presentation for breakfast master class at Imaintain 2012

1. Analytics open a new dimension in maintenance
I-Maintain Breakfast Masterclass
22 March 2012
Marc Hoppenbrouwers - Accenture
Marc Couturier - SAS
Copyright © 2012 Accenture All Rights Reserved. 1

2. Introducing Accenture
Copyright © 2012 Accenture All Rights Reserved. 2

3. Production and manufacturing companies all face similar
strategic and tactical challenges...
Sustainable
Small developments, Increase
Reduce • Due to decreasing margins
margins rules and Operational the revenues need to
Reliability
regulations Expenses increase and expenditure
has to reduce
• Yet the western industry are
facing cost reductions in
CAPEX and OPEX, an
aging workforce are limiting
the ability to handover
Knowledge knowledge and experience
Low Capital Aging Aging
Management & to new skilled workers
Investments Equipments Workforce
Transfer
• Additionally new regulations
(environmental, energy
trading, ISO/PAS/OSHA)
demand to change to more
sustainable operations
Copyright © 2012 Accenture All Rights Reserved. 3

4. Asset Performance Management requires continuous
improvement in two dimensions...
Asset Performance Management requires continuous improvement in efficiency;
increase process performance; and effectiveness; increase plant performance.
effective Right maintenance Right maintenance
poorly executed Excellent executed
Plant Performance
Wrong maintenance Wrong maintenance
Poorly executed Excellent executed
ineffective
inefficient Process Performance efficient
Copyright © 2012 Accenture All Rights Reserved. 4

5. Maintenance maturity: efficiency
Maintenance maturity roadmap
focus on execution efficiency
Basic levels of maintenance Maintenance best practices
Performance based
maintenance
D
Condition based Maintenance
Benefits • Define root causes of failures
• Monitor asset condition
Risk based
5 • Set warning and alarm levels
• Determine p-f interval
maintenance
C
Usage based Maintenance
4 • Introduce timers e.g. runhours, mileage
Condition based
maintenance • Logical meters
• Nesting of tasks
Preventive
maintenance B
3 Basic preventive maintenance
Planned • Time based maintenance
maintenance
D • Regulatory tasks
Breakdown
• Vendor recommended actions
maintenance 2 • Operator Asset Care
C
B
A Work initiation & prioritizing
1
• Clear notifications
A
0 • Gatekeeping on work requests
• Work Request Prioritization
Capability • Equipment Criticality
maturity
Copyright © 2012 Accenture All Rights Reserved. 5

6. Maintenance maturity: effectiveness
Maintenance maturity roadmap
focus on asset performance
Advanced levels of maintenance Maintenance best practices
Performance based
maintenance
H
Predictive Asset Maintenance
Benefits
• Integrate data sources
5 • Data driven models to generate early
Risk based warnings
maintenance
• Simulate maintenance scenarios
H • Optimise maintenance planning
G G
Performance monitoring
4 • Define performance KPIs
Condition based
maintenance • Assure data quality & integrity
F • Monitor plant performance in real time
• Combine operating and decision
Preventive E functions in one operations centre
maintenance F
3 Living reliability centred maintenance
Planned • Criticality Ranking on value drivers
maintenance
• Define failure modes and assess risks
• Optimize maintenance intervals
Breakdown
maintenance 2 • Close improvement loop using failure
codes
E Preventive Maintenance Optimisation
1 • Optimise maintenance strategy based
on bad actor Pareto analysis Preventative
0 • Reduce consequences
Maintenance
Planning
Maintenance
Optimization
Maintenance
Execution
Capability • Schedule compliance
maturity
Copyright © 2012 Accenture All Rights Reserved. 6

7. Technology enablers
EAM landscape
Integrated Best practice EAM Software solution overview
Performance Analytics & Predictive Master Data Document management
monitoring Asset Maintenance management system
(Historians/MES)
Control systems Maintenance management (EAM/CMMS) Performance
(DCS/SCADA) Dashboards
Condition Monitoring Maintenance strategy Spare part Planning/Scheduling
(CBM) (RCM / RBI) management
Copyright © 2012 Accenture All Rights Reserved. 7

8. EAM issue
Current EAM system Issue: integration with operations
The best-in-class enterprise asset
management (EAM) systems fail to make
this crucial connection to operations,
focusing instead on measures like number
of work orders outstanding, task
completion against standards and norms,
or MRO inventory costs
Smarter Assets Require Smarter EAM
18 February 2010
Copyright © 2012 Accenture All Rights Reserved. 8

9. EAM trends
The main driver for EAM systems is to increase reliability,
analytics will play an important role in achieving this
Copyright © 2012 Accenture All Rights Reserved. Source: ARC best practices – February 2012 9

10. Analytics
Analytics define a new dimension in the industry
Analytics Definition
“What’s the best that can
Optimization
happen?”
Predictive
“What will happen next?” Predictive
Modeling
Competitive Advantage
Analytics
Forecasting/ “What if these trends (the “so what”) Analytics will
Extrapolation continue?”
help our clients become more
Statistical
“Why is this happening?” insightful decision makers
Analysis
who implement more
Alerts “What actions are needed?”
impactful interventions to
Query/ improve business outcomes,
“What exactly is the problem?”
Drill down i.e. the “now what!”
Descriptive
“How many, how often, Analytics
Ad hoc Reports
where?” (the “what”)
Standard
“What happened?”
Reports
Sophistication of Intelligence
Source: Competing on Analytics: The New
Science of Winning (Davenport / Harris)
Copyright © 2012 Accenture All Rights Reserved. 10

11. Analytics: the data challenge
The challenge – Too many surprises
Collect Analyze Decide Act Maint. $ Availability
Copyright © 2012 Accenture All Rights Reserved. 11

12. Analytics: informed decision making
Analytics offer the solution to reduce surprises
Collect Analyze Decide Act Maint. $ Availability
Data Strategy & Socialization
Infrastructure policy
Intelligence
Descriptive Organization
Analytics
Predictive
Analytics
Copyright © 2012 Accenture All Rights Reserved. 12

13. Analytics: integration of data sources
Analytics - better cooperation based on better data
Reliance has one control room for their entire downstream operations in India
Copyright © 2012 Accenture All Rights Reserved. 13

14. Analytics: industry
Predictive Asset Maintenance (PAM) –
Different industries and time horizons require different predictive
methodologies and that defines the business value gained
value created based on predictive asset maintenance analytical methods applied
Predictive Asset Maintenance
High
 Similarity –Based Models
Petroleum
Petroleum Power Up stream
Power Down stream
 Proportional  Markov Models
Medium
Hazard Models
Hydro Wind Farm
off-shore
 Bayesian Models
Wind Farm
Natural Gas
on-shore
Nuclear
 Condition Monitoring
Power
 Regression models  Survivor Analysis
Chemicals
Industry
Low
 Expert Systems
Short term Mid Term Long Term
Time Horizon
Copyright © 2012 Accenture All Rights Reserved. 14

15. Analytics: @ work
The value of Analytics
APPS
BI Analytics
Copyright © 2012 Accenture All Rights Reserved. 15