Collaboration

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Improving Maintenance Through Information
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Typical Customer Project Objective

• To
• Implement a condition monitoring Improvement
  Program
• In a way that
• Examines current practices against worlds best
  practices and chooses appropriate components to
  implement
• So that
• Customer can improve uptime, save money on
  machine failures and improve profitability

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Conoco Dingo Capabilities
Most of the best practices solution we propose
contain the following major elements

• 1. Needs Assessment Study
• 2. Software Products
• 3. Implementation Services
• 4. Condition Monitoring Education and Training
• 5. On-going Training and Support Services
• 6. Systems Integration

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Case Study 1Pre-empting an Engine Failure

• 5 MM ton coal mine in Hunter Valley
• Unit 445 Dresser 830 Truck at 17,788 hrs
• Extreme iron wear rate at 0.27 ppm/hr a High tin
  wear rate at 0.031 ppm/hr Moderate Chromium wear
  rate of 0.09 ppm/hr.
• Characteristic of cylinder kit problems for
  Detroit 149 engines on site.
• Engine inspected the following day
• 5R piston skirt badly cracked and scuffed
• Piston was very close to complete destruction
• Would have only lasted another couple of days at
  most.
• Estimated Savings 40,000 parts alone

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Products

• Dingo FleetOil for Windows
• Flagship product
• High end power users
• Advanced features
• Powerful reports and analysis
• Extra Fleet Features

• Dingo Lab Manager
• Oracle Database
• High end power users
• Testing database
• Ideal for in-house labs
• Remote locations
• Rio Tinto, Alcoa

• Dingo Lube Explorer
• Entry Level product
• Beginner users
• Simple to install
• Basic Features
• Easy to use

• Dingo Lube Professional
• Latest Product
• Large Power Users and Small Labs
• Expert System generates recommendation for action
  based on triggers and conditions
• Powerful reports and analysis

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Services Overview

• Implementation
• Training
• Education Classes (Noria Franchisee)
• Technical Support
• Consulting
• Custom software development

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1. Needs Assessment

• What is a Needs Assessment?
• A Needs Assessment is an intensive interactive
  exercise designed to
• Understand and define the goals
• Analyze current practices against worlds best
  practice
• Define the Scope of the transition
• Develop and document a comprehensive solution
• Present benefits (and a ROI worksheet)

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Assessment Process
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Goals
Opportunity Assessment
Plan Control
Strategic
Benchmarking / Best Practices
Opportunity ?
Business
Process Review / Reengineering
Quantify
Operational
Brainstorming
Prioritized Schedule
Maintenance Goal 1..N
KPI
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Benefits

• Some of the many benefits of performing such a
  study are
• Simplicity Understanding the problem in detail,
  leads to a simpler, more comprehensive solution.
  The process generally uncovers many new and
  beneficial opportunities for adding value by
  examining the business processes in more detail.
• Speed By understanding all issues before
  embarking on the project, the fastest deployment
  and most efficient use of resources is ensured.
• Risk containment All aspects of the project are
  understood and defined up front. A well designed
  project is less likely to fail or incur cost
  overruns.
• Control The report is a good tool for
  communicating a concise plan with senior
  executives and those responsible for
  implementation. Costs can be well defined,
  budgeted and controlled.
• Gain Support Opportunity for the team to have
  input to designing the solution. This leads to
  better support when resources are required.

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Dingo Collaborative Maintenance Network
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What is Collaborative Maintenance?
The ability for site maintenance people to share
data and collaborate via the internet to solve
business (maintenance) problems with external
experts.
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Collaboration
Ive just received an alert. The iron is up in
Engine 301 Any ideas?
Equipment Mfgr. Design Engineer Peoria, IL
Copper is also increasing. The piston
liners could be wearing.
Internet
Customer Maintenance planner Gillette, WY
Weve seen this at other customers. We had great
results with ...
Conoco Lubricant Engineer Denver, CO
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Content - adding value
Policies,environment, safety, production
-context from other systems
Business Results!

• recommendations
• action taken
• cost savings result

• case studies
• group reporting
• tips and hints

Engineers research and publish globally via
intranet
Finish
Global Database
Start

• raw data
• low value
• high volume

• information
• higher value
• generic rules

Site Condition Monitoring Data
Experts Collaborate Analyze Data
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Consolidation
Before
After
Site A
Site A
Site B
Oil Analysis
Vibration Analysis
Thermography
Site B
Microsoft DNA Architecture MS SQL Web server
Single global, multi site, multi application
database
Corporate HQ
Oil Analysis
Vibration Analysis
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Commonality
MaintenanceGuy.com
Enterprise Asset Management
Alert
Work Request
Assets
Assets
History
History
Other
Other
Event History
Work Orders
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3. Professional Implementation Services

• Development of implementation plan with site
  team, project management.

Sample Project Team
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4. Education Training

• Software - Application Based Training
• Oil Analysis
• Trades
• Basic
• Advanced
• Integrated CM.

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5. Professional Support

• Software
• Dedicated support team
• Developers of the software
• Remote dial in support capability
• Internet support
• E-mail support
• Enhanced support with regular visits
• Annual User Conference
• Condition Monitoring
• Engineers
• Oil Analysis Experience

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6. Systems Integration.

