2 Hach Integrated Information Management Waste Water, Drinking Water, Industrial Applications PerformancePrice/Operations & Business InformationOperations ControlMaintenance InformationLaboratory Sample InformationHach Water InformationManagement SolutionTMHach WIMSTMRange of productsEnterprise,Professional,Deluxe,Standard,Single UserComputerizedMaintenanceManagement SystemsInventory and AssetExamples:Maximo, Hansen,DataforumLaboratory InformationManagement SystemsDesigned for commercialand highly centralizedlaboratoriesExamples:ATL, TribalSupervisory Control and Data Acquisition(SCADA)Hach LAB CalTMSample Schedulingand Tracking SolutionAffordable, Effective,Lab Data Managementdesigned for samplescheduling workflowin water utility labs*requires WIMSOnDemand SaaSHach JOB Cal® BasicHach JOB Cal® PlusMaintenance Schedulingand Tracking SolutionEasy to set up..Easy to learn..Easy to useExamples:GE iFix (built-in interface) Wonderware, Foxboro, RockwellData from automated & manual sources in a central, secure repository providingeasy regulatory & ad hoc reporting, analysis & monitoringWIMSSCADACMMSLIMSHach solutions
3 Why Have a Maintenance Strategy Helps to manage your timePlan when you do jobsKeep a record of what you doStay organizedImproved system reliabilityHelps you save money!Reduce down time (fix before it breaks)Meet regulatory complianceBetter inventory managementIncrease the residual value of your equipmentHaving a maintenance strategy, whether computerized or not, will help to save money and time by providing consistency and generally assuring that things stay under control. At minimum help with managing warranties – to prove you have done your part. Meeting regulatory compliance is in helping you save money as a worst case scenario – it can help you avoid fines by providing audit information on required equipment maintenance.
4 Maintenance System Options Manage maintenance department manuallyAutomate the management of the maintenance departmentAutomate Asset Management and MaintenanceThere are a wide range of options. There are many factors that help to determine what will work best for you. Certainly the size of your facility, the amount of equipment that needs to be maintained, the liability that you would incur should something fail, the impact of unscheduled downtime, the impact of the loss of a piece of equipment without spares to backup strategies. The need for ease of use, IT strategies, and inventory levels, maintenance and business information required can all play a determining factor.Many solutions exist over the entire range and careful consideration is required to find the solution that fits. At the end of the day – any tool is only helpful if it is used.
5 Manual Method Pro: Con: Uses spreadsheets, 3x5 cards, paper calendars tomanage the maintenance schedulePro:Very easy to implementInexpensiveCon:Reduces likelihood of implementing a rigorous maintenance schedulePotential unscheduled down time increases costsPaper work to manage – file, track, lose?Summary reports are very difficult to doDo Job 1Go to site 3This can be a very viable solution if thought and care are incorporated into the maintenance strategy. A little discipline and sticking to a defined process can go a long way to having a workable solution. Summary reports would require a big effort to go through all of your records to pull all of the information together – the likelihood that it will be done is slim.
6 Some Potential CMMS ROIs* CMMS users gain productivity: ~28%Inventory reduction: ~18%Downtime reduction: ~20%Maintenance labor reduction: ~ 10% to 40%Energy cost savings: 5% to 10%Project Management efficiency increase: ~5%Increase equipment value for resale: ~10% to 20%*various studiesWhile some ROIs come along with a well thought out and implemented manual strategy, most experts will say that the ROIS will increase when you add some level of automation into the mix. Primarily because of the likelihood of having a more robust strategy with a higher likelihood of follow through.Avoid failures, may be able to eliminate some inventory, revise maintenance schedules (example?), get PM baselines, defend lawsuits (safety, upsets, etc)
7 Asset & Maintenance Management A computer program with a wide range of capabilities for an organization’s maintenance operations.Pro:A comprehensive tool with lots of featuresIdeal for finance and asset managersCon:Over 60% of implementations fail!Typically require big changesCostly ~ 50K+ to $4.5MComplex systems: garbage in – garbage outJumping to the other end of the spectrum, I’d like to talk about the high end of CMMS. These fully featured solutions bring a lot to the table. Most combine the scheduling and maintenance activities with asset management activities. Asset management entails the management of the physical components from acquisition through disposal. Common business practices include request and approval process, procurement management, life cycle management, redeployment and disposal management. A key component is capturing the financial information about the hardware life cycle which aids the organization in making business decisions based on meaningful and measurable financial objectives. This adds a complete other dimension to any solution increasing the complexityTampa Florida had a big, complex installation that wound up costing over 4M
8 Example: DATASTREAMHere is a typical screen from Datastream, the largest company in maintenance software. It has a lot of fields and many fields have linked tables. The advantage to this approach is the ability to do powerful queries which lends itself to complex reporting functions. This is probably overkill for the person who just wants to see what needs to be done and maintain some basic information about the operation.
