 (PI notifications)Central Data Historian
Customer Council Canada
M. van Veen Slide 29
notificationfrom Solutions
through Business Process Integration!
Liquiphant’s message!
Customer Council Canada
M. van Veen Slide 30
E+H Service working on customer’s case remotely
