Report for PS PdM-RxM Survey 2020

1. What is your primary job function?

12% Plant manager12% Plant manager

16% Maintenance manager16% Maintenance manager

8% Maintenance engineer8% Maintenance engineer

13% Maintenance technician13% Maintenance technician19% Reliability engineer19% Reliability engineer

8% Reliability technician8% Reliability technician

2% Controls engineer2% Controls engineer

5% Plant engineer5% Plant engineer

8% Sales/marketing8% Sales/marketing

2% Applications engineer2% Applications engineer

1% IT1% IT

5% Corporate executive5% Corporate executive

Value Percent

Plant manag er 12.4%

Maintenance manag er 15.5%

Maintenance eng ineer 8.2%

Maintenance technician 13.4%

Reliability eng ineer 18.6%

Reliability technician 8.2%

Controls eng ineer 2.1%

Plant eng ineer 5.2%

Sales/marketing 8.2%

Applications eng ineer 2.1%

IT 1.0 %

Corporate executive 5.2%

2. How big is the maintenance/reliability staff at your plant?

7% Just me (the MRO isoutsourced)7% Just me (the MRO isoutsourced)

19% 2-4 people19% 2-4 people

20% 5-1020% 5-10

26% 11-5026% 11-50

10% 51-10010% 51-100

19% More than 10019% More than 100

Value Percent

Just me (the MRO is outsourced) 7.2%

2-4 people 18.6%

5-10 19.6%

11-50 25.8%

51-10 0 10 .3%

More than 10 0 18.6%

3. What is the annual revenue of your organization?

22% Less than $50 million22% Less than $50 million

23% $50-500 million23% $50-500 million

18% $500 million-$5 billion18% $500 million-$5 billion

11% $5 billion-$100 billion11% $5 billion-$100 billion

9% More than $100 billion9% More than $100 billion

18% Not sure18% Not sure

Value Percent

Less than $50 million 21.6%

$50 -50 0 million 22.7%

$50 0 million-$5 billion 17.5%

$5 billion-$10 0 billion 11.3%

More than $10 0 billion 9.3%

Not sure 17.5%

4. How many total plants does your organization manage?

21% 1 plant21% 1 plant

31% 2-5 plants31% 2-5 plants

12% 6-15 plants12% 6-15 plants

36% More than 15 plants36% More than 15 plants

Value Percent

1 plant 20 .6%

2-5 plants 30 .9%

6-15 plants 12.4%

More than 15 plants 36.1%

5. What vertical does your plant most closely align with? (Please check all thatapply.)

Per

cent

Food and to

bacco

Pulp and p

aper

Oil and g

as

Automotiv

e

Chemical/p

harmace

utical m

anufactu

ring

Utility/

power genera

tion

Metals

and mining

Lumber, wood a

nd furn

iture

Metals

fabric

ation

Electronics

and in

struments

Commercial m

achinery

Transp

ortatio

n

Other (

please sp

ecify)

0

10

20

30

Value Percent

Food and tobacco 20 .6%

Pulp and paper 12.4%

Oil and g as 24.7%

Automotive 13.4%

Chemical/pharmaceutical manufacturing 18.6%

Utility/power g eneration 19.6%

Metals and mining 12.4%

Lumber, wood and furniture 4.1%

Metals fabrication 11.3%

Electronics and instruments 10 .3%

Commercial machinery 6.2%

T ransportation 10 .3%

Other (please specify) 16.5%

6. Who in your plant makes decisions on asset monitoring tools and configurations?(Please check all that apply.)

Per

cent

Plant manager

Maintenance

manager

Maintenance

engineer

Maintenance

tech

nician

Reliabilit

y engineer

Reliabilit

y tech

nician

Controls

engineer (se

nsors

are e

mbedded in m

achinery)

Plant engineer

Sales/marke

ting

Applicatio

ns engineer IT

Corpora

te e

xecu

tive

0

50

25

75

Value Percent

Plant manag er 44.8%

Maintenance manag er 56.3%

Maintenance eng ineer 18.4%

Maintenance technician 14.9%

Reliability eng ineer 28.7%

Reliability technician 8.0 %

Controls eng ineer (sensors are embedded in machinery) 18.4%

Plant eng ineer 13.8%

Sales/marketing 3.4%

Applications eng ineer 5.7%

IT 6.9%

Corporate executive 20 .7%

7. Which of these technologies are you using to monitor assets?

Usingnow

In2020budget

Within3years

Noplans

Controls equipment (controllers, networks, software)

Row % 77.9% 3.5% 5.8% 12.8%

Self-diag nostic (smart) instrumentation and final control elements

(drives, valves)

Row %

46.5% 7.0 % 16.3% 30 .2%

Specialized system control systems (combustion controls, steam

trap monitors, water/wastewater, cooling systems, compressed

air)

