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1 기업의생산성향상과운영효율화를위한 Proactive 한설비자산관리방안 PLM Solution RoadShow IBM Corporation
2 목차 I Proactive 한설비자산관리방안 II PLM 과 ALM(Asset Life Cycle Management) III IBM Maximo Asset Management 소개 2
3 시작하기전 결과는가장취약한부분에의해서결정된다 비젼과목표의중요성 3% 10% 87% 자산생애관리에대한비용 운영비용 ( 인력, 시설, 유틸리티, 에너지 ) 훈련비용 ( 운전자 & 정비원 ) 정비비용 소프트웨어비용 ( 운영, 유지정비 ) 시험 & 지원설비비용폐기처리비용 제품공급비용 ( 운송, 취급 ) 지원비용 ( 예비품, 재고, 소재지원 ) 운영비용 ( 인력, 시설, 유틸리티, 에너지 ) 훈련비용 ( 운전자 & 정비원 ) 정비비용 소프트웨어비용 ( 운영, 유지정비 ) 시험 & 지원설비비용폐기처리비용 제품공급비용 ( 운송, 취급 ) 지원비용 ( 예비품, 재고, 소재지원 ) 3
4 설비형태의변화 기업은생산설비, 차량, 시설등을보유하며, 설비는복잡해지고 IT 와의융합을통한개발이이루어지고있습니다. Asset Management 연결된운영자산 설비 / 장비 시설 IT가자산의성능을향상시킴 원격모니터링을위해서네트웤에의해서연결되어있음 유지관리자동화를위해서네트웤에연결되어있음 Change Management IT Configuration Management 임베디드 IT 내장된 IT가자산을복잡하게함 복잡하고자동화된역활 기계장치가복잡한전기장치로대체되는경향 운송 4
5 설비관리의목적 사람 (Man) - (Have Time, Lower Load) 비용 (Cost) Low Cost, High Profit 수명 (Life Cycle) - (Long Life) 고장 (Failure) - (No Failure) 5
6 비용적인측면을고려한설비관리 Annual Cost ($) 최소의설비관리비용 종합설비관리비용 최소수준의예방보전 예방보전비용 Degree of Preventive Maintenance 사후보전비용 6
7 고장율 Proactive Maintenance 를위한방안 설비의안정적인운영과고장율을최소화하기위해서는설비개선을통하여근본적인고장을감소시켜나가는방법인신뢰성보전중심 (Reliability-Centered Maintenance) 및선행보전 (Proactive Maintenance) 을목표로하여야합니다. 선행보전 (Proactive Maintenance) 예지보전 (Predictive Maintenance) 고장보전 (Breakdown Maintenance) Proactive Maintence Target 초기고장 점검 진동 / 소음 유분석 과열 연기 고장 No Failure, Long Life 운전시간 7
8 설비보전방식 보전활동 보전활동은크게계획보전과비계획사후보전이있으며경제성을바탕으로계획보전의비중을증가시켜야함 Failure Probability 계획보전 Planned Maintenance 예방보전 PM(Preventive Maintenance) Failure Pattern with Condition-Based Maintenance 개량보전고장발생시점진동소음열 / 화재 Condition 예지보전 (Predictive Maintenance) Time P-F 시간비계획사후보전 EM(Emergency Maintenance) BM(Breakdown Maintenance) P-Cost < F-Cost P-Cost : Preventive Cost F-Cost : Failure Cost (The Potential Failure Curve) CM (Corrective Maintenance) 계획사후보전 STOP PBM(Planned Breakdown Maintenance) P-Cost > F-Cost Time Potential Failure( 잠재적고장 ) 란현재기능고장이일어나고있는지또는일어날것인지를확인가능한상태이다. 정기보전 (Time Based Maintenance) 자산관리정기보전점검 Failure Probability TBM(Time Based Maintenance) 예지보전 수 교 PdM(Predictive Maintenance) CBM(Condition Based Maintenance) 진 리 체 단 이력 분석 Time Trend Failure Pattern with Time-Based Maintenance Number of Forced Outages Post-Maintenance Failures 2,000문제원인 1,500 개선 1, FMEA < 1 wk 보전예방 MP (Maintenance Prevention) Note PM (Preventive Maintenance) : 정기적인Time 정비, Following 교체, 점검, 진단및감시등의계획적인보전활동 Planned Shutdown BM (Breakdown Maintenance) : 고장수리등의비계획적이며돌발적인보전활동 CBM (Condition Based Maintenance) : 장비의조건에따라실행하는보전활동 TBM (Time Based Maintenance) : 시간기준으로하여정기적으로실행하는보전활동 1-2 wk 2-3 wk 3-4 wk 1-2 mo 2-3 mo > 3mo Thermal Power Plants 8
9 Conditon Based Maintenance Condition Based Maintenance (CBM) 선행보전 (Proactive) 전략 예지보전 (PdM) 고장의근원 개선의대상 고장의전조와손상 Balancing/Alignment 오염모니터링 / Viscosity/ 이력분석 / 개조 기술 마모분석, 진동분석, 열화상분석, 모터의전류치분석 기계의수명연장 결과 고장의조기발견 9
