Asset Monitoring & Predictive Maintenance · PDF file• Conduct criticality assessment training ... • Enhanced spares planning and inventory optimization • Reduced buffer WIP

Asset Monitoring & Predictive Maintenance

M A Y 2 0 1 7

A Turnkey IoT Solution for Manufacturing

2 | Copyright © 2017 Deloitte Development LLC. All rights reserved.

Maintenance Strategy & Processes

TOOLS

PEOPLE

TECHNOLOGY

EQUIPMENT

PARTS

DOCUMENTS

We understand maintenance operationsWe will bring a multi-disciplinary team with an integrated perspective of maintenance operations

Exponential technologies can augment, rather than replace, programmatic elements, allowing more rapid and robust leveraging of information to drive step-function improvement

A comprehensive maintenance program includes an integrated set of people, process, and technology elements

From the fundamentals… …to advanced enablers & accelerators

Maintenance Strategy & Processes

TOOLS

PEOPLE

TECHNOLOGY

EQUIPMENT

PARTS

DOCUMENTS

AUGMENTEDREALITY

3D PRINTING

ROBOTICSIoT

CLOUDCOMPUTING

ARTIFICIALINTELLIGENCE


Unlocking value through Smart Predictive MaintenanceSmart Predictive Maintenance can deliver additional value than traditional maintenance methods

A S S E T M O N I T O R I N G & H E A L T H

C O N D I T I O N - B A S E D M A I N T E N A N C E

P E R F O R M A N C E - B A S E D M A I N T E N A N C E

P R E D I C T I O N - B A S E D M A I N T E N A N C E

S M A R T P R E D I C T I V EM A I N T E N A N C E

Real-time data on individual assets is displayed

Parameters are established and intelligent alerts are generated

Parameters are tweaked and optimal performance ranges are defined

Models predict when an asset will fail

Maintenance planning is automated and execution enhanced by digital technologies

VA

LU

E C

RE

AT

ION


Traditional maintenance process today

I don’t know what happened. It just stopped working.

How long is it going to be down this time?

Even with all these extra parts, I still don’t have what I need. Going to have to order one.Well that took

all afternoon.

Three days!?! Just get it to me as quickly as possible.

Being down 3 days is really going to hurt our numbers this month.

Every month we keep getting worse. Something has to change!

I’m tired of waiting for a ‘new’ process that never makes things better.


Common Maintenance Issues

Unplanned downtime and machine failure

Low plant velocity and throughput (downtime-related)

Low OEE and machine availability

High spares inventory and maintenance costs

Poor first-pass-yield (FPY) and quality metrics

Rework caused by out-of-spec machine

Missed delivery dates

Inability to identify root causes

Risk to employee / public safety and environmental impacts

Every month we keep getting worse. Something has to change!


Our approachWe utilize our Think Big, Start Small, Scale Fast approach to tackling issues such as predictive maintenance

No one ever got anywhere important without pushing the envelope.

Think bigIt’s important to know how much is too much, and we have this down to a science.

Start smallOur knowledge and service breadth allow us to move quickly and get results.

Scale fast

In today’s hyper-competitive world, innovation is everything. If you’re not thinking big—like really big, the competition’s buzzing by. We know how—and where—to use IoT to create an actionable plan that can put your business ahead of the pack.

By pursuing maximum innovation, it’s really easy to go too fast too quickly. That’s why we design a game plan with achievable phases and just the right amount of ambition. We then apply powerful technology to real-life customers and environments. This all sums up to quick wins and big insights.

Going fast requires a deep and dynamic team. With our powerful blend of cross-functional capabilities, creative thinking, and pre-built assets, we can ramp up lightning-quick. Leaning on our global network, as well as an ecosystem of alliances, you can rest assured we have the people and breadth to deliver big results—and real business value—at the speed of tomorrow.


