Leveraging SAP to Support Reliability Analytics
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ConAgra Foods leveraged SAP to support reliability analytics across its consumer plants. It created a Reliability Center of Excellence to optimize SAP configuration for reliability, including developing a taxonomy, criticality analysis, and workflows. Key aspects included linking failure mode and effect analysis to technical object catalogs, developing granular criticality ratings, and optimizing maintenance workflows. The presentation provided examples of how these reliability tools and processes were implemented in SAP.
Leveraging SAP to Support Reliability Analytics
- 1. Produced by:Platinum SponsorPremier Sponsor Leveraging SAP to Support Reliability Analytics Chris Zawislak & Mike Poland ConAgra Foods, Inc Life Cycle Engineering, Inc.
- 2. • ConAgra Overview • Taxonomy • Criticality • Workflows • Key points to take home • Questions What I’ll Cover
- 3. ConAgra Foods overview Slide 3 ConAgra Foods started in 1919 as Nebraska Consolidated Mills. In 1971 it was renamed ConAgra, Inc., and the company became ConAgra Foods in 2000. ConAgra Foods is a Fortune 500 company with more than 24,000 employees, with the company’s world headquarters located in Omaha, Neb. ConAgra Foods is one of North America’s leading food companies, with brands in 97 percent of America’s households. In fiscal year 2010, ConAgra Foods brought in $12+ billion in net sales.
- 6. Introduction & Overview Executive Vision • Leverage CPS to improve performance • Leverage SAP to drive cost down
- 7. Situation • 2007 PM Pillar established • Working to establish foundation (PM Step 1) • Implemented SAP across consumer plants • Currently working to develop reliability competencies • SAP configuration was adequate to support foundation but requires optimization to support reliability analytics and other continuous improvement activities
- 8. SAP PM Risk Analysis Failure Mode and Effect Analysis Severity of Failure Likelihood of Occurrence Delectability of Failure Risk Ranking Control Plans Reliability Analysis Asset Module of EAM Continuous Improvement Functional Hierarchy Criticality Analysis Reliability Maturity
- 9. Action Create a Reliability Center of Excellence • Reliability Action Team • Reliability Focus Team • Reliability Engineering function and resource development • Reliability Infrastructure – SAP Configuration Taxonomy Criticality Workflows
- 10. •Learning to See Process Flow Diagram Value Stream Mapping Relationship Models Equipment Criticality Failure Analysis Risk Analysis Risk Ranking Standard Work Operating Procedures Preventive Predictive Condition Monitoring Remote Monitoring Operator Care Critical Spares OEE TCO Asset Utilization MTBF MTTR OPERATIONAL STABILITY MeasureControlAnalyzeClassify Continuous Improvement Plan Do Check Act Reliability Infrastructure
- 11. Slide 11 Taxonomy “Systematic classification of items into generic groups based on factors possibly common to several of the items” ISO 14224, Petroleum and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
- 12. Slide 12 Hierarchy (1) Business Category (2) Installation/ Business Unit (3) Cost Center/ Op Unit (4) Function (5) System/ Process Line (6) Sub system/Asset/Equipment (7) Component/Maintainable Item (8) Part/ BOM Use/LocationDataEquipmentSubdivision Taxonomy per ISO 14224:2006
- 13. Functional Block Diagram In Feed Assembly Out feed AssemblyFill Table Shaker VFD Drive Unit PLC Rotary Filler – Technical Object Objects
