Sometimes, maintenance becomes a customer service issue. Helicopter manufacturer Sikorsky Aircraft Corp., in Chicago, monitors and maintains its finished products for customers in the commercial, industrial and military industries. In order to increase customer loyalty, the company took measures to increase aircraft availability by implementing a software solution that identifies and predicts equipment maintenance needs or potential malfunction.
Sikorsky deployed software from SPSS Inc., an IBM company in Chicago that produces predictive maintenance analytics software used in plants to monitor manufacturing equipment. The goal is to determine the relationship between how the aircraft is being operated and maintained, and the consumption of parts.
分析的最终目标是在发生故障之前捕获故障，从而确保更多的可用性。SPSS使用相同的工具来监视植物设备。SPSS的高级产品经理Marcus Hearne说：“植物正在从感官和反应转变为预测和效果。”“有了预测，您就可以在发生之前发现未知或看不见的事件。”
Hearne notes that the industries that show the most interest in predictive data analysis are those that are most reliant on high availability. “Electricity plants are a big user because it’s critical that they keep availability at the highest level,” Hearne observes.
As the economic recovery gains momentum in the manufacturing world, plant operators are looking at the possibility of running full steam for the first time in nearly three years. Much has changed during that time, including an industry-wide push toward greater efficiency.
With dollars in short supply after a prolonged recession, manufacturers need to get the most out of their existing equipment. The board room isn’t in any mood to invest in new assets. So plant operators need to increase their uptime and extend the lifetime of their current assets. And that requires a new way of monitoring and maintaining equipment.
Asset performance management (APM) has become the new buzzword for getting more out of existing equipment. The term includes everything from condition monitoring to analysis of historical data to determine when a valve may stick and cause a stoppage. The goal of APM is efficiency—it can be described by the old saying: a stitch in time saves nine.
近年来，很少有工厂能够全部运行。许多制造商可以追溯到2007年，是最后一次容量是一个问题。同时，许多知识渊博的工人被解雇了。现在，许多工厂期待今年秋天的全部产能。问题是：制造商是否准备好充分利用他们的资产，尤其是随着许多知识渊博的工人消失了吗？
从经济低迷中出来，制造商发现，他们必须使用与较低生产水平相同的设备来增加生产。“现在，许多工厂都来到我们身边，以使其更加系统，并提高其可靠性。他们想开始在上涨之前开始这一点。“他们感觉到市场正在发生变化，他们的订单书将有所改善。但是他们的现金真的很紧，所以他们想使用相同的设备。”
回到未来
对于某些植物来说，使用相同的设备加速并不容易。美国汽车行业最近面临着这一挑战。汽车制造商必须生产更新，技术上更先进的汽车，以提供更高的燃油效率，同时使用与过去使用过的相同设备。
That can work if you have knowledgeable engineers. Unfortunately, many plants reduced their engineering population. “Plants that did not cut down all that much on knowledgeable personnel may be able to ramp up to 2007 levels pretty quickly, while others will struggle,” says Pousette. “Those that cut back didn’t make a bad decision. When you only have 30 percent of your usual orders, you have to cut back.” In many cases, plants will turn to technology—APM programs—to help run their equipment effectively.
Reliable, predictable uptime is a major goal at every plant. Reliability was the leading goal for Rubbermaid Commercial Products, in Winchester, Va., when the company decided to adopt ABB’s maintenance management service. The Winchester plant has 55 major production machine centers and 1,300 equipment assets that need maintenance. The plant operates 355 days a year, 24 hours per day.
The company analyzed its operation and found an unacceptable level of preventive maintenance tasks and a high rate of unpredictable equipment failure, which increased machine downtime. The result was missed customer order deadlines, a poor return on net assets and an environment of reactive maintenance.
Rubbermaid操作员实施了ABB的PM30托管管理服务，以改善其整体维护计划。该系统改进了产品和设备上的数据收集，并分析了数据以识别潜在的故障。“ PM30的一致管理，其内容的灵活修改和输出的管理可以使卓越的持续发展驱动力，” Rubbermaid的运营维护经理Rich Sankovich说。
Sankovich notes that ABB’s service helps the plant regularly achieve a 20 percent higher preventive maintenance completion rate. Plus, improved reliability has provided better planning and scheduling. Equipment failure has also decreased dramatically.