Predictive Maintenance, Why Now?PdM has been around for years, but reduced cost and improved analytics have finally made it worth pursuing

Collecting, storing and processing IoT-sized data used to be cost-prohibitive, but today it’s adding value

And technology has gone far beyond traditional spreadsheets, graphs and charts

1 9 9 2 T O D A Y

CO

ST

OF

PE

RF

OR

MA

NC

E

$1,245 per Gbps

$569 per GB

Bandwidth<$10

Storage<$0.01

Computing<$0.06

$222 per million transistors

Source: Deloitte analysis | DUPress.com

Big Data

Robo

tics

Artificial IntelligenceInternet of ThingsCloud Computing

Data Science

Wea

rabl

es

3D P

rintin

g

Real-Time StreamingNatural Language ProcessingM

achi

ne L

earn

ing

Cognitive Automation

Low-Code Apps

Prescriptive Analytics

Augmented Reality


A Turnkey IoT Solution for ManufacturingThis out-of-the box accelerated solution for high impact IoT use cases combines best-of-breed analytics, software, infrastructure, security, and professional services into a single pre-configured solution

8 week proof-of-concept to drive new outcomes

Quick and easy setup and data analysis

Edge data acquisition and analytics

Immediate business results from analyzed data

Global distribution, services, and scalability

Best of Breed Solution Attributes

I N F R A S T R U C T U R E

S E R V I C E S

S E C U R I T Y

S O F T W A R E

A N A L Y T I C S

#1

#2

#3

#4

#5


A Turnkey IoT Solution for ManufacturingThis out-of-the box accelerated solution for high impact IoT use cases combines best-of-breed analytics, software, infrastructure, security, and professional services into a single pre-configured solution

Best of Breed Solution Pre-configured Solution

S O L U T I O N C O N S O R T I U M

Compute/ Storage/Network

InfraManagementConnectivity Sensors


VisualizationAdvanced AnalyticsAnd Algorithmic Science

BusinessIntelligence

PerformanceManagement

A N A L Y T I C S

Access Control/Authentication

Privacy AndData Protection

DeviceSafety

RegulatoryCompliance Encryption

S E C U R I T Y

0 1 01 0 10 1 1


S E R V I C E S

S E C U R I T Y

S O F T W A R E

A N A L Y T I C S

Data AggregationData Acquisition

D A T A M A N A G E M E N T


Maintenance re-imagined with a turnkey IoT solution I never thought change

could be seen in such a short time.

Hi Jim, it’s great to be here. I’ll have everything set up by the end of the day.

Great, another ‘easy fix’.

With this we can remotely monitor the machines health.

We’re connected and starting to receive new data already.

With all this information, our condition-based model is really going to help.

Machine 1 will fail in the next 4 days.

With a click of a button I got the right parts and was able to fix the machine before it went down.

Wow! Every month we keep getting better!

Day 1

Week 1

Week 6

Week 7


Project scope and deliverablesThe POC will deliver a working product

Hi Jim, it’s great to be here. I’ll have everything set up by the end of the day.

With this we can remotely monitor the machines health.

Day 1

• Maintenance POC Solution, minimum viable product (MVP) including:

- Connectivity / data ingestion (e.g., MES, OSISofthistorian, existing sensors)

- New active sensors (or sensor array) as needed

- Predictive analytics / algorithms

- Dashboards / Visualizations (max 4 Personas)

• POC asset performance baseline and asset-specific maintenance assessment (including gap assessment)

• Initial (quick) recommendations for improving existing maintenance program

• Rollout phasing and scaling considerations

• Single Asset

• Single Plant Location

• Turnkey IoT Solution Maintenance Accelerator

• Maintenance Program for the POC asset

• 8 week program (discovery phase, sprint development phase, release phase)

• Agile delivery (agile training to be included)

• Not in scope for POC- Security requirements

- Solution industrialization

- Enterprise maintenance program

POC Project Scope Key Project Deliverables


Utilize an Agile Methodology

• Program of frequent releases means quicker speed to solution

• Smaller batches of work can mean easier focus on quality control and risk management

• Increased user involvement provides greater visibility of progress and product

• Less process and more discipline means an organization that can be more responsive to change

• The scope of the product and its features become the variable, rather than the cost or time

• More active involvement, self-organization and autonomy increases employee engagement

Potential Results

Agile ProcessAgile can deliver business value by…

P R O D U C TV I S I O N R E L E A S E

Ongoing backlog grooming

1 2

Sprint readiness

Stabilization sprint

453

Forecast

6 Continuous integration

Initial release planning & forward-looking, rolling forecast

Design, Dev, Test

Sprint2 Weeks(Product

backlog)(Sprint

backlog)

Re-plan

Reducing the time between request and delivery

Allowing Business/IT to respond quickly to changing needs

Building only the software needed

Avoiding delivering software with quality problems

Meeting project commitments by reprioritizing scope


Sprint ApproachA typical project has 3 phases: Discovery, Sprint/Development Cycle, and Release. Each of these phases have a specific purpose and the Agile Scrum nature is implemented in the Sprint Cycle Phase.