- 14. FMEA to SAP Slide 14 FAILURE MODE (FUNCTIONAL FAILURE) POTENTIAL CAUSE(S) CURRENT CONTROL(S) SEVERITY PROBABILITY DETECTION RISK PRIORITY NUMBER STRATEGY: CM ‐ Corrective (RTF) PM ‐ Time Based CBM ‐ Condition Based MOD ‐ Modification THERMOGRAPHY VIBRATION ANALYSIS ULTRASOUND OIL ANALYSIS MOTOR CIRCUIT ANALYSIS TEMPERATURE READING INSPECTION LUBRICATION SCHEDULED REBUILD SCHEDULED REPLACEMENT ROUTINE CLEANING AMD CLEANING AMD INSPECTION AMD LUBRICATION CSD VALIDATION RUN TO FAILURE DINNER OUT OF POSITION AND OR DOES NOT TRANSFER LUG MISALIGNMENT DAILY PM INSPECTION 3 2 2 12 CBM D CHAIN STRETCH DAILY PM INSPECTION, AUTO LUBE 8 2 1 16 CBM D RAIL MISALIGNMENT DAILY PM INSPECTION 3 2 2 12 CBM D SERVO MOTOR FAILURE 1W PM INSPECTION (VISUAL) 5 4 9 180 CBM 1M 1W PHOTO EYE FAILURE (2) NONE 3 5 7 105 PM 1M DRIVE CHAIN FAILURE 1W PM INSPECTION (VISUAL) 4 2 3 24 CBM 1W DRIVE SPROCKET WORN 1W PM INSPECTION (VISUAL) 4 2 3 24 CBM 1W LUG CHAIN CONTAMINATION (PRODUCT FALLING) NONE 2 5 9 90 MOD DINNER NOT IN 4 X 5 MATRIX RAIL MISALIGNMENT INFORMAL PM DAILY INSPECTION 3 2 4 24 MOD BELT CONTAMINATION NONE 3 8 8 192 MOD SERVO MOTOR FAILURE NONE 5 4 9 180 CM, POSSIBLE MOD BELT DRIVE GEAR(2) FAILURE (ONE PLASTIC, ONE METAL) DAILY PM INSPECTION 4 2 2 16 CBM D BELT TORN OR EXCESSIVELY WORN INFORMAL PM DAILY INSPECTION 3 3 3 27 CBM D Damage Codes Cause Codes Task Codes
- 15. Rotary Filler Catalog Profile Code Component Description In feed Fill Table Out Feed Shaker Drive Unit VFD PLC 1001 Rail Misalignment X X 1002 Failed Bearing X X 1003 Worn Gear X X X X 1004 Air Leak X 1005 Failed Electrical Circuit X X X 1006 Failed Belt X X 1007 Programming Error 1008 Failed Belt X 1009 Failed Chain X 1010 Failed eye X X Cause Code Catalog Code Component Description In feed Fill Table Out Feed Shaker Drive Unit VFD PLC 2001 Process Stopped X X X X X X 2002 Process Slow X X X X X X 2003 Process Fast X X 2004 Over fill X X X X X 2005 Under fill X X Damage Code Catalog Rotary Filler Cause Code Group Rotary Filler Task Code Group Rotary Filler Damage Code Group Maintenance Plan
- 16. Finding: ABC Indicator does provide adequate granularity for equipment criticality Result: Insufficient indicators provide requisite separation of assets for prioritizing the application of corporate resources Recommendation: Develop a criticality business process and RACI to at least Base-10 There are 36 characters available in ABC Indicator which provide considerable granularity but often only 3 are used…. Criticality Analysis Slide 16
- 17. Criticality Analysis • Single point failure • Impact to value stream • Impact to corporate objectives • Replacement asset value • Impact on reputation • Impact on EHS
- 19. RIME Index Slide 19 Work Order Type EquipmentCriticality 10 9 8 7 6 5 4 3 2 1 10 100 90 80 70 60 50 40 30 20 10 9 90 81 72 63 54 45 36 27 18 9 8 80 72 64 56 48 40 32 24 16 8 7 70 63 56 49 42 35 28 21 14 7 6 60 54 48 42 36 30 24 18 12 6 5 50 45 40 35 30 25 20 15 10 5 4 40 36 32 28 24 20 16 12 8 4 3 30 27 24 21 18 15 12 9 6 3 2 20 18 16 14 12 10 8 6 4 2 1 10 9 8 7 6 5 4 3 2 1
- 21. Key Points to Take Home • SAP configuration needs to mature along with your organization • Collaboration between reliability, maintenance, and IT professionals is key • Control strategy performance indicators should depend on work order accuracy • Leverage FMEA for development of technical object catalogs as well as overall control strategy • FMEA and technical object catalogs are living documents and should be updated when appropriate • Criticality needs to be granular enough to support reliability analytics and backlog management • Task, damage, and cause codes are linked to equipment class for ease of replication across the enterprise
- 22. Build or Migrate Database Risk Analysis Failure Mode and Effect Analysis Severity of Failure Likelihood of Occurrence Detectability of Failure Risk Ranking Control Plans Reliability Analysis Asset Module of EAM Continuous Improvement Functional Hierarchy Criticality Analysis Close the Loop
- 23. Produced by:Platinum SponsorPremier Sponsor Chris Zawislak, CMRP ConAgra Foods, Inc. Christopher.Zawislak@conagrafoods.com Mike Poland, CMRP Life Cycle Engineering, Inc. MPoland@LCE.com
- 24. Produced by:Platinum SponsorPremier Sponsor March 27 – 30, 2011 Hyatt Regency Huntington Beach Resort and Spa Huntington Beach, California