Efficient Plant October 2017 - 15

feature | reliability & profitability
Plant-maintenance personnel can determine their activities from the profitability and reliability risk
information and adjust their actions and responses accordingly. Photo courtesy Schneider Electric

control is a reality. Since the technology isn't
quite there yet, in the current state, as with
real-time manual-reliability control, the
operator becomes a real-time profitability
controller. However, as technology advances,
reliability and profitability control could
happen separately and automatically.
How does real-time operational profitability control tie to real-time reliability control,
i.e., how does increased reliability drive
operational profitability? From a controltheory perspective, profitability control
would cascade to reliability control (See Fig.
5). This enables reliability control to be implemented in a manner that drives optimal
profitability. The output of the operational
profitability controller serves as the set point
for the reliability controller.
Since both of these real-time control
domains are in their infancy, it might be
best to think about how process control
was accomplished early in the Industrial
Revolution, when relatively little experience
with real-time control existed. At that time,
process operators performed the control
functions manually. Gauges provided the
data they needed to implement real-time
process measurement, which empowered
them to effectively control the processes.
In like manner, empowering today's
industrial workforce with real-time operational profitability data, along with process
control and real-time reliability risk information, will turn them into operation- and
business-performance managers. Operators
will be able to adjust set points and see
the impact they and their adjustments are
having, not only on the process, but on the
profitability and reliability of the assets. They
can then apply this feedback to make operating and business decisions that maximize
profitability without significantly increasing
reliability risk.

OCTOBER 2017

Likewise, plant-maintenance personnel
can determine their maintenance activities
from the profitability and reliability risk
information provided by the control system,
and adjust their actions and responses accordingly. Since operations and maintenance
personnel work from the common objective
of improving operational profitability, they
will work much more collaboratively.
For example, in a gas operation, in which
the real-time profitability metrics were in
place and operating, the maintenance and
operations teams started planning maintenance schedules together, focusing on
contracts that included financial penalties
for not meeting terms and commitments
on time. Because they were able to keep the
operations and assets up and running long
enough to meet the contracts, the teams
helped increase operational profitability for
the business.
We can, therefore, see that a profitable
reliability approach that combines real-time
reliability risk control, real-time operational profitability control, and higher-level
reliability management, will go a long way
toward helping industrial manufacturers
meet their short- and long-term operating
and business objectives. Profitable reliability
control is the next evolution of maintenance-technology solutions. The result will
be greater levels of reliable, safe, operational
profitability. EP
Peter Martin, Ph.D., is a recognized leader
and innovator in automation and control. He
has been a practitioner in the field for almost
40 years, authored and coauthored numerous
publications, holds or has pending multiple
patents in the areas of real-time business measurement and control, and was recognized by
Fortune magazine as a Hero of U.S. Manufacturing. Martin is also a recipient of ISA's Life
Achievement Award.

DEFINING MAINTENANCE
Maintenance can be defined at
four distinct levels. The goal is to
move away from the reactive level
and embrace the prescriptive
level:
 Prescriptive maintenance:
Analytics indicate that a piece
of equipment is headed for
trouble and can prescribe
prioritized, pre-determined,
expert-driven mitigation or
repair.
 Predictive maintenance:
Tools and techniques
determine the condition of inservice equipment and predict
when maintenance should be
performed.
 Preventive maintenance:
Regular maintenance
is performed while the
equipment is operating so
that it does not break down
unexpectedly. This approach
also lessens the likelihood of
failure.
 Reactive maintenance:
Repairs are implemented when
equipment fails with a focus on
restoring the equipment to its
normal operating condition.

Interview with Peter Martin
Hear Peter Martin talk more
about reliability and profitability
in manufacturing in an Efficient
Plant podcast at efficientplantmag.
com/1710schneider.

EFFICIENTPLANTMAG.COM |

15


https://www.efficientplantmag.com/2017/10/profitable-reliability-control-horizon/ 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
Efficient Plant October 2017 - Cover3
Efficient Plant October 2017 - Cover4
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