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- 1. Global Asset Sustainability Jon F. Mortensen, April 2008 Copyright © 2001-2008 Infor Global Solutions
- 3. CO 2 -e Conversion Factors for Electricity Consumed Copyright © 2001-2008 Infor Global Solutions GHG emissions (t CO2-e) = Q x EF / 1000 Where: Q (Activity) is the electricity consumed by the reporting organisation in kWh; and EF is the relevant emission factor expressed in kg CO 2 -e/kWh in Columns A, C and E Source: National Greenhouse Accounts (NGA) Factors, February 2008
- 4. Does Carbon Have a Price? Copyright © 2001-2008 Infor Global Solutions The introduction of a price on emissions is the primary instrument for securing the environmental objective. Interim Report to the Commonwealth, State and Territory Governments of Australia. February 2008.
- 5. Does Carbon Have a Price? Copyright © 2001-2008 Infor Global Solutions The politically attuned know it hasn't yet dawned on many people that doing something about climate change involves more than signing international agreements and will increase the prices we pay for electricity, gas and petrol. Kyoto: it's not the end of the world Ross Gittins – 19 December 2007
- 6. What is your CO 2 -e Consumption? Copyright © 2001-2008 Infor Global Solutions
- 7. Bringing GHG Emissions into Context for your Assets A Simple Example Copyright © 2001-2008 Infor Global Solutions
- 14. On the Ground Reality – Efficiency Reduced over Time Copyright © 2001-2008 Infor Global Solutions Asset performance management can reduce energy consumption by 6% to 11%. These percentages have been established by international studies which indicate that a company’s asset management operations would benefit from integrating energy consumption into their asset management strategy. Terry Wireman; Benchmarking Best Practices in Maintenance Management ISBN: 0-8311-3168-3
- 15. Consumption Adds up Across the Organisation Copyright © 2001-2008 Infor Global Solutions
- 16. The ROI – Extending to the Organisational Whole Copyright © 2001-2008 Infor Global Solutions
- 17. How EAM ASE Assists in Global Asset Sustainability The GAS Index Copyright © 2001-2008 Infor Global Solutions
- 21. GAS Index Copyright © 2001-2008 Infor Global Solutions
- 22. Infor EAM Asset Sustainability Edition Copyright © 2001-2008 Infor Global Solutions iPROCURE Asset Sustainability Edition ALERT MANAGEMENT ENERGY INTEGRATION PROGRAM PLANNING FUGITIVE EMISSIONS MANAGEMENT CO2 MANAGEMENT CONFIGURED KPIs, Inbox, Reports
- 24. Continuous Commissioning Process – Infor EAM ASE Copyright © 2001-2008 Infor Global Solutions Preliminary Data Collection (e.g. equipment nameplate information, set points, energy efficiency, operations limits) Continuously monitor and run equivalent functional asset tests Continuously record, analyse and interpret observations and functional test results Manually correct problems, change installation, replace, repair Report results. store and archive data Infor Asset Sustainability is an enterprise repository for all asset data Infor Asset Sustainability alert management provides continuous AFDD monitoring & testing Infor Asset Sustainability alert management records, interprets, and tests real time BAS and metering observations Infor Asset Sustainability automatically generates work orders to rectify anomalies and validate fixes Infor Asset Sustainability quantifies results, and stores data for anomaly determinant Commission fixes
Notas do Editor
- Copyright © 2001-2007 Infor Global Solutions
- Copyright © 2001-2007 Infor Global Solutions The capacity factor of a manufacturing facility is the amount of product that it produces over a period of time, divided by the amount of product it could have produced if it had run at full capacity over that time period. Capacity factors vary greatly depending on the age of the assets, engineering design basis of the asset configuration, and the asset management life-cycle management programs. Capacity factor should not be confused with availability factor. There are two main reasons why a manufacturing facility would not have a capacity factor of 100%. The first reason is equipment that is out of service, either due to failures or routine maintenance. This accounts for most of the unused capacity of facilities in continuous use. Continuous use (24x7) facilities have the lowest costs per unit of production because they are designed for maximum efficiency and are operated continuously at high output. The second reason that a plant has a capacity factor lower than 100% it that output is curtailed because the product is not needed or because the price of product is too low to make production economical. This accounts for most of the unused capacity of non-continuous. Non-continuous facilities may operate only a few