• Intergration of Systems to allow
• Improved Management of and Access to Data
• More Informed Maintenance Decisions
• Examples
• Oil Analysis
• Asset Management and Enterprise Resource Planning
  (e.g. MIMS, SAP, MP5)
• Vibration Analysis
• Thermography
• Ultrasonics
• Process Control (e.g. Tritronics, Wonderware)
• Vehicle Management Systems (e.g. VIMS, DDEC)
• Dispatch Systems

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Customer Benefits

• Improved asset performance
• Asset life cycle cost reduction
• Global improvement in Condition Monitoring
  standards
• Reduced lubricant, parts and labour costs
• Faster problem resolution through real time
  collaboration
• Reduced system administration and overhead

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Five Best Practices in Condition Monitoring
1. Setting Goals
2. Selecting the Laboratories/Vendors
3. Taking Samples/Readings
4. Analysing the results
5. Taking Action Feedback
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1. Setting Goals

• Quantify the opportunity.
• Examine available resources.
• Define and set goals.
• CM Analysis for PM .
• CM Analysis for PdM.
• CM Analysis to support the goal of potential
  reliability (RCM or ProActive).
• Communicate them throughout the organisation.

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2. Lab and Vendor Selection

• Laboratory/vendor audit.
• What certification/standards the
  laboratory/vendor operates under.
• What analysis the laboratory/vendor can do and
  compare that to what you require based on the
  goals set in Step 1.
• Strengths and limitations of analysis - lubricant
  technical specs.
• Communication between lab and site.

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3. Taking the Samples/Tests

• Determine what gets sampled.
• Error free labelling techniques.
• Representative sampling.
• Sample point identification.
• Maintain education and feedback to those taking
  samples.
• Determination of Sample Interval.

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4. Analysing the results

• Knowledge of equipment and metallurgy of
  components
• Awareness of site specific contaminants.
• Understanding of lubricants and filters in use.
• Monitoring of Trends (Abs and Wear).
• Establishing site specific exception levels.
• Compare to other maintenance data sources.
• Analysis to determine effectivesness.

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5. Taking Action

• Set standards of action (Proactive, Predictive
  Levels).
• Used before failure, not after.
• Document in software.
• Do extensive studies or pilot programs before
  making global changes.
• Continous improvement processes.

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What is Reengineering?

• Original term by Michael Hammer in Harvard
  Business Review in 1993
• Radical redesign of a companys processes,
  organization, and culture to achieve a quantum
  leap in performance
• Four Key words
• Fundamental
• Radical
• Dramatic
• Processes

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Rethinking business processes

• Several Jobs are combined into one
• Workers make decisions
• Steps are performed in a natural order
• Processes have multiple versions
• Work is performed where it makes the most sense
• Checks and controls are reduced
• Reconciliation is minimized
• Case Manager provides single point of contact
• Hybrid Centarlized/Decentralized operations are
  prevalent

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Reengineering applied to Opportunity Assessment

• Oil Analysis is a business process which involves
  significant resources
• As such reengineering can and should be applied
• Information technology is key
• Emerging technologies should always be evaluated
  for applicability!

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Oil Analysis Process
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Information Technology

• is an Essential Enabler
• change from deductive to inductive thinking
• first recognising a powerful solution and then
  seek the problems it might solve
• Shift in thinking
• Old Rule
• Disruptive Technology
• New Rule

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Information technology
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Combining Jobs Metropolitan Transit Authority

• Old
• Receipt of US Mail reports (1000 per month)
• Manual Calculation of rate of Change values
• Review against alarm levels
• Consult reference material on Oil Analysis
• Secondary System to record Action
• Manual adjustment of alarm levels
• Filing of Information

• New
• Software Automatically
• Downloads results
• Calculates Wear Rates
• Triggers Exceptions
• Adjusts Alarms
• Stores all historical information
• Oil Analysis Info stored in System
• Audit Trail of Action

Disruptive Technology
Computer Database
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Workers Making Better DecisionsAluminum Smelters
Disruptive Technology

• Old
• Communication gap between External Lab, Planners
  and Workers
• Poor sampling procedures
• Pain involved in analysing numerical data halted
  progress

• New
• Info shared by Lab, Management and Workers
• Workers taking more ownership
• Access to vital integrated information allows
  pro-active behaviour during PM activities
• Workers making higher value maintenance decisions

Computers, Software, Networks
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Work is Performed Where it Makes the Most Sense

• Old
• Rely solely on lab for analysis
• No site conditions considered in Analysis
• Limited understanding of Oil Analysis on site

• New
• Analysis performed on site, considering lab and
  other input
• Site specific alarms
• Comparisons amongst similar equipment
• Action taken based on site goals
• Manage risks against benefits

Disruptive Technology
Analysis software e-mail
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Other Reengineering Examples
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The Internet

• The challenge that most corporations fail to
  meet is the business possibilities that lie
  latent in technology
• Rengineering the Corporation, Michael Hammer
  and James Champy, 1993

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Dingo MaintenanceGuy.com

• World first collaborative web product
• Intranet portal for Maintenance Staff
• Single large database
• Multi-site, Multi lingual
• Data Portability
• Multiple technologies
• Re-Engineering Principles applied to the Web
• Able to access data on multiple machines that are
  geographically dispersed
• Can connect to legacy systems on other operating
  system platforms
• WANs, Internet and low speed connections
  supported