Row %

52.3% 9.3% 8.1% 30 .2%

Predictive maintenance (PdM) technolog ies for condition-

monitoring (thermog raphy, oil analysis, vibration, ultrasound,

motor testing )

Row %

66.7% 10 .3% 12.6% 10 .3%

Instrumentation (valve analysis, sig nal processing and alarm

manag ement software)

Row %

60 .0 % 8.2% 12.9% 18.8%

Automation, data archiving , and reporting software

Row % 54.7% 17.4% 15.1% 12.8%

Automation of work order g eneration (including repair history,

diag nostics, procedure and parts information)

Row %

48.8% 14.0 % 17.4% 19.8%

Embedded remote monitoring devices

Row % 35.3% 11.8% 24.7% 28.2%

Energ y monitoring and control devices (drives, valve actuators)

Row % 42.4% 11.8% 18.8% 27.1%

8. Which types of maintenance approaches are currently deployed by your plant?(Please check all that apply.)

Per

cent

Reactive (i.e., runto fail)

Preventive (i.e.,periodic and/orroute-based)

Condition-based(i.e., inspections)

Predictive (i.e.,diagnostics ahead

of failure)

Prescriptive (i.e.,both diagnosticsand guidance for

repair)

0

20

40

60

80

Value Percent

Reactive (i.e ., run to fail) 75.3%

Preventive (i.e ., periodic and/or route-based) 76.6%

Condition-based (i.e ., inspections) 63.6%

Predictive (i.e ., diag nostics ahead of failure) 51.9%

Prescriptive (i.e ., both diag nostics and g uidance for repair) 22.1%

9. T o what degree does your team or organization currently engage inRxM prescriptive maintenance?

31% Using now31% Using now

7% In 2020 plans/budget7% In 2020 plans/budget

25% Within 3 years25% Within 3 years

38% No plans38% No plans

Value Percent

Using now 31.2%

In 20 20 plans/budg et 6.5%

Within 3 years 24.7%

No plans 37.7%

10. Which mature predictive maintenance (PdM) technologies have you deployed orare you planning to deploy?

Using now In 2020 budget Within 3 years No plans

Vibration

Row % 70 .1% 5.2% 10 .4% 14.3%

Ultrasonic

Row % 44.7% 7.9% 21.1% 26.3%

Acoustic

Row % 21.1% 10 .5% 18.4% 50 .0 %

Corrosion

Row % 39.5% 14.5% 9.2% 36.8%

Infrared

Row % 56.6% 19.7% 7.9% 15.8%

Oil analysis

Row % 63.6% 13.0 % 5.2% 18.2%

Predictive modeling software

Row % 15.6% 13.0 % 22.1% 49.4%

Electric motor testing

Row % 44.2% 15.6% 13.0 % 27.3%

11. What percent of assets are on each technology?

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Vibration

Row % 22.1% 10 .4% 5.2% 7.8% 6.5% 11.7% 7.8% 13.0 % 10 .4% 0 .0 % 5.2%

Ultrasonic

Row % 34.2% 15.8% 9.2% 6.6% 5.3% 7.9% 5.3% 2.6% 6.6% 2.6% 3.9%

Acoustic

Row % 57.9% 6.6% 7.9% 6.6% 2.6% 1.3% 3.9% 3.9% 3.9% 3.9% 1.3%

Corrosion

Row % 42.1% 10 .5% 6.6% 2.6% 1.3% 3.9% 2.6% 11.8% 10 .5% 5.3% 2.6%

Infrared

Row % 23.7% 9.2% 11.8% 14.5% 2.6% 5.3% 3.9% 3.9% 15.8% 6.6% 2.6%

Oil

analysis

Row %

23.7% 13.2% 1.3% 13.2% 5.3% 5.3% 10 .5% 6.6% 10 .5% 7.9% 2.6%

Predictive

modeling

software

Row %

68.8% 2.6% 6.5% 0 .0 % 0 .0 % 3.9% 1.3% 6.5% 3.9% 3.9% 2.6%

Electric

motor

testing

Row %

33.8% 14.3% 6.5% 2.6% 5.2% 10 .4% 5.2% 6.5% 10 .4% 2.6% 2.6%

12. Which advanced PdM features have you deployed?

Usingnow

In 2020budget

Within 3years

Noplans

Internet-enabled / IIoT technolog ies

Row % 26.3% 11.8% 26.3% 35.5%

T roubleshooting decision tree

Row % 43.4% 9.2% 18.4% 28.9%

HMI with color-coded alerts

Row % 42.1% 10 .5% 14.5% 32.9%

Optimized PdM work processes

Row % 43.4% 11.8% 19.7% 25.0 %

Route optimization for mechanics and

operators

Row %

44.7% 11.8% 19.7% 23.7%

Energ y consumption of assets

Row % 31.6% 17.1% 21.1% 30 .3%

13. Please rate the drivers for deploying your PdM solutions.

Not a factor Low Medium High

Reduce maintenance costs

Row % 10 .4% 9.1% 37.7% 42.9%

Reduce operational costs

Row % 10 .4% 9.1% 33.8% 46.8%

Improve uptime

Row % 10 .4% 5.2% 24.7% 59.7%

Knowledg e capture

Row % 13.0 % 28.6% 41.6% 16.9%

Increase visibility into troubled assets

Row % 14.3% 16.9% 41.6% 27.3%

Environmental, health, and safety issues

Row % 13.0 % 14.3% 35.1% 37.7%

Reg ulatory compliance

Row % 13.0 % 22.1% 28.6% 36.4%

Energ y manag ement

Row % 18.2% 26.0 % 36.4% 19.5%

Reduce risk

Row % 10 .4% 10 .4% 37.7% 41.6%

14. Who uses the information provided by your PdM systems and with whatfrequency?

Never Weekly Monthly Quarterly

In-house maintenance

Row % 13.0 % 54.5% 22.1% 10 .4%

In-house operations

Row % 23.7% 40 .8% 30 .3% 5.3%

In-house reliability eng ineers

Row % 23.7% 47.4% 23.7% 5.3%

T otally outsourced to third-party maintenance and

repair

Row %

53.9% 5.3% 21.1% 19.7%

T hird-party remote monitoring

Row % 69.7% 9.2% 15.8% 5.3%

OEM supplier

Row % 61.8% 5.3% 22.4% 10 .5%

15. Please rate the performance of your PdM program over the past 12 months.

17% Not effective17% Not effective

33% Needs some improvement33% Needs some improvement

21% Satisfactory21% Satisfactory

23% Effective23% Effective

7% Very effective7% Very effective

Value Percent

Not effective 16.9%

Needs some improvement 32.5%

Satisfactory 20 .8%

Effective 23.4%

Very effective 6.5%

Usingnow

In 2020budget

Within 3years

Noplans

Asset type notinstalled

Automation assets (field devices,

control valves)

Row %

45.3% 4.7% 10 .9% 25.0 % 14.1%

Control system assets (DCS, I/O,

controllers, networks)

Row %

40 .6% 7.8% 15.6% 21.9% 14.1%

Production assets (rotating

equipment, mechanical pumps)