hours per year or up to a several hours per day. Their operation is relatively expensive. It is uneconomical, even wasteful, to make a non-continuous facility as efficient as a continuous operations because they do not operate enough to pay for the extra equipment cost, and perhaps not enough to offset the embodied operation of the additional assets and components. The availability factor of a manufacturing facility is the amount of time that it is able to produce product over a certain period, divided by the amount of the time in the period. Occasions where only partial capacity is available may or may not be deducted. The availability factor should not be confused with the capacity factor. The availability of a manufacturing facility varies greatly depending on the the design of the facility and how the facility is operated. Everything else being equal, facilities that are run less frequently have higher availability factors because they require less maintenance. Most manufacturing facilities have availability factors between 70% to 90%. Newer plants tend to have significantly higher availability factor, but preventive maintenance is as important as improvements in design and technology. These facilities, as a rule-of-thumb, have relatively high capacity factors, ranging from 80% to 99%. Indicator below these ranges would warrant further investigation. Quality is an indicator of the of the cost of sales. The quality factor of a manufacturing facility is the amount of product produced per unit consumed divided by the product produced utilizing 100% of the input. This measure is directly impacted by asset performance. Asset and operations and configuration specification tolerance, and maintenance processes and procedures all influence quality. Manufacturing process quality results in increased product at less cost.
- Copyright © 2001-2007 Infor Global Solutions On the other hand Tasmania is almost exclusively Hydro-electric. There are three areas for reporting GHG for organisations. These are: Scope 1: GHG produced on site by the facility Scope 2: Indirect GHG emissions from the consumption of electricity, heat and steam – consumed by a facility that is generated offsite (e.g. the electricity purchased from the Grid) Scope 3: Is currently considered to be voluntary and represents other indirect emissions It should be noted that the Department of Climate Change provides consumption of electricity produces both Scope 2 and Scope 3 emissions
- Copyright © 2001-2007 Infor Global Solutions Now all this stuff about GHG, electricity and carbon is it really relevant to my organisation?
- Copyright © 2001-2007 Infor Global Solutions http://www.environment.gov.au/settlements/gwci/households.html Department of the environment, water, heritage and the arts Average Australian household produces 14tonnes of GHG a year 5% on lighting Therefore the scope 2 emissions savings from this one motor is equivalent to around 50 households moving to energy efficient light globes
- Copyright © 2001-2007 Infor Global Solutions At 82% efficiency we create 3293 a difference of 358tonnes or $7160 worth of carbon permits at $20 a tonne with
- Copyright © 2001-2007 Infor Global Solutions Now all this stuff about GHG, electricity and carbon is it really relevant to my organisation?
- Copyright © 2001-2007 Infor Global Solutions We asked these respondents to identify those factors that were driving their investments in assets and systems to manage them. At the top of this list, 57% cite the need to maximize capacity, increase availability, and improve flexibility among their top three priorities – this is a reflection of external factors. Companies are being asked to do more with less – more frequently. Second most important on this list at 48% is product quality – many companies are focused on improving quality with their Six Sigma and Lean programs. Even those that don’t have formal programs can’t afford to downplay quality – often it is legislated or can affect the safety of customers and workers. A close third on the list at 47% is the need to align assets to meet market dynamics – this might mean ensuring that packaging lines are not only up and running 24 by 7, but can also be easily reconfigured to meet customer and local market demand – some companies also take a more strategic view – for instance, if the China market is opening up for snack foods, then it may be a matter of building plants in-country to better serve the market. Regulatory compliance is clearly a factor & should be higher for many industries – but again we had a mix – and more companies are taking the long term view of asset reliability as facilities and equipment continue to age. These were the external drivers, now let’s take a closer look at what the internal obstacles are.
