Downtime and/or OEE is a significant focus for most production facilities. Deeper downtime analysis can drive improvements based on accurately documenting how much lost production has occurred and the reasons for this. Often this is manually recorded and in many cases is inaccurate and/or subjective.
Downtime and its associated reporting can take many forms depending on the industry. Here are some examples:
1. GADS
2. OEE
OEE or Overall Equipment Effectiveness provides a breakdown of availability, performance and quality or efficiency of production.
3. PRODUCTION LOSS ACCOUNTING (PLA)
Generally, this is downtime with the added metric of lost production and the costs associated with the lost production.
4. TIME USAGE MODEL
A Time Usage Model provides a consistent reporting methodology of how a time period (e.g. a shift, day, or a month) is split across productive, unscheduled and scheduled downtime. Tools like Power BI are a great way to visualise this type of information. This model is common in the mining industry.
Asset Intellect along with PI Asset Framework collects and manages data to capture events using accurate time stamps directly from PI. Capability is provided to configure initiation of downtime events, which automatically prompts operators to select reason codes. The layout and structure of how to categorize the downtime is configurable with multiple levels of reason codes.
Not only does Asset Intellect provide reporting of the metrics defined above, it also has the ability to leverage your other operational data to understand the reasons behind the headline numbers.
Additional information can be attached to the event such as operator comments, screen capture, process data analysis, maintenance, photos, alarm and events and more.
From the downtime event users can navigate to an associated PI Vision screen to better understand the cause.
Finally, this data can be validated and surfaced into an electronic logbook, shift handover notes or into reporting tools such as Power BI and Tableau.
FEATURES
- Automatic event classification
- Define multiple levels of downtime classification
- Flexibility to split reason codes such as:
- Site/Unit/Line
- Planned or unplanned
- By Shift and Operator
- By Asset Category/subcategory
- Integration with standard tools such SQL for use in Power BI
- Calculate production losses and costs
- KPI dashboards
- Integration with relevant CMMS data
- Integration with process data
- Integration with alarm and event logs
- Integration with IoT data and predictive analytics
- Integration with electronic logbook
- Attach documents/screen shots/photos
- Automatic shift report generation
BENEFITS
Asset Intellect provides complete visualization of operational data including navigation built to seamlessly move between applications within a single pane of glass.
Downtime is a key performance indicator but the immediate questions that follow are all contextual requiring seamless and simple integration to other complimentary data. It is this deep integration of all operational data that allows Asset Intellect customers to quickly analyze the root causes of downtime, and to determine if this is a common reoccurring theme with an asset or mode of operation that can be rectified.
Maximize availability, productivity and reliability of assets. Easily identify root causes of failure. Supplement your move to CBM and improve asset optimization with fast accurate analysis.
Asset Intellect helps you answer these questions:
- The cost breakdown of downtime
- What is the maintenance history?
- How does this compare to other similar assets?
- Is the downtime a potential process safety risk?
- Is there a history of problems associated with this asset?
- Are there analytics indicating a worsening of the situation?
- Should we put in IoT monitoring devices to provide better information?
- Should we consider replacing a troublesome asset?
