Efficient Plant October 2017 - 14

feature | reliability & profitability
and area asset sets of the operation.
Accurate Reliability Curves are Key
After real-time reliability risk
is measured, real-time reliability
control becomes possible (See
Fig. 2). This significantly and
positively extends traditional
maintenance management. For
example, if it is likely that a compressor will fail within the next
six hours, i.e., the risk is high, the
real-time reliability controller, in
the form of the process operator
Fig. 1: Accurate reliability curves, coupled with condition and
process measurement, make it possible to precisely measure
(this function could eventually
asset-reliability risk.
be handled by an automatic asset
controller), might immediately respond by slowing compressor
Measurement
rotation, thus extending the reliability time
is the Driver
threshold and avoiding a short-term failure.
This provides time to optimally and more permanently respond to the condition.
The availability of real-time reliability control
will lead to a two-level asset-reliability model
for industrial operations (See Fig. 3). At the
lowest level will be real-time control offering
real-time reliability risk measurement and the
appropriate control response to increase asset
Fig. 2: After real-time reliability risk is
measured, real-time reliability control
reliability. At the upper level will be sophisticatbecomes possible. This significantly
ed asset-reliability-management functions, such
and positively extends traditional
maintenance management.
as prognostics and maintenance planning and
scheduling. Together, this two-tier approach

Control Results
In a Two-Level
Operations Model

Fig. 3: Real-time reliability control
leads to a two-level asset-reliability
model for industrial operations.

14

| EFFICIENTPLANTMAG.COM

Measurement
Leads to Empowerment

Fig. 4: Real-time accounting enables profitability
measurement, leading to an empowered workforce,
through specialized asset analytics software, to
control the real-time operation profitability.

will increase asset reliability, which naturally
leads to more output from every asset in the
operation and increased operational reliability.

OPERATIONAL PROFITABILITY
However, the two-tier approach does not offer
a direct tie to improving safe operational
profitability, which is the ultimate objective. It
is tempting to assume that any increase in asset
reliability directly translates into profitability
improvement, but this might not be the case.
For instance, if the compressor in the above
example is slowed down to extend its time to
failure, the short-term result will be a less profitability because throughput will also be reduced.
Therefore, the best way to ensure that this
new approach has a positive impact is to directly
measure operational profitability factors in real
time, at the asset level. In fact, as with a reliability-control loop, an operational profitability control loop can be developed once the profitability
factors are measured (See Fig. 3).
Using real-time accounting can enable
profitability measurement, which would then
empower the workforce, through specialized
asset analytics software, to control the real-time
operation profitability. Figure 4 illustrates a
functional, not necessarily physical, model. The
line from Operational Profitability Measurement to Operational Profitability Control can
only be deployed when automatic reliability

Reliability Drives Profitability

Fig. 5: Profitability control cascades to reliability
control, enabling implementation in a manner
that drives optimal profitability. Operational
profitability controller output serves as the set
point for the reliability controller.

OCTOBER 2017


http://www.EFFICIENTPLANTMAG.COM

Table of Contents for the Digital Edition of Efficient Plant October 2017

Editorial
Implementations
Profitable Reliability Control On Your Horizon
Experts Provide IIoT Insights
Integrating Automation Into Shade Manufacturing
Fluid-Flow Challenges
Looking For Failure In All The Wrong Places
Closer Human/Robot Collaboration
Note These Causes Of Motor Failure
Reliable Pumping Supplement: Food & Beverage Processing
On The Floor
Uptime
IIoT
Pump 'Cavitation' Might Not Be
Never Too Late For Basic Navigation
Audit or Assess? Understand The Difference
A Perfect Pair: Barcodes and Your CMMS
Lubrication Strategies
Products
Ad Index
Showcase
Efficiency Insight
Efficient Plant October 2017 - 1
Efficient Plant October 2017 - Cover1
Efficient Plant October 2017 - Cover2
Efficient Plant October 2017 - 1
Efficient Plant October 2017 - 2
Efficient Plant October 2017 - 3
Efficient Plant October 2017 - 4
Efficient Plant October 2017 - 5
Efficient Plant October 2017 - 6
Efficient Plant October 2017 - 7
Efficient Plant October 2017 - Editorial
Efficient Plant October 2017 - 9
Efficient Plant October 2017 - Implementations
Efficient Plant October 2017 - 11
Efficient Plant October 2017 - Profitable Reliability Control On Your Horizon
Efficient Plant October 2017 - 13
Efficient Plant October 2017 - 14
Efficient Plant October 2017 - 15
Efficient Plant October 2017 - Experts Provide IIoT Insights
Efficient Plant October 2017 - Integrating Automation Into Shade Manufacturing
Efficient Plant October 2017 - 21
Efficient Plant October 2017 - 22
Efficient Plant October 2017 - 23
Efficient Plant October 2017 - 17
Efficient Plant October 2017 - 18
Efficient Plant October 2017 - 19
Efficient Plant October 2017 - Integrating Automation Into Shade Manufacturing
Efficient Plant October 2017 - 21
Efficient Plant October 2017 - 22
Efficient Plant October 2017 - 23
Efficient Plant October 2017 - 24
Efficient Plant October 2017 - Fluid-Flow Challenges
Efficient Plant October 2017 - 26
Efficient Plant October 2017 - 27
Efficient Plant October 2017 - 28
Efficient Plant October 2017 - Looking For Failure In All The Wrong Places
Efficient Plant October 2017 - 30
Efficient Plant October 2017 - 31
Efficient Plant October 2017 - 32
Efficient Plant October 2017 - 33
Efficient Plant October 2017 - Closer Human/Robot Collaboration
Efficient Plant October 2017 - 35
Efficient Plant October 2017 - Note These Causes Of Motor Failure
Efficient Plant October 2017 - 37
Efficient Plant October 2017 - 38
Efficient Plant October 2017 - Reliable Pumping Supplement: Food & Beverage Processing
Efficient Plant October 2017 - 40
Efficient Plant October 2017 - 41
Efficient Plant October 2017 - 42
Efficient Plant October 2017 - 43
Efficient Plant October 2017 - 44
Efficient Plant October 2017 - 45
Efficient Plant October 2017 - 46
Efficient Plant October 2017 - On The Floor
Efficient Plant October 2017 - 48
Efficient Plant October 2017 - Uptime
Efficient Plant October 2017 - IIoT
Efficient Plant October 2017 - Pump 'Cavitation' Might Not Be
Efficient Plant October 2017 - Never Too Late For Basic Navigation
Efficient Plant October 2017 - Audit or Assess? Understand The Difference
Efficient Plant October 2017 - A Perfect Pair: Barcodes and Your CMMS
Efficient Plant October 2017 - Lubrication Strategies
Efficient Plant October 2017 - 56
Efficient Plant October 2017 - 57
Efficient Plant October 2017 - 58
Efficient Plant October 2017 - 59
Efficient Plant October 2017 - Products
Efficient Plant October 2017 - 61
Efficient Plant October 2017 - Ad Index
Efficient Plant October 2017 - Showcase
Efficient Plant October 2017 - Efficiency Insight
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Efficient Plant October 2017 - Cover4
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