(GRP) ISPE Chapter Meeting November 18 th , 2014 Global Reliability - - PowerPoint PPT Presentation

Pfizer’s Global Reliability Program (GRP)

ISPE Chapter Meeting – November 18th, 2014

Global Reliability Program

Supports 56 Manufacturing Sites

Suzhou, China (1) Buenos Aires, Argentina Algiers, Algeria Dakar, Senegal El Jadida, Morocco Jakarta, Indonesia Perth, Australia Franklin, OH Dalian, China Toluca, Mexico Wuxi, China Tuas, Singapore (1) Ascoli, Italy Kalamazoo, MI Aprilia, Italy Hsinchu, Taiwan (1) Goa, India Karachi, Pakistan (2) Andover, MA Sanford, NC

• St. Laurent, Canada

Brandon, Canada Albany, GA Itapevi, Brazil Algete, Spain Valencia, Venezuela Cairo, Egypt Istanbul, Turkey Strangnas, Sweden Freiberg, Germany Puurs, Belgium Catania, Italy Havant, England Middleton, WI Rochester, MI Ringaskiddy, Ireland Newbridge, Ireland Grange Castle, Ireland Vega Baja, PR Nagoya, Japan Barceloneta, PR Guayama, PR (1) Cluj, Romania Foothill Ranch, CA Carlisle, PA Tunis, Tunisia Søborg, Denmark Rouses Point, NY Pearl River, NY Thane, India

• W. Ryde, Australia

Amboise, France Illertissen, Germany Little Island, Ireland Guarulhos, Brazil

Parts Distribution Reliability for Contractors Predictive Maintenance OEE Optimization Calibration Excellence Life Cycle Management Priority Mgt Backlog Mgt OT Management

Global Reliability Program Site-level Implementation Plan Roadmap

Training Training Training

Work Management Reliability Based Maintenance Service Models Planning & Scheduling EAMS / SAPPM Utilization Study PM Optimization Bad Actors (MTBF) RCFA, FMEA, RRI Reliability Engineering MRO Management Vendor Consolidation Integrated Suppliers OEM Replacement

Site Maintenance Master Plan Site Maintenance Assessment

Performance Tracking Balanced Scorecard, Visual Metrics, Engineering Templates, GRP Implementation Dashboard (Mtce%/Plt Exp, ,PM/CM/ER %, OT)

Planning Activities Execution Activities (Tools)

Planning & Scheduling, with Coaching sessions Reliability Excellence & Reliability Certification, Lean/Operational Excellence 6Sigma - Method 1, Greenbelt,

2006 and Beyond

Asset or Value Stream Based Maintenance Strategy Maintenance Strategy – Maintenance as a Business Assessment completed, EMU CT completed, ROI Analysis Performed, Maintenance Master Plan, PM analysis completed, Schedule Compliance Tracked, Bad Actors (MTBF/MTTR*)Rates Tracked/Trended, Labor Productivity Tracked

Pillars of GRP TPM

P ag e

GRP TPM

Environmental Health & Safety Plant Partnership

Reliability Based Maintenance Autonomous Maintenance Operator Care Improve Asset Effectiveness Work Management Education & Training Equipment Design & Interface

Quality

Total Productive Maintenance

Invert the Model

Gemba & Andon Approach

Why TPM?

6

Pfizer’s Early Adopters of Operator Care Have Achieved:

• Reduction in Manufacturing Investigations – Identify it before it’s a problem.
• Increase in Run Time Efficiency of 40%
• 50% Reduction of PM Down Time (1 More Production Shift per Month)
• Improved OEE as part of Lean Programs

Equipment Design and Life Cycle Cost:

• New Packaging Line STARTED at 80% Efficiency
• $3 Million Reduction in Capital Cost
• $2 Million Reduction in Annual Cost of Goods

Planned Maintenance & Work Management:

• PM Down Time Reduction of 35%-50% is Common
• Reduced Work Order Completion time by 75%
• Create Maintenance Capacity

Focuses on Increasing Reliability and Availability of Equipment by reducing the Breakdown of Machines

(Some Focus Areas for Pfizer)

7

Reliability Based Maintenance

TPM Pillar Overview

8

Project - Intelligent Maintenance Program Brief Description – Real time asset health data is used to proactively schedule maintenance interventions and reduces breakdowns. Business Driver – Zero Defects Enabler - Early signs of trouble prevents breakdowns. – Improve Operating Efficiency & Equipment Availability. – Reducing Maintenance Cost. Proven Solution – Path forward: – Technology deployed at 10 sites already and monitoring over 500 assets. – Average Operating cost savings is $2k/asset. – Seven additional Site deployments in the early implementation or planning stage