10 진단기법 Technology Failure Mode Equipment 진동 불평형, 정렬불량, 베어링결함, 기어결함, 유동 회전설비, 왕복동설비, 윤활 / 마멸입자분석 윤활불량, 비정상마멸 회전설비, 기계요소 설비진단기술 열화상 (IRT) 전기신호분석 (ESA) 접촉불량, 비정상마찰, 침식, 누수, Crack, 전동기절연파괴, 단락, 편심, 베어링결함,. 전기부품, 기계요소, 빌딩, 구조물등 전동기 음향방출 (AE) Stress Crack 압력용기, 배관류, 구조물등 기타 * Leak, Crack, Partial Discharge, 용접불량등 다양함 ** * Power Quality Analysis, Partial Discharge, Corona Detection, Gas Detection,.. ** Hydraulic pump, Air/steam/vacuum system, Power distribution, Electrical switchgear and Overhead transmission, Bearing 10
11 설비보전방식 > 전통적인설비고장의패러다임 고장발생가능성 Life A small number of random failures 대부분의설비는동일한시점에마모로인한고장발행 Age 위의관점을기준으로정기적인오버홀과분해수리작업이수행되었음 11
12 설비보전방식 > 설비고장의패러다임변화 1960s 부터 1970s 까지항공부분의연구에의하면다양한형태의고장메커니즘을보여주고있음 Age related 11% A B 4% 2% 패턴 A: The Bathtub Curve High infant mortality, then a low level of random failure, then a wear out zone. 패턴 B: The Traditional View A low level of random failure, then a wear out zone. C 5% 패턴 C: A steady increase in the probability of failure but with no identifiable wear out age. Not age related 89% D E 7% 14% 패턴 D: 설치시점급속하게고장이증가하고일정한고장발행됨 패턴 E: Random Failure 사용기간에대한영향도가거의없음 F 68% 패턴 F: The Reversed J curve 초기고장이매우높은형태로복잡한전기전자설비가여기에속함 Source: Report on Reliability Centred Maintenance, Nowlan & Heap, US DoD
13 설비보전방식 > FMEA 의의한설비관리전술도출 설비별 FMEA 수행 6.X-axis Clamping Lubrication Moving 3.Cross Rail Clamping Lubrication Moving Static 4.PLC Display Unit #5 Unit #4 Unit #3 Unit #2 Unit #1 설비별정비업무추출 Head Cross Rail CNC PLC Table Chip Conveyor Static 7.Z-axis Balancing Clamping Lubrication Moving Static 공작물 5.Table Clamping Gear Change Indexing Lubrication Moving 1. 일반 Chip Conveyor Coolant( 절삭유 ) Lifting Hydraulic 설비기능분석 2.CNC Display Accessory I/O Drive No. : : : Syste m X-axis Table : 고장모드 : : : : : : 고장영향및고장모드결정 고장모드별위험도분석 Task FMEA 이력 Data 주요고장모드별정비 Task 도출 자주보전영역도출 계획보전영역도출 대상설비선정 설비관리정보 Data ( 고장이력 ) Data ( 재무 ) 설비별고장이력분석 설비내부품단위별 MTBF 산출 설비이력 DB 활용 Process ( 설비별 FMEA) 13
14 설비보전방식 > 선행보전 (Proactive) 을위한방안 자산 컴포넌트 고장 장애유형 (AC Motor Sample) AC Motor Rotor Cracked/Worn Rotor Mechanical Looseness Unbalance Unbalance Broken/Cracked Rotor Bars Rotor Bar Pass Freq. Stator Loose Stator Harmonics of Line Freq. Eccentric Stator Eccentric Stator Bearing Excessive Friction Bearing Damage Lack of Lubrication 14
15 예지정비프로세스구축 설비관리시스템과설비모니터링시스템의통합을통해예방 / 예측정비의최적화전략을수립, 실행하는 Process 를가져가야하며, 또한설비유형별특성에알맞은정비전략을수립하고, 효율적인정비전략을통한설비활용극대화를지원함. Upper Action [ CBM WO 생성 ] WO 자동생성 [ 관찰기준 WO 생성 ] 입력문자값을이용하여작업오더생성 측정데이터 진동 데이터유형관리 측정점측정점1 측정점그룹 Motor 설비정보 위치 L1 Spec Upper Warning Lower Warning Warning 값 Spec Upper Action WO 생성 온도 게이지형 측정점2 측정점3 PUMP 위치 L2 Lower Action Time 정상 Time 윤활 증가형 측정점4 측정점5 설비 L1 Meter 값 Gauge 온도, 압력, 진동 Characteristic 높음, 낮음, 오일색상 점검 설비상태 (PLC) 텍스트형 측정점6.. 설비 L2 설비 / 시설 Factory floor Equipment A Equipment B 작업이력 사진 도면 / 참고자료 이력데이터 문서 / 이미지 작업이력 예방작업 공장이력 진단이력 15
