Pfizer’s Global Reliability Program (GRP) ISPE Chapter Meeting – November 18 th , 2014
Global Reliability Program Supports 56 Manufacturing Sites Newbridge, Ireland Grange Castle, Ireland Havant, England Little Island, Ireland Puurs, Belgium Ringaskiddy, Ireland Franklin, OH Carlisle, PA Rochester, MI Pearl River, NY Kalamazoo, MI Rouses Point, NY Strangnas, Sweden St. Laurent, Canada Søborg, Denmark Middleton, WI Andover, MA Wuxi, China Brandon, Canada Freiberg, Germany Cluj, Romania Illertissen, Germany Dalian, China Istanbul, Turkey Nagoya, Japan Sanford, NC Catania, Italy Albany, Cairo, Egypt Foothill Ranch, CA GA Suzhou, China (1) Ascoli, Italy Hsinchu, Taiwan Aprilia, Italy Thane, India (1) Toluca, Mexico Tunis, Tunisia Dakar, Senegal Tuas, Singapore (1) Goa, India El Jadida, Morocco Algiers, Algeria Valencia, Venezuela Amboise, France Algete, Spain Guarulhos, Brazil Jakarta, Indonesia Vega Baja, PR Itapevi, Brazil W. Ryde, Australia Perth, Australia Buenos Aires, Argentina Barceloneta, Karachi, Pakistan PR (2) Guayama, PR (1)
Global Reliability Program Site-level Implementation Plan Roadmap Planning Activities Execution Activities (Tools) Training Planning Priority Mgt Work & Scheduling Backlog Mgt Site Maintenance Assessment EAMS / SAPPM Site Maintenance Master Plan Management OT Management Utilization Study Asset or Value Stream Based Planning & Scheduling, with Coaching sessions Training Predictive Maintenance PM Optimization Reliability Maintenance Strategy OEE Optimization Bad Actors (MTBF) Based Calibration Excellence RCFA, FMEA, RRI Maintenance Reliability Engineering Life Cycle Management Reliability Excellence & Reliability Certification, Lean/Operational Excellence 6Sigma - Method 1, Greenbelt, Training MRO Management Service Parts Distribution Vendor Consolidation Models Reliability for Contractors Integrated Suppliers OEM Replacement 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 Performance Tracking Balanced Scorecard, Visual Metrics, Engineering Templates, GRP Implementation Dashboard (Mtce%/Plt Exp, ,PM/CM/ER %, OT) 2006 and Beyond
Pillars of GRP TPM Reliability Based Maintenance Autonomous Maintenance Operator Care Total Productive Maintenance Environmental Health & Safety Plant Partnership Improve Asset Effectiveness GRP TPM Quality Work Management Education & Training Equipment Design & Interface e ag P
Invert the Model Gemba & Andon Approach
Why TPM? 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 6
TPM Pillar Overview Focuses on Increasing Reliability and Reliability Based Maintenance Availability of Equipment by reducing the Breakdown of Machines (Some Focus Areas for Pfizer) 7
Online Monitoring of Equipment Health to Prevent Failures 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 Proven Solution – Path forward : Availability. – – Technology deployed at 10 sites already and Reducing Maintenance Cost. monitoring over 500 assets. – Average Operating cost savings is $2k/asset. – Seven additional Site deployments in the early implementation or planning stage 8
Access to the Data IMP: Intelligent Maintenance Program 2014 Progress Planned 2015 Automsoft • Number of Assets Rapid Catalyst monitored via IMP In Progress* PANS II SQL Aspentech DB IP21 increased by over Live 50% in 2014 • 7 new site Johnson PEPS OEE *Connections Controls BMS integrations for Databases used in multiple progressed site prioritized for replication CMMS • 3 new historian types Monitored Embedded PI connections GE iHistorian Delta V • 5 New Alert Types delivered Siemens SQL Wonder BMS* Ware • Program well placed for further growth in Honeywell OSI PI 2015 with PGS BT & BMS GRP Project Plan
Reliability Analytics Forecast Failures CMMS WO data Project - Advanced Reliability Analytics graphical outputs 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: Strength of Pfizer GRP Reliability Team: – Zero Defects Enabler – Forecasting Failures prevents breakdowns. – Two year effort between Center & Site- – Increase OEE - minimizing equipment based Reliability SMEs. downtime and maintenance costs. – New Process, Tools and Training are making – Forecasts Equipment wear out for better it easier for Pfizer’s Reliability Engineers to capital decisions. 1 get this analysis done. 0
Data Analysis used to Identify the Best Maintenance Strategies Site’s Data Project – Data Analysis Drives Maintenance Optimize- Strategies (Unfiltered) Standardize Data Analysis Brief Description: – Standard process finds the best maintenance strategy for equipment types. – Data analysis on Maintenance Histories Shared to improve each others enables us to harmonize & standardize our Programs strategies. – Process aligns data into usable format: 65+ facilities, 14 languages, 10,000 users Examples: Business Driver: – Calibration Community is Optimizing and Standardizing policies and practices across – Zero Defects Enabler – Expediting learnings the network. across the Network – Equipment reviews improve OEE while – Standardize-Harmonize Reducing Maintenance Costs. – Determine Good Practices and Replicate 1 1
Calibration Lifecycle Areas to Optimize Calibration and Save Rework New and Existing Instruments Set Limits Document Paper or Final Sticker Ranges, Execution Classification Approval Closed Retire Complete Paperless Calibration less ID Loop vs. Process Instrument Dataspy OOT Review by OOF Exception Data Analysis coupled with Scheduling a Risk Based approach Work Instructions Parts has identified layer of Opportunties. Existing Instruments Shifting Calibrations to On- Demand or Extend Frequencies based on System Data. Going Paperless - Saves on Incorporate a Prescreening average 5-10 minutes of a Process on OOT’s for product Mechanics time per work order. impact. We target 90% paperless 12
TPM Pillar Overview Autonomous Maintenance/Operator Care involves operators in maintaining and improving equipment Autonomous Maintenance performance. Operator Care
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 Unprotected Wires Imminent Belt Failures Hydraulic Line Wearing in Contact With Rotating Shaft Electrical Cable In Contact With Rotating Gear 14
‘Up Skilling’ Your Operations Phase 4 World Class Performance TPM all Key lines Phase 3 Basic Concept - Cleaning - Inspections - Tightening Bolts Phase 2 TPM all Key lines - Safety Checks Outstanding Performance Basic Concept Extended Features - Cleaning - Lubrication - Inspections - Minor Repairs Level 1 TPM all Key lines - Tightening Bolts - Safety Checks Problem Solving Basic Concept - Activity Board - Cleaning Extended Features - OEE targets Introduction - Inspections - Lubrication - Kaizen Problem Solving - Tightening Bolts - Minor Repairs Activity Board - Safety Checks Method 1
Example of 5S in Action
Visual Management – Equipment Modifications
TPM Ongoing Journey… OEE evolution 50 45 OEE % 40 35 30 OEE OEE OEE OEE OEE OEE OEE OEE OEE Target 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 OEE 34.2 35.4 38.6 38.3 39.3 39.4 43.4 44.5 45.6 47 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.
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