- Copyright © 2001-2007 Infor Global Solutions Gas index = Availability * Performance * Quality * Energy Efficiency Where: Availability = All downtime / Scheduled time All downtime = The total hours a piece of equipment is down. This is always derived from a work order. Downtime will roll-up to higher level objects if there is a structure. This means that when a chiller is down, the building is considered down or a packaging machine is down, the whole production line is down. Scheduled time = The total hours the equipment is needed. The building for example is only scheduled to be in use Monday through Friday from 7 am to 9 pm. At night and during weekends it is not scheduled for use, regardless if people actually are working on the weekend or not. There is no real attribute in Infor EAM for this purpose, so we recommend use of a meter reading to capture this data. Entry of the hours scheduled will be recorded as a meter reading against unit of measure OEE-SCHED-HOURS. Performance = Actual output for scheduled time / Design output for scheduled time Actual output for scheduled time = Output depends on what is produced. It could be gallons, units, hours, etc. To calculate performance this is not relevant however. Simply capturing the output as a quantitative measure is sufficient to calculate performance. Actual output will be recorded as a meter reading against unit of measure OEE-ACTUAL-OUTPUT. Design output for scheduled time = Design output can be measured by multiplying the scheduled time with the output per hour. Output per hour can be measured again in different UOM’s, but again all we really need to know is a quantity. This quantity can be recorded as a custom attribute on the asset. The custom attribute will be OEE-DESO (OEE Design Output) and can be found on equipment, the category of the equipment or on the part. Quality = Total production minus Defects or Rework / Total production Total production = Just like Output Total Production depends on what is produced. It could be gallons, units, hours, etc. To calculate quality this is not relevant however. Simply capturing total production as a quantitative measure is sufficient to calculate quality. Total Production will be recorded as a meter reading against unit of measure OEE-PRODUCTION-OUTPUT. Note: OEE-ACTUAL-OUTPUT is only measured against scheduled time, while OEE-PRODUCTION-OUTPUT is all time. Defects or Rework = Similar as total production, but indicates the produced units that were defect or required rework. Total Production will be recorded as a meter reading against unit of measure OEE-DEFECT-OUTPUT. For buildings this formula can be replaced by the facility index. The facility index is calculated by taking the building improvement costs as a percentage of the building replacement cost. Subtract the FCI from 100 and you will have building quality. Energy Efficiency = Design energy consumption / Actual energy consumption Actual energy consumption = Actual consumption will be recorded as a meter reading against unit of measure KWH. Note: Actual usage is not just usage for the scheduled time. Actual usage will include usage during unscheduled times as well. Design consumption = For equipment the design consumption is not a standard attribute in Infor EAM and therefore will be recorded as a custom attribute. The custom attribute will be OEE-DCON (OEE Design Consumption) and can be found on equipment, the category of the equipment or on the part. However this custom attribute only records the usage per unit of use. So in order to get the total design consumption we need to multiply this number with the actual usage of the equipment. The actual usage will be recorded as a meter reading against unit of measure OEE-ACTUAL-USAGE. Note: Design consumption will be recorded as the consumption when the equipment is running at maximum speeds. Obviously this is not always the case. Part of the day the equipment may run at only half the speed or less. Tracking this is not assumed a function of the EAM, but a function of the process monitoring. Therefore if the equipment was used for 10 hours, but only on average at 80% of its capacity we expect to receive 8 hours for actual usage.