16 선행 (Proactive) 한설비관리를위한시스템통합 설비의운영을관리하는 MES 와설비의상태를모니터링하는 CMS 그리고 PLM 을통합하여모든설비관련정보를통합설비정보관리시스템에서관리하여설비의상태를논리적으로확인하여자동으로작업오더를발행하도록합니다. ERP PLM 구매 / 자재관리고정자산관리 인사관리 자산정보 인원정보 ( 사원 ) 자재입출고 구매요청 엔지니어링정보 중요대상설비선정 고장유형예측 (Damage Mechanism) 통합설비정보관리시스템 Monitoring 방안정립 설비정보관리 작업오더관리 자재관리구매관리 외주관리 작업표준관리 안전표준관리지표및분석관리 PM Master Update ( 작업 / 점검항목, 주기 ) N On-line 화가능 Y CBM 기준 설비운영데이터 TBM 기준 계약관리 시스템관리진동, 온도데이터 Procedure, BOM 보완 예방보전 고장판단 logic 구성 설비상태관리 (W/O, Alarm) MES/SCADA/DCS 고장 CMS 설비 *CMS : Condition Monitoring System 16
17 목차 I 자산관리개요 II PLM 과 ALM(Asset Life Cycle Management) III IBM Maximo Asset Management 소개 17
18 PLM/ALM(Asset Life Cycle Management) 이란? PLM 과 ALM 의협업을이용한자산의전생애를관리합니다. 자산구축 2-5 years Engineering / Development years Operations / Management Requiremt Specif. Initial Design Detailed Engineering Construction & Start-up Operations &Maint.Mgt Upgrade project Operations &Maint.Mgt Revamping Operations project &Maint.Mgt Retirement Maximo Life cycle of the asset 설비투자프로젝트관리 설비개조프로젝트 자산관리 18
19 MRO and PLM PLM and PDM systems manage engineering data relating to Parts, Structures, Documents, Engineering Changes etc from a design and manufacture perspective. Design World (design BoM) Product A Part x Part y Part z There is not a lot of collaboration between the two worlds MRO systems manage performance, historical and operational data relating to in service parts Service World(As-Is Bom) ASSET 1 Part x Serial 1 Part y Serial 1 Part z Serial 1 Service World (Asset History) Part x Serial 1 Event 1 Event 2 Event 3 19
20 Aerospace Example - Day in the Life Scenario 항공에서고장보고 설비관리관리자가고장조치를위해보전작업자할당 보전작업자가문제해결을위한 Part 교체및수리 Shop 수리및고장의원인파악 개조작업 근본적인개조를위한스케줄링 향후고장의재발을방지하기위한개조안생성 가용성향상 비용절감 20
21 Aerospace Example - Day in the Life Scenario Sent to Maximo Entered into Maximo Created in Delmia Service Bulletin Life Cycle All Affected Assets are Identified and Scheduled for Work Install / Remove Processes Performed Work Completed Notification Sent To Delmia 21
22 OEM Service-after Sales Cycle Basic Tomorrow Manufacturer Systems or large equipment (OEM) Parts Basic MRO Services Service Supplier MRO Service Owner Operator Manufacturer Systems or Large Equipment (OEM) Service Supplier MRO Embedded Services Muli Plant & Fleet Owner Operator Local MRO MRO Parts Systems Integrators & Large Equipment Suppliers Parts Parts Service Parts Systems Integrators & Large Equipment Suppliers Parts & Sub-Systems 22
23 목차 I 자산관리개요 II PLM 과 ALM(Asset Life Cycle Management) III IBM Maximo Asset Management 소개 23
24 IBM Maximo 솔루션소개 > IBM Maximo 모듈구성도 자산관리작업관리자재관리구매관리계약관리 자원관리 위치관리자산관리고장코드관리컨디션모니터링측정점관리측정점그룹관리 작업오더관리신속보고작업자보고할당관리자액티비티 & 태스크서비스요청작업계획예방작업마스터 PM 경로안전계획안전위험요소안전주의사항안전절차및표지 재고관리품목마스터창고출고 & 이동컨디션코드관리재고도구도구서비스항목 구매요청구매오더견적요청입고송장조건및컨디션데스크탑요청회사회사마스터 구매계약보증계약리스 / 렌탈게약작업자비용계약마스터계약조건및컨디션 인원인원그룹직종작업자자격 Workflow Event Driven, Context-based / Escalation Manager KPIs / Reporting / Analysis Security / Administration / Configuration / Integration Service Oriented Architecture Platform 24
