Pfizer’s Global Reliability Program
(GRP)
ISPE Chapter Meeting – November 18th, 2014
Global Reliability Program
Supports 56 Manufacturing Sites
Newbridge, Ireland
Grange Castle, Ireland
Little Island, Ireland
Ringaskiddy, Ireland
Havant, England
Puurs, Belgium
Franklin, OH
Rochester, MI
Kalamazoo, MI
Middleton, WI
Brandon, Canada
Carlisle, PA
Pearl River, NY
Rouses Point, NY
St. Laurent, Canada
Andover, MA
Strangnas, Sweden
Søborg, Denmark
Wuxi, China
Freiberg, Germany
Cluj, Romania
Illertissen, Germany
Istanbul, Turkey
Sanford, NC
Albany,
GA
Foothill Ranch, CA
Toluca, Mexico
Dakar, Senegal
El Jadida, Morocco
Valencia, Venezuela
Guarulhos, Brazil
Vega Baja, PR
Barceloneta,
PR
Guayama, PR (1)
Itapevi, Brazil
Buenos Aires, Argentina
Catania, Italy
Cairo, Egypt
Ascoli, Italy
Aprilia, Italy
Tunis, Tunisia
Dalian, China
Nagoya, Japan
Thane, India
Goa, India
Suzhou, China (1)
Hsinchu, Taiwan
(1)
Tuas, Singapore (1)
Algiers, Algeria
Amboise, France
Algete, Spain
Jakarta, Indonesia
Perth, Australia
Karachi, Pakistan
(2)
W. Ryde, Australia
Global Reliability Program
Site-level Implementation Plan Roadmap
Training
Execution Activities (Tools)
Work
Management
Planning
& Scheduling
EAMS / SAPPM
Utilization Study
Priority Mgt
Backlog Mgt
OT Management
Training
Planning & Scheduling, with Coaching sessions
Reliability
Based
Maintenance
PM Optimization
Bad Actors (MTBF)
RCFA, FMEA, RRI
Reliability Engineering
Predictive Maintenance
OEE Optimization
Calibration Excellence
Life Cycle Management
Reliability Excellence & Reliability Certification, Lean/Operational Excellence 6Sigma - Method 1, Greenbelt,
Training
Asset or Value Stream Based
Maintenance Strategy
Site Maintenance Master Plan
Site Maintenance Assessment
Planning Activities
Service
Models
MRO Management
Vendor Consolidation
Integrated Suppliers
OEM Replacement
Parts Distribution
Reliability for Contractors
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
Equipment Design & Interface
Education & Training
Work Management
Improve Asset Effectiveness
Autonomous Maintenance
Operator Care
Reliability Based Maintenance
Pillars of GRP TPM
GRP TPM
Total Productive Maintenance
Quality
Environmental Health & Safety
Plant Partnership
P
ag
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
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Reliability Based Maintenance
TPM Pillar Overview
Focuses on Increasing Reliability and
Availability of Equipment by reducing the
Breakdown of Machines
(Some Focus Areas for Pfizer)
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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
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
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Access to the Data
IMP: Intelligent Maintenance Program
2014 Progress
•
•
•
•
•
7 new site
integrations
progressed
Planned 2015
Automsoft
Rapid
Catalyst
Number of Assets
monitored via IMP
increased by over
50% in 2014
PANS II SQL
DB
In Progress*
Aspentech
IP21
Live
Johnson
Controls BMS
PEPS OEE
CMMS
3 new historian types
connections
Monitored
Embedded PI
Delta V
GE iHistorian
5 New Alert Types
delivered
Program well placed
for further growth in
2015 with PGS BT &
GRP Project Plan
Siemens
BMS*
SQL Wonder
Ware
Honeywell
BMS
OSI PI
*Connections
for Databases
used in multiple
site prioritized
for replication
Reliability Analytics Forecast Failures
Project - Advanced Reliability Analytics
CMMS WO data 
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:
– 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 & Sitebased Reliability SMEs.
– New Process, Tools and Training are making
it easier for Pfizer’s Reliability Engineers to
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get this analysis done.
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Data Analysis used to Identify the Best
Maintenance Strategies
Site’s Data
(Unfiltered)
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
OptimizeStandardize
Data Analysis
Project – Data Analysis Drives Maintenance
Strategies
Shared to improve
each others
Programs
Examples:
– Calibration Community is Optimizing and
Standardizing policies and practices across
the network.
– Equipment reviews improve OEE while
Reducing Maintenance Costs.
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1
Calibration Lifecycle
Areas to Optimize Calibration and Save
Rework
New and Existing
Instruments
Classification
Set Limits
Ranges,
ID Loop vs.
Instrument
Document
Approval
Process
Paper or
Paperless
Execution
Sticker
less
OOT
OOF
Data Analysis coupled with
a Risk Based approach
has identified layer of
Opportunties.
Complete
Closed
Final
Calibration
Retire
Dataspy
Review by
Exception
Scheduling
Work Instructions
Parts
Existing Instruments
Shifting Calibrations to OnDemand or Extend Frequencies
based on System Data.
Incorporate a Prescreening
Process on OOT’s for product
impact.
Going Paperless - Saves on
average 5-10 minutes of a
Mechanics time per work order.
We target
12 90% paperless
Autonomous Maintenance
Operator Care
TPM Pillar Overview
Autonomous Maintenance/Operator Care involves
operators in maintaining and improving equipment
performance.
Operator Care: Cleaning and
Inspection
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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
Imminent Belt Failures
Unprotected Wires
Hydraulic Line Wearing in
Contact With Rotating Shaft
Electrical Cable In Contact
With Rotating Gear
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‘Up Skilling’ Your Operations
Phase 4
World Class
Performance
Phase 3
Phase 2
Level 1
Introduction
Problem Solving
Activity Board
Method 1
TPM all Key lines
Basic Concept
- Cleaning
- Inspections
- Tightening Bolts
- Safety Checks
TPM all Key lines
Basic Concept
- Cleaning
- Inspections
- Tightening Bolts
- Safety Checks
Extended Features
- Lubrication
- Minor Repairs
TPM all Key lines
Basic Concept
- Cleaning
- Inspections
- Tightening Bolts
- Safety Checks
Extended Features
- Lubrication
- Minor Repairs
Problem Solving
- Activity Board
- OEE targets
- Kaizen
Outstanding
Performance
Example of 5S in Action
Visual Management – Equipment
Modifications
TPM Ongoing Journey…
50
OEE evolution
OEE %
45
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
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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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