9 Automate the Maintenance Department A computerized maintenance management program for maintenance operationsPro:Simplicity of features focused on the maintenance departmentEasy to setup, learn and useCon:Not well suited for large organizations with complex needsLess is more! In many cases, all that is needed is the ability to get the job done. Complicated systems just get in the way.
10 Features of an Automated Solution Designed for maintenance peopleEasy, cost effective maintenance scheduling solutionEasy to use calendarTracks details that matter to maintenanceProvides instructions, equipment drawings and pictures.Stays with a familiar format and simple processProvides maintenance and business informationWork order basicsInventory, vendors and purchasingWho did the work and how long did it take
11 It Should Work the Way You Do! You put your jobs on a calendar.You check them off when they are done.You record the work in the equipment card file...At the end of the day it has to work for you. Does anyone here remember preventative maintenance before computers? There was a calendar on the wall with the major overhauls and PM’s... And a big crayon to cross them out when they were done. In a really good shop, they had an index card for each piece of equipment with a place for the date and to write down what was done. A computerized system should be that simple while providing an underlying capability to enhance your efficiencyIf done well – it worked in certain situations.
12 Interactive, Color-coded Calendar A simple calendar easily manipulatedFlexible scheduling of preventative work ordersTrack corrective work ordersSo what should this look like. An intuitive, color coded calendar is the easiest way to track . You should be able to just drag work orders to the correct day to make changesSchedule by days, meter, days/meter, # of starts12
13 Generate Work OrdersIncorporate graphics, detailed instructions, manualsPrint for all or just for specific workersAdd as many details as you needUse portables for accuracy and flexibilityWork orders should be easily generated and distributed. You can print work orders, but you don’t have to. Many jobs are so simple, you don’t need to kill a tree. Just check on the screen and go do the work. Use portables , reduce data entry, reduce errors, increase data accuracy. For complicated jobs, you can print a work order complete with assignments, inventory, instructions and even CAD drawings.Details: inventory, costs, vendors, etc
14 Document Your Work Document what you need to: Who What Parts used Parts costLabor hoursYou should be able to easily capture the essential information you need but you can should be easily able to record anything you want for future reference. Labor, costs, inventory and any notes you want for the record. This information should be available in a historical database so you can have the data to run your organization they way you want to.
15 Generate Maintenance and Business Reports Equipment HistoryTop Ten ListOpen work ordersEquipment list???You should be able to easily generate helpful reports based on the data you’ve captured. These reports will help you with regulatory compliance, warranty compliance and to help manage your resources.
16 Consider Ease of Set Up Flexibility Security Link to SCADA Where many systems fall down is in the level of complexity– need to make sure the complexity fits your needs.Other considerations are the level of flexibility required, level of security for data storage and access, need for portability, automated links to SCADA systems or PLCs.
17 Key Probing Questions Describe your current maintenance solution? How many pieces of equipment do you have to maintain?Do you have a regular maintenance schedule that you can easily manage?Can you easily generate work orders?Can you easily track and summarize the activities?If manualwould a simple, easy to use, very visual solution help your efficiencyA solution targeted specifically for maintenance that works the way the maintenance department worksIf using a big solution like MaximoHas the maintenance department been able to make it workIs it providing the type of functionality you need?
18 Request for a JOB Cal comes in Ask quote questions to determine which versionContact Tech supportopt 2JC Basic/PlusComplex quote(interfaces, portables, custom reports)Simple quote(no interfaces, portables)Tech Support provides Statement of Work to complete quoteCreate Opportunity in SLXRSM as Opportunity ManagerGenerate quote with either standard offer or template
19 More Information General Information, videos, RSM lookup Contact us directly:Contact your Hach Field Representative
20 Materials Web SLX Lori will combine/store Data sheets, videos, ordering evals (not there yet), webinars, general information, QRGs (not there yet), list of standard interfacesSLXStandard offers, templates (eventually)Lori will combine/storeQRGsQuestionsPresentationJOB Cal Eval - JOBCALPLUS-EVAL