25 IBM Maximo 프로세스 The Business: (Missions, Goals, Customers, Users) Business Drivers Risks Regulations Performance HSE Market Primavera Mobile Work Service Request ERP Reporting and Governance Procurement PR s, PO s RFQ s Invoices Receipts Materials Mgmt Contract Mgmt Safety Work Mgmt Incident Investigation Improvement Change Cost Resource Management Planning & Scheduling Operations Management Inventory Inspections Tools Storerooms Conditions Production Assets Leases Warranties Purchase Labour Qualifications Hazards Precautions Plans RCFA Authorization Work Orders Activities Job Plans Priority Matrix Facility Assets Work Log Solutions Templates Communications Defects Incidents Global Issue Failure Reporting Escalations Investigations Job Plans AAR Documents Benefits Regulations Losses SLAs Actions Transportation Assets Drilling Assets Completion Assets Pipeline Assets Oil & Gas Asset Management Standards ISO14224/API 689 Preventive Maintenance Projects Improvements MOC IT Assets Action Assets Locations Relationships Item Master Systems Integration Real Time Engineering MS Project GIS 25
26 IBM Maximo 솔루션소개 > IBM Maximo 설비관리업무프로세스 개선작업 보전자재재고관리 구매요청 보전자재구매관리 견적요청 구매입고송장 혁신활동 분석 서비스요청 설비수리 자산이동 점검기준 고장조치 공사관리 점검작업 작업지시관리 (TBM, CBM, BM, CM 등 ) 작업파악작업계획스케줄링할당실행분석 이력관리 실행 계획수립 효과분석 항목도출 예방보전기준 예지보전기준 정기작업 (TBM) 예지작업 (CBM) 위치 자산 작업계획 안전계획 계약관리 외주용역단가 26
27 IBM Maximo Solutions General Solutions Maximo Asset Asset Management Asset AssetManagement for for IT IT Industry Solutions Utilities Utilities Life Life Sciences Nuclear Power Power Transportation Government Oil Oil & Gas Gas Add-On Solutions Linear Linear Assets Assets Change & Corrective Action Action Mgr Mgr Spatial Spatial Service Service Provider Calibration Asset Asset Configuration Manager SLA SLA Manager Asset Asset Navigator Options Mobile Mobile Work Work Manager SAP SAP ERP ERP Adapter Adapter for for MS MS Project Project * * Generic Generic Enterprise Enterprise Adapter Adapter Mobile Mobile Inventory Manager Oracle Oracle ERP ERP Adapter Adapter for for Primavera Compliance Compliance Assistance Assistance * Included with MAM 7.1 Documentation Documentation 27
28 IBM Maximo 의가치 IBM 의강점 컨설팅 / 솔루션 / 개발 / 하드웨어등기업의전영역에걸쳐고객사의동반자로서의 IBM 자산및시설관리에대한전세계약 700여명의전문가보유 국내의글로벌수준의삼성전자 / 현대자동차등의자산관리시스템구현경험 기능우수성 40 년간의자산및시설관리분야의전문솔루션임 유연성이우수하며, Coding 없이사용자화면을 Application Designer를이용하여변경및생성할수있음 보전작업자중심의편의성을최대한고려한시스템 장비의도입부터폐기까지라이프사이클관리 시설및장비의신뢰성을극대화하고관리비용을최소화할수있는있도록지원 다양한구축사례 13 of the 13 largest PHARMACEUTICALS companies in the world are using Maximo 6 of the 6 largest AUTOMOTIVE companies in the world are using Maximo 8 of the 10 largest OIL & GAS companies in the world are using Maximo 7 of the 9 largest AEROSPACE & DEFENSE companies in the world are using Maximo 6 of the 9 largest COMPUTERS & OFFICE EQUIPMENT companies in the world are using Maximo 7 of the 12 largest ENERGY companies in the world are using Maximo 11 of the 15 US Federal Cabinet Agencies are using Maximo 시스템들에대한미래비전제시 프로세스칩시스템인프라 28
29 감사합니다. 29
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