Row %

70 .3% 3.1% 14.1% 6.3% 6.3%

Distribution pipelines

Row % 31.3% 7.8% 15.6% 23.4% 21.9%

Electrical systems

Row % 56.3% 6.3% 17.2% 17.2% 3.1%

Fleet vehicles

Row % 21.9% 6.3% 14.1% 35.9% 21.9%

HVAC/R system

Row % 37.5% 7.8% 12.5% 35.9% 6.3%

16. What types of assets are managed by your PdM solutions?

17. Please rate the importance of PdM in relation to other investments?

1- LeastImportant 2

3 - ModeratelyImportant 4

5 - MostImportant

PdM technolog ies

Row % 17.2% 9.4% 29.7% 29.7% 14.1%

Reliability solutions

Row % 14.1% 10 .9% 21.9% 31.3% 21.9%

EAM/CMMS

Row % 14.1% 10 .9% 29.7% 25.0 % 20 .3%

Safety systems

Row % 9.4% 10 .9% 17.2% 20 .3% 42.2%

DCS

Row % 15.6% 18.8% 25.0 % 18.8% 21.9%

Field devices

Row % 20 .3% 15.6% 29.7% 21.9% 12.5%

Plant process networks

Row % 17.2% 15.6% 21.9% 28.1% 17.2%

EH&S solutions

Row % 14.1% 14.1% 31.3% 17.2% 23.4%

Sustainable & energ y

manag ement

Row %

9.4% 15.6% 26.6% 32.8% 15.6%

18. Please rate the obstacles limiting the success of your PdM initiatives.

Not a factor Low Medium High

No improvements needed

Row % 42.2% 18.8% 20 .3% 18.8%

Budg et constraints

Row % 4.7% 7.8% 35.9% 51.6%

Undefined financial benefits

Row % 6.3% 23.4% 32.8% 37.5%

Limited IT resources

Row % 10 .9% 29.7% 29.7% 29.7%

Lack of executive support

Row % 9.4% 23.4% 32.8% 34.4%

Limited eng ineering resources

Row % 9.4% 29.7% 35.9% 25.0 %

Undefined operational benefit

Row % 7.8% 29.7% 37.5% 25.0 %

Lack of EAM integ ration

Row % 15.6% 23.4% 35.9% 25.0 %

Poor prog ram execution

Row % 7.8% 39.1% 29.7% 23.4%

Level of employee eng ag ement

Row % 9.4% 23.4% 40 .6% 26.6%

19. What data collection methods do you use with your PdM system?

Usingnow

In 2020budget

Within 3years

Noplans

Paper-based system

Row % 62.5% 6.3% 3.1% 28.1%

Handheld data collector

Row % 60 .9% 9.4% 14.1% 15.6%

Embedded sensors/monitoring

devices

Row %

54.7% 10 .9% 18.8% 15.6%

Wireless sensors/transmitters

Row % 42.2% 14.1% 18.8% 25.0 %

Internet-enabled sensors

Row % 26.6% 9.4% 18.8% 45.3%

Industrial-g rade smartphone

Row % 10 .9% 6.3% 18.8% 64.1%

Consumer-g rade smartphone

Row % 21.9% 7.8% 6.3% 64.1%

Industrial-g rade tablet

Row % 29.7% 6.3% 28.1% 35.9%

Consumer-g rade tablet

Row % 18.8% 6.3% 12.5% 62.5%

Industrial-g rade PC

Row % 37.5% 9.4% 17.2% 35.9%

Consumer-g rade PC

Row % 40 .6% 14.1% 6.3% 39.1%

20. Is your PdM system integrated with any of the following higher-level systems?

Using now In 2020 budget Within 3 years No plans

Reliability solutions

Row % 36.7% 5.0 % 16.7% 41.7%

Historian

Row % 41.7% 6.7% 8.3% 43.3%

EAM/CMMS system

Row % 48.3% 13.3% 10 .0 % 28.3%

