FIELD AND PLANT PERFORMANCE

MONITORING
EPGE012A
Key Performance Indicators
Field and Plant Performance Monitoring

INDEX

1. Field and Plant Overview

2. Elements to Monitor

3. Criticalities

4. Key Performance Indicators - KPI

5. Production Optimization

6. Case Studies

2
Key Performance Indicators

Definition

 Key Performance Indicators - KPIs are ratios between available data

that may be used to check and evaluate different aspects of the
performance;

 KPIs are essential tools for checking effectiveness and to which extent
planned goals are achieved;
 KPIs are chosen to fit company purposes;

 KPI must start from real technical and economic data and must be
easily calculated (data quality);

 It is not necessary to have a great number of KPIs.

 In any case it is necessary to define procedures to link KPIs in order to

better understand the changes in the parameters to be controlled.

3
Key Performance Indicators

4
Key Performance Indicators

Effective KPIs - Which requirements?

An effective KPI should be:

 Specific (cost, quality, duration…);

 Measurable (certain, value, range…);

 Applicable / Assignable (achievable, flexible, consistent…);

 Reliable / Realistic (trust, accuracy…);

 Time defined (short, medium, long term…).

5
Key Performance Indicators

6
Key Performance Indicators

KPIs Standard

 General;
 Effectiveness;
 Efficiency;
 Organization;
 Safety.

In addition, KPIs may also be

 Historical;
 Timely;
 Critical.

7
Key Performance Indicators

General KPIs

 Maintenance personnel (hours) / production personnel (hours);

 Corrective maintenance work orders / total work orders;

 Yearly maintenance cost / fixed capital;

 Instrumentation maintenance cost / total maintenance cost;

 Maintenance cost of equipment / total maintenance cost.

8
Key Performance Indicators

Effectiveness KPIs

 Available time / required time;

 Material and spare parts cost / total maintenance cost;

 Corrective maintenance cost / total maintenance cost;

Efficiency KPIs
 Number of failures / operating time (1/MTBF).

 Work orders closed / total work orders opened;

 Material and spare parts monthly used / material and spare

parts stock.

9
Key Performance Indicators

Organization KPIs

 Maintenance education and training cost / maintenance

personnel cost;

 Maintenance personnel cost / total personnel cost.

Safety KPIs

 Accidents frequency;

 Accidents severity.

10
Key Performance Indicators

What is my influence on KPIs?

Every person on site has an influence on some specific KPIs and

business objectives

11
Key Performance Indicators

……..More KPIs…..

 Warehouse management cost / total maintenance cost;

 Direct maintenance time / total maintenance time;

 Logistic time / total maintenance time.

12
Key Performance Indicators

Performance Indicators - Production

13
Key Performance Indicators

Performance Indicators - Production

 Production KPIs are a tool towards operational excellence;

 Production KPIs need software applications and solutions;

 Production KPIs need process measurements.

14
Key Performance Indicators

Achieving Operational Excellence

15
Key Performance Indicators

Oil and Gas Operational Excellence…

 Must perform in the best possible way…

 People;

 Assets;

 Process;

 Business.

 …with the equipment, assets, production configuration available now.

16
Key Performance Indicators

…Oil and Gas Operational Excellence…

 From minute-to-minute, hour-to-hour, day-to-day;

 For improved management of:

 Safety;

 Reliability;

 Security;

 Process and production performance optimization;

 Production management.

17
Key Performance Indicators

KPIs on a monthly basis

 Actual production / planned production;

 Real cost / budget cost;

 Actual operating time / planned operating time;

 Production loss for maintenance / planned production;

 Production loss due to failures / planned production;

 Production loss due to unavailable spare parts / planned production.

18
Key Performance Indicators
Operational Best Practices
Production Cost reduction / control
– Reliability, Uptime!
– Personnel
– Work Practices improvement
Detect Problems, Mitigate Impact
– Safety Management
– Reliability, Uptime! : need to track
health and performance of all plant
and automation assets
– Environmental Monitoring/compliance
Lifecycle Costs
–Plan and Manage Version-up &
obsolescence to capture operational
improvements
Focus on more reliability, more safety
Increased top line revenue
– Reliability, Uptime!
– Maximize production from existing
facilities
– Push constraints
– Optimize process
Improve People Effectiveness
– Work Practices improvement
– Learn from Operations
– Safety Management
– Integrated Management of
automation asset WITH the plant
asset
19
Key Performance Indicators

Performance Indicators – Maintenance

 Performance indicators will be required to measure maintenance

performance and the effectiveness of the adopted strategies;

 Performance indicators will be used to evaluate the general

productivity of maintenance against set measures to achieve
production targets;

 Performance indicators will be used to evaluate:

 Equipment performance;
 Plant losses;
 Plant availability;
 Failure frequencies.