Assess current state and prepare for build • Establish project and develop charter

• Conduct workshop sessions and agile development training

• Collect maintenance process and asset performance data

• Define pre-requisites, use cases, as-is technical architecture

• Create personas, user stories, journey maps

• Baseline asset-specific maintenance process and identity issues/challenges

• Execute communication activities

• Gather/define requirements

• Define reliability criteria

• Create component level asset tree

• Conduct criticality assessment training

• Conduct top-down estimate of POC MVP rollout cost across similar machines network-wide

Design, build and iterate solution & processes Maintain, release solution and assess value proposition• Conduct component criticality assessment

• Identify failure modes

• Conduct root cause analysis for failure modes

• Build minimum viable product

• Collect/detect data failures

• Update training material after each sprint cycle

• Work with users to gain feedback for next sprint cycle

• Manage communication approach and ongoing communications to stakeholders

• Establish KPIs to monitor progress

• Train end users on new processes/technology

• Conduct user acceptance testing (UAT)

• Sprint release of incremental part of viable system

• Updated product backlog

• Conduct interviews to understand and document implications of broader maintenance process changes across network

Discovery Phase ( 1 W E E K )

Sprint Cycle Phase ( 6 W E E K S )

Release Phase ( 1 W E E K )


Predictive Maintenance Solution - MVP

• Analyze and classify asset component criticalities

• Assess and augment (as needed) sensor array

• Collect data from sensors & PLCs

• Analyze data to predict impending failures

• Create/augment maintenance programs

• Create visualization

MVP Capabilities & Characteristics MVP Example Dashboard

With all this information, our condition based model is really going to help.

Week 6

The Minimum Viable Product (MVP) is a development technique in which a new product is developed with sufficient features to satisfy early adopters. The final, complete set of features is only designed and developed after considering feedback from the product's initial users.

MVP Objective

The MVP should deliver an enhanced preventive/ predictive maintenance program with a responsive web application that will bring insight into asset performance trends & potential failures.


Attaining Value in ScaleThe initial investment lays the foundation to scale the vision by creating the platform, metrics, and predictive algorithms, which can also improve with scale as users learn from each other

Week 7

Machine 1 will fail in the next 4 days.

P I L O T A S S E T P R O D U C T L I N E F A C T O R Y S U P P L Y N E T W O R K

One-time costs:• Platform / applications• Algorithms• KPI / Metrics• Training materials

V A L U E

C O S T / M A C H I N E

Sensors, condition-based analytics

IoT, predictive analytics

Machine learning

Cognitive automation

Sustain

F A C T O R Y 1 F A C T O R Y 1 F A C T O R Y 1 F A C T O R Y 1

F A C T O R Y 2

F A C T O R Y 3


The Turnkey IoT Solution Drives ValueSmart Predictive Maintenance drives real value that can be realized in weeks instead of months and years

Wow! Every month we keep getting better!

• Increased customer satisfaction with improved ability to make deliveries on-time or to deploy smarter MRO aftermarket service

• Improved forecasting of planned shut-downs with less “fire-fighting” and increased wrench time

• Enhanced spares planning and inventory optimization

• Reduced buffer WIP due to increased reliability

• Reduced spend on expediting parts

• Reduced OEM spend

• Improved resource planning, with less unplanned overtime

• Improved safety and sustainability

Smart Predictive Maintenance Value* Other Potential Benefits

*Benefit ranges based on case studies

Reduced Maintenance Costs

Increased OEE

Reduced Unplanned Downtime

Increased Throughput and OTD

Improved Quality

20% – 30%

5% – 15% (availability, performance, quality)

15% – 30%

10% – 20%

10% – 35%

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Documents

Asset Monitoring & Predictive Maintenance · PDF file• Conduct criticality assessment training ... • Enhanced spares planning and inventory optimization • Reduced buffer WIP