Online Monitoring of Equipment Health to Prevent Failures

Access to the Data

Planned 2015 In Progress* Live

CMMS Monitored Automsoft Rapid Catalyst Aspentech IP21 Johnson Controls BMS GE iHistorian SQL Wonder Ware OSI PI Honeywell BMS Siemens BMS* Embedded PI Delta V PEPS OEE PANS II SQL DB

2014 Progress

• Number of Assets

monitored via IMP increased by over 50% in 2014

• 7 new site

integrations progressed

• 3 new historian types

connections

• 5 New Alert Types

delivered

• Program well placed

for further growth in 2015 with PGS BT & GRP Project Plan

*Connections for Databases used in multiple site prioritized for replication

IMP: Intelligent Maintenance Program

1

Project - Advanced Reliability Analytics Brief Description: – Reliability Engineers analysis asset health and performance. – Trending Equipment failures to Forecasting Future failures. – Data analytics perform industry-standard statistical analysis: Weibull & Crow-AMSAA Business Driver: – Zero Defects Enabler – Forecasting Failures prevents breakdowns. – Increase OEE - minimizing equipment downtime and maintenance costs. – Forecasts Equipment wear out for better capital decisions. Strength of Pfizer GRP Reliability Team: – Two year effort between Center & Site- based Reliability SMEs. – New Process, Tools and Training are making it easier for Pfizer’s Reliability Engineers to get this analysis done.

Reliability Analytics Forecast Failures

CMMS WO data  graphical outputs

1 1

Project – Data Analysis Drives Maintenance Strategies Brief Description: – Standard process finds the best maintenance strategy for equipment types. – Data analysis on Maintenance Histories enables us to harmonize & standardize our strategies. – Process aligns data into usable format: 65+ facilities, 14 languages, 10,000 users Business Driver: – Zero Defects Enabler – Expediting learnings across the Network – Standardize-Harmonize – Determine Good Practices and Replicate Examples: – Calibration Community is Optimizing and Standardizing policies and practices across the network. – Equipment reviews improve OEE while Reducing Maintenance Costs.

Data Analysis used to Identify the Best Maintenance Strategies

Optimize- Standardize

Data Analysis

Site’s Data (Unfiltered)

Shared to improve each others Programs

Classification

Calibration Lifecycle

12

Set Limits Ranges, ID Loop vs. Instrument Document Approval Process Paper or Paperless Execution Sticker less Complete Closed Final Calibration Retire New and Existing Instruments OOT OOF Dataspy Review by Exception Existing Instruments Rework

Areas to Optimize Calibration and Save

Scheduling Work Instructions Parts

Going Paperless - Saves on average 5-10 minutes of a Mechanics time per work order. We target 90% paperless

Data Analysis coupled with a Risk Based approach has identified layer of Opportunties.

Shifting Calibrations to On- Demand or Extend Frequencies based on System Data. Incorporate a Prescreening Process on OOT’s for product impact.

Autonomous Maintenance Operator Care

Autonomous Maintenance/Operator Care involves

• perators in maintaining and improving equipment

performance.

TPM Pillar Overview

Operator Care: Cleaning and Inspection

• Clean Equipment and Work Areas to “Like New” Condition
• Perform Detailed Inspections to Identify and Correct all Equipment Problems
• Create Inspection Tasks or Design Out the Failure Modes

14

Imminent Belt Failures Unprotected Wires

Hydraulic Line Wearing in Contact With Rotating Shaft

Electrical Cable In Contact With Rotating Gear

‘Up Skilling’ Your Operations

World Class Performance Introduction Problem Solving Activity Board Method 1 TPM all Key lines Basic Concept

• Cleaning
• Inspections
• Tightening Bolts
• Safety Checks

Outstanding Performance TPM all Key lines Basic Concept

• Cleaning
• Inspections
• Tightening Bolts
• Safety Checks

Extended Features

• Lubrication
• Minor Repairs

Level 1 Phase 2 Phase 3 Phase 4

TPM all Key lines Basic Concept

• Cleaning
• Inspections
• Tightening Bolts
• Safety Checks

Extended Features

• Lubrication
• Minor Repairs

Problem Solving

• Activity Board
• OEE targets
• Kaizen

Example of 5S in Action

Visual Management – Equipment Modifications

TPM Ongoing Journey…

30 35 40 45 50 OEE % OEE 2004 OEE 2005 OEE 2006 OEE 2007 OEE 2008 OEE 2009 OEE 2010 OEE 2011 OEE 2012 Target 2013 OEE 34.2 35.4 38.6 38.3 39.3 39.4 43.4 44.5 45.6 47

OEE evolution Reduction in Manufacturing Investigation – Faster Resolution Number of Break Down (BD)from 2/100 hours  .6/100 hours of Operation OEE increase from 34%  46% PM downtime reduction of 30% Maintenance budget reduced 5%/yr since 2007.

19