20
Key Performance Indicators

Performance Indicators – Maintenance

Costs

 Total maintenance expenditure;

 Major contracts expenditure;

 Equipment / system costs (labor and materials).

21
Key Performance Indicators

Performance Indicators – Maintenance

Implementation Effectiveness

 Routine compliance (work completed vs. scheduled);

 Backlog / overdue work;

 Work completed (Jobs / Man-hours);

 Workload split (Preventive Maintenance - PM vs. Corrective - CM);

 Non-production Time Analysis.

22
Key Performance Indicators

Performance Indicators – Maintenance

…..Other

 Labor utilization;

 Benefit / cost;

 Maintenance / plant efficiency;

 HSE performance.

23
Key Performance Indicators

Availability

 Availability is a measure of how much a system is available for use:

 It is the fraction of time that the system is in use;

 It takes repair and restart time into account;

 Availability of 0.998 means equipment is available for 998 out of 1000 time
units.

 Uptime refers to the capability to perform the desired task;

 Downtime refers to “not being able” to perform the task.

24
Key Performance Indicators

Equipment Time Elements

Total (calendar) time (T0)

Planned (target) time (T1) t1
Available time (T2) t2
Operating (used) time (T3) t3
Net operating time or uptime (T4) t4

Productive time (T5) t5

Non-productive time (TL)
t1 = Planned down time
t2 = Unplanned down time Total time losses
t3 = Standby time
t4 = Speed losses time
t5 = Quality losses time

25
Key Performance Indicators

Reliability

 Reliability deals with reducing the frequency of failures over a time

interval;

 Reliability is a measure of the probability for failure-free operation

during a given interval, i.e. it is a measure of success for a failure
free operation;

 The probability that equipment fulfils a specific process (no failure)

under specific operation conditions during a specific period;

 It is often expressed as: R(t) = exp(-t/MTBF) = exp(-λt)

λ = Constant failure rate

MTBF = Mean Time Between Failures.

26
Key Performance Indicators

Maintainability

 Maintainability deals with duration of maintenance outages or how

long it takes to complete (ease and speed) maintenance actions
compared to a datum;

 The datum includes maintenance (all actions necessary for retaining

an item in, or restoring an item to, a specified good condition)
performed by personnel having specified skill levels, using prescribed
procedures and resources, at each prescribed level of maintenance;

 A key maintainability figure is the Mean Time To Repair (MTTR) and

a limit for the maximum repair time.

27
Key Performance Indicators

Recent KPIs

 Overall Equipment Effectiveness (OEE):

 OEE = Equipment Availability × Performance Efficiency × Quality Rate.

 Total Effective Equipment Productivity (TEEP):

 TEEP =Utilization × Availability × Performance Efficiency × Quality rate.

 Net Equipment Effectiveness (NEE):

 NEE = Uptime ratio × Performance Efficiency × Quality Rate.

28
Key Performance Indicators

Cost of Quality

 Total maintenance cost, or cost of quality, is the sum of preventive

and corrective maintenance costs;

 Preventive maintenance cost is the cost associated with

maintenance carried out at predetermined intervals or other
prescribed criteria intended to reduce the probability of failure or
the degradation of performance of equipment (or plant);

 Corrective maintenance cost is the cost associated with

maintenance carried out on a defect which has caused equipment
(or plant) to be taken out of service during scheduled operating
time. Corrective maintenance can be either planned or unplanned.

29
Key Performance Indicators

KPIs and CMMS

 From a Computerized Maintenance Management System - CMMS it

is possible to obtain dashboard-like gauges where KPIs provide a
snapshot of how assets are performing compared to user defined
benchmarks; the data to calculate the requested KPIs will be given
by the CMMS;

 In case data from different information systems are combined

(finance, operations, personnel, engineering, warehouse, etc.), on-
line data transfer will provide unobstructed generation of KPIs;

 The KPIs required by management are subdivided into a number of

frameworks.

30
Key Performance Indicators

KPI Dashboard Example

31
Key Performance Indicators

KPI Dashboard Example

32