Mining data
技术在改善资产绩效方面起着一个因素。植物运营商正在部署更多的传感器并收集更广泛的历史数据，以确定一块机械或设备容易出现故障。波士顿的Aberdeen Group Inc.分析师Mehul Shah说：“多年来，资产密集型制造工厂一直在资产管理和维护上进行大量投资。”“公司面临着增加股东压力，以最大程度地提高资产回报率并降低制造成本。”
数据挖掘和分析是延长设备寿命的一种方法。您可以在故障之前揭示设备的弱点并修复它们。“工厂必须与已经拥有的设备一起做，因此他们试图更好地了解设备，”自动化供应商Invensys Operations Management的产品营销总监Kim Custeau在得克萨斯州普莱诺市。“过去，他们的设备数据一直在不同的孤岛。现在，他们将这些数据汇总到了预测系统中。”
Custeau指出，植物运营商开始研究整体设备景观，而不是看单个设备。Custeau说：“每件设备都有自己的手册，但并不是为设备的安装方式而写的。”“您必须将设备监控调整为环境。它靠近振动吗？是在阿拉斯加的寒冷还是在南部的热点？”
Plant operators are also working to manage their electricity so it’s easier on equipment and so the equipment runs more reliably. “Operators are seeing a need to manage the power going to the equipment a lot better than they did before,” says Rich Chmielewski, manager for process automation at Siemens Industry Inc., the Alpharetta, Ga.-based automation supplier. “Before, you had spikes and sags, as well as harmonics and grounding issues. Operators are looking for a power flow that runs the equipment optimally while also providing energy efficiency.”
使用无线
In some situations, the condition of an asset can’t be monitored easily, either because parts of the asset are in places that are hard to reach with wiring or because the asset is so spread out that wiring is simply too expensive. In these cases, operators are turning to wireless technology to monitor assets.
一个例子来自自动化供应商Honeywell Process Solutions，该解决方案部署了无线系统来监视油轮上的操作。油轮操作员需要保护旋转资产，提高满载运营的能力，并主动管理较长的交货时间维护时间表。有超过500点，手动监视旋转设备将需要三个月。跑步电线的想法是不可能的。费用将超过每英尺100美元。资产的宽度为900英尺，宽度为150英尺。
Deploying wireless sensors was a challenge. Inherent vibration in the ship itself can affect sensors. Honeywell had to assess the interference points and consider how the equipment would behave with a sensor attached.
最终安装了系统后，操作员每天可以五次阅读和收集数据，这会导致积极的维护，这可以安排在船舶进入端口时的时间。“无线解决方案告诉他们最早可能出了什么问题，”凤凰城霍尼韦尔流程解决方案的全球高级产品经理拉贾特·萨达纳（Rajat Sadana）说。“这是一个环游世界的油轮，因此很难进行维护。”萨达纳（Sadana）指出，该系统已帮助操作员避免或推迟干燥码头中的昂贵咒语。
资产绩效管理采用一系列形式，从在船上，直升机上或消费产品工厂的监视设备进行监控。这些工具可以包括无线传感器，条件监控系统和数据误解，以在故障之前揭示故障模式。APM的基本主题归结为预测性维护。如果您可以在引起工作停止之前解决问题，则可以改善正常运行时间，并有可能延长资产的寿命 - 及时的针迹节省了九个。
相关栏——新名字Existing Tools
To read the article accompanying this story, go to www.myenum.com/feature-6827.
Sikorsky deployed software from SPSS Inc., an IBM company in Chicago that produces predictive maintenance analytics software used in plants to monitor manufacturing equipment. The goal is to determine the relationship between how the aircraft is being operated and maintained, and the consumption of parts.
分析的最终目标是在发生故障之前捕获故障，从而确保更多的可用性。SPSS使用相同的工具来监视植物设备。SPSS的高级产品经理Marcus Hearne说：“植物正在从感官和反应转变为预测和效果。”“有了预测，您就可以在发生之前发现未知或看不见的事件。”
Hearne notes that the industries that show the most interest in predictive data analysis are those that are most reliant on high availability. “Electricity plants are a big user because it’s critical that they keep availability at the highest level,” Hearne observes.
As the economic recovery gains momentum in the manufacturing world, plant operators are looking at the possibility of running full steam for the first time in nearly three years. Much has changed during that time, including an industry-wide push toward greater efficiency.
With dollars in short supply after a prolonged recession, manufacturers need to get the most out of their existing equipment. The board room isn’t in any mood to invest in new assets. So plant operators need to increase their uptime and extend the lifetime of their current assets. And that requires a new way of monitoring and maintaining equipment.
Asset performance management (APM) has become the new buzzword for getting more out of existing equipment. The term includes everything from condition monitoring to analysis of historical data to determine when a valve may stick and cause a stoppage. The goal of APM is efficiency—it can be described by the old saying: a stitch in time saves nine.
近年来，很少有工厂能够全部运行。许多制造商可以追溯到2007年，是最后一次容量是一个问题。同时，许多知识渊博的工人被解雇了。现在，许多工厂期待今年秋天的全部产能。问题是：制造商是否准备好充分利用他们的资产，尤其是随着许多知识渊博的工人消失了吗？
从经济低迷中出来，制造商发现，他们必须使用与较低生产水平相同的设备来增加生产。“现在，许多工厂都来到我们身边，以使其更加系统，并提高其可靠性。他们想开始在上涨之前开始这一点。“他们感觉到市场正在发生变化，他们的订单书将有所改善。但是他们的现金真的很紧，所以他们想使用相同的设备。”
回到未来
对于某些植物来说，使用相同的设备加速并不容易。美国汽车行业最近面临着这一挑战。汽车制造商必须生产更新，技术上更先进的汽车，以提供更高的燃油效率，同时使用与过去使用过的相同设备。
That can work if you have knowledgeable engineers. Unfortunately, many plants reduced their engineering population. “Plants that did not cut down all that much on knowledgeable personnel may be able to ramp up to 2007 levels pretty quickly, while others will struggle,” says Pousette. “Those that cut back didn’t make a bad decision. When you only have 30 percent of your usual orders, you have to cut back.” In many cases, plants will turn to technology—APM programs—to help run their equipment effectively.