- Copyright © 2001-2007 Infor Global Solutions Additional Standard Functionality: Meters. Infor EAM offers an extensive metering function that allows an unlimited number of meters to be associated with a single piece of equipment. Metered usage values flow down a customer-defined equipment hierarchy to selected components, eliminating the need for supplemental metering. Warranties and Warranty Claims . The Warranties and Warranty Claims feature of Infor EAM allows users to track asset warranties, process warranty claims and provide for unlimited warranties against any asset. Infor EAM accommodates both meter- and date-based warranties and automatically tracks all work orders in the system that have a potential claim. In addition it allows for time-elapse warranties on consumable parts not registered as assets. Application Program Interfaces (APIs) Data Collection APIs facilitate communication between the server and mobile products allowing information to pass between handheld and disconnected products. These APIs are used for transaction management. Hardware and software for the Data Collection functions are sold as separate advanced modules. Comment Spell Checker. This feature is critical given that comments can encompass all textual procedures, instructions, inspection results, and other key information throughout the system. By using a spellchecker, users are ensured improved accuracy and clarity associated of tasks within Infor EAM EE. Customer Service Request. Infor EAM EE Service Requests are ideal for facilities management where a Infor EAM EE customer has a number of internal "customers" who need a simple method for reporting maintenance problems. Such reporting involves a simple Caller ID and the selection of a preformatted list of common problems. The Caller has the opportunity to submit free-format comments to clarify the problem being submitted. Examples for Service Request operation include universities (dormitories), hospitals, apartment complexes, and the like. Configuration Manager. The Configuration Manager module enables customers to export their Infor EAM development environment base configurations to a special XML-formatted file that may be imported into another Infor EAM environment. This enables system administrators to set up a test environment and build their unique configurations. Depreciation. Infor EAM includes the ability to calculate and display any of four asset depreciation methods, including straight-line, double declining rate, sum-of-the-years-digits and units of production. Linear Assets . The Linear Assets module enables users to define an asset in terms of linear reference details like length, unit of measure and geographic reference. Users can write work orders against any portion or point on that asset by specifying to and from points. Multi-Organization Support . Infor EAM is often used by companies located in multiple countries, requiring the use of a variety of currencies and languages. With flexible multi-organization features, regional, national and multi-national organizations can manage multiple legal entities with one database and apply security settings to determine a user’s access. Each site within the organization is able to view and edit its own data. Preventive Maintenance (PM) Flexibility. With PM Flexibility, users create PM tasks based on a fixed date, flexible time period or metered usage. Users may incorporate routes with a PM task to service multiple assets that share similar PM requirements under a single work order. Infor EAM can automatically adjust PM schedules to compensate for early or late PM work accomplishment. Infor EAM also offers PM Revision Control to track modifications and control the authorization of modifications to PM scheduled task, materials and routes. Repairable Spares . The Repairable Spares functionality allows customers to designate parts or equipment as being “repairable.” Items designated for refurbishment can be automatically placed in a “To Be Repaired” location when returned to the storeroom following maintenance action. Reports . The Infor EAM Reports module enables users to select from a variety of pre-defined reports including assets, materials, purchasing, schedule, work, budget analysis, projects and commercial services. Also available is the Infor EAM Advanced Reporting module, which offers a variety of reporting requirements from ad hoc query, managed reports and business reports to invoice statements and bills. Upload Utility. The Upload utility is a tool that uses Web services to insert or update selected tables in Infor EAM. This facilitates rapid insertion of data into the system without the need for manual data entry. For example, users can now load 100,000 part items from a newly acquired warehouse in a matter of seconds. Additional Advanced Functionality: The following list outlines the Advance Modules available for Infor EAM Enterprise Edition (formerly Datastream 7i), v 8.2. The modules can be provided at additional cost at the option of each client Barcoding. Barcoding allows users to design and print labels for assets, providing increased mobility and systems functionality. Labeling assets streamlines the tracking and relocating of assets, warranty activation and updating, work registration and other functions. Fleet. The Fleet module includes Vehicle Maintenance Reporting Standards (VMRS) codes and additional customers’ fields. Focusing on the transportation industry’s greatest opportunities for productivity and cost-per-mile savings, the Fleet module enables transportation companies to process warranty claims, manage tires and fuel, and improve vehicle performance through preventive maintenance. Connector. Connector enables interactive, synchronous access to the solution through the Web services interface. The connector interface provides access to the Infor EAM EE data for use in portals, reports, and websites and access to Infor EAM EE functions allowing the creation of external applications in commonly used user interfaces like Microsoft Outlook, Lotus notes, Pervasive Devices, Visual Basic, and Java. Example: Work Request interface for operational personnel created in Visual Basic for Applications utilizing SOAP and XML and deployed using Microsoft Outlook. Any user that needs real time list of values for validation through external application. Requestor. Infor EAM EE Requestor is ideally suited for users needing only Requisition and Work Request functionality including field selections for items such as store, suppliers, part numbers, departments, individual pieces of equipment, cost codes, work priority, requested start/end date for the work item, and associated user-defined fields. Examples of ideal Requestor users include administrative workers with a need to submit purchase requisitions and occasional users of Infor EAM EE needing only ability to submit work requests for a general area of a business.
- Copyright © 2001-2007 Infor Global Solutions Its not just about electricity.