Reliable, predictable uptime is a major goal at every plant. Reliability was the leading goal for Rubbermaid Commercial Products, in Winchester, Va., when the company decided to adopt ABB’s maintenance management service. The Winchester plant has 55 major production machine centers and 1,300 equipment assets that need maintenance. The plant operates 355 days a year, 24 hours per day.
The company analyzed its operation and found an unacceptable level of preventive maintenance tasks and a high rate of unpredictable equipment failure, which increased machine downtime. The result was missed customer order deadlines, a poor return on net assets and an environment of reactive maintenance.
Rubbermaid操作员实施了ABB的PM30托管管理服务，以改善其整体维护计划。该系统改进了产品和设备上的数据收集，并分析了数据以识别潜在的故障。“ PM30的一致管理，其内容的灵活修改和输出的管理可以使卓越的持续发展驱动力，” Rubbermaid的运营维护经理Rich Sankovich说。
Sankovich notes that ABB’s service helps the plant regularly achieve a 20 percent higher preventive maintenance completion rate. Plus, improved reliability has provided better planning and scheduling. Equipment failure has also decreased dramatically.
Mining data
技术在改善资产绩效方面起着一个因素。植物运营商正在部署更多的传感器并收集更广泛的历史数据，以确定一块机械或设备容易出现故障。波士顿的Aberdeen Group Inc.分析师Mehul Shah说：“多年来，资产密集型制造工厂一直在资产管理和维护上进行大量投资。”“公司面临着增加股东压力，以最大程度地提高资产回报率并降低制造成本。”
数据挖掘和分析是延长设备寿命的一种方法。您可以在故障之前揭示设备的弱点并修复它们。“工厂必须与已经拥有的设备一起做，因此他们试图更好地了解设备，”自动化供应商Invensys Operations Management的产品营销总监Kim Custeau在得克萨斯州普莱诺市。“过去，他们的设备数据一直在不同的孤岛。现在，他们将这些数据汇总到了预测系统中。”
Custeau指出，植物运营商开始研究整体设备景观，而不是看单个设备。Custeau说：“每件设备都有自己的手册，但并不是为设备的安装方式而写的。”“您必须将设备监控调整为环境。它靠近振动吗？是在阿拉斯加的寒冷还是在南部的热点？”
Plant operators are also working to manage their electricity so it’s easier on equipment and so the equipment runs more reliably. “Operators are seeing a need to manage the power going to the equipment a lot better than they did before,” says Rich Chmielewski, manager for process automation at Siemens Industry Inc., the Alpharetta, Ga.-based automation supplier. “Before, you had spikes and sags, as well as harmonics and grounding issues. Operators are looking for a power flow that runs the equipment optimally while also providing energy efficiency.”
使用无线
In some situations, the condition of an asset can’t be monitored easily, either because parts of the asset are in places that are hard to reach with wiring or because the asset is so spread out that wiring is simply too expensive. In these cases, operators are turning to wireless technology to monitor assets.
一个例子来自自动化供应商Honeywell Process Solutions，该解决方案部署了无线系统来监视油轮上的操作。油轮操作员需要保护旋转资产，提高满载运营的能力，并主动管理较长的交货时间维护时间表。有超过500点，手动监视旋转设备将需要三个月。跑步电线的想法是不可能的。费用将超过每英尺100美元。资产的宽度为900英尺，宽度为150英尺。
Deploying wireless sensors was a challenge. Inherent vibration in the ship itself can affect sensors. Honeywell had to assess the interference points and consider how the equipment would behave with a sensor attached.
最终安装了系统后，操作员每天可以五次阅读和收集数据，这会导致积极的维护，这可以安排在船舶进入端口时的时间。“无线解决方案告诉他们最早可能出了什么问题，”凤凰城霍尼韦尔流程解决方案的全球高级产品经理拉贾特·萨达纳（Rajat Sadana）说。“这是一个环游世界的油轮，因此很难进行维护。”萨达纳（Sadana）指出，该系统已帮助操作员避免或推迟干燥码头中的昂贵咒语。
资产绩效管理采用一系列形式，从在船上，直升机上或消费产品工厂的监视设备进行监控。这些工具可以包括无线传感器，条件监控系统和数据误解，以在故障之前揭示故障模式。APM的基本主题归结为预测性维护。如果您可以在引起工作停止之前解决问题，则可以改善正常运行时间，并有可能延长资产的寿命 - 及时的针迹节省了九个。
相关栏——新名字Existing Tools
To read the article accompanying this story, go to www.myenum.com/feature-6827.
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