EH+S solution

Row % 13.3% 13.3% 13.3% 60 .0 %

ERP system

Row % 26.7% 11.7% 16.7% 45.0 %

Cloud-based analytics

Row % 15.0 % 11.7% 23.3% 50 .0 %

21. Are you using OEM-enabled remote monitoring technologies and/or services?

38% Using now38% Using now

5% In 2020 budget5% In 2020 budget

13% Within 3 years13% Within 3 years

43% No plans43% No plans

Value Percent

Using now 38.3%

In 20 20 budg et 5.0 %

Within 3 years 13.3%

No plans 43.3%

DecliningNochange

Increase 0 -5%

Increase >5%

Control systems (DCS, PLC)

Row % 5.0 % 60 .0 % 25.0 % 10 .0 %

Production assets (rotating equipment,

compressors)

Row %

5.0 % 46.7% 35.0 % 13.3%

Instrumentation

Row % 3.3% 51.7% 31.7% 13.3%

EAM/CMMS

Row % 6.7% 61.7% 20 .0 % 11.7%

Data historian

Row % 11.7% 63.3% 20 .0 % 5.0 %

Predictive analytics software

Row % 8.3% 56.7% 31.7% 3.3%

22. What changes, if any, are planned in your PdM investments for the following?

23. What is your percent Reactive Maintenance (annual average)?

Per

cent

0% 4% 8%12%

16%20%

24%28%

32%36%

40%44%

48%52%

56%60%

64%68%

72%76%

80%84%

88%92%

96%100%

0

2.5

5

7.5

10

12.5

24. What is your annual Maintenance Cost / Replacement Asset Value?

Per

cent

0%

378566%

757132%

1135698%

1514264%

1892830%

2271396%

2649962%

3028528%

3407094%

3785660%

4164226%

4542792%

4921358%

5299924%

5678490%

6057056%

6435622%

6814188%

7192754%

7571320%

7949886%

8328452%

8707018%

9085584%

9464150%

9842716%

0

2

4

6

8

10

25. How much of your maintenance technology effort is predictive routes (PdM)versus condition based maintenance (CBM)?

18% All or mostly PdM18% All or mostly PdM

15% About 80% PdM and lessthan 20% CBM15% About 80% PdM and lessthan 20% CBM

5% About 60% PdM and less than40% CBM5% About 60% PdM and less than40% CBM

23% About 40% PdM and lessthan 60% CBM23% About 40% PdM and lessthan 60% CBM

17% About 20% PdM and lessthan 80% CBM17% About 20% PdM and lessthan 80% CBM

22% All or mostly CBM22% All or mostly CBM

Value Percent

All or mostly PdM 18.3%

About 80 % PdM and less than 20 % CBM 15.0 %

About 60 % PdM and less than 40 % CBM 5.0 %

About 40 % PdM and less than 60 % CBM 23.3%

About 20 % PdM and less than 80 % CBM 16.7%

All or mostly CBM 21.7%

26. How is your Reliability/Maintainability/PdM/CBM programorganized/supported? (check all that apply)

Per

cent

RCM initia

tive u

nder

Reliabilit

y Departm

ent

RCM initia

tive u

nder Mainte

nance D

epartment

RCM initia

tive u

nder Engineerin

g Departm

ent

As part

of a L

ean Manufa

cturin

g initia

tive o

r under O

peratio

ns

As part

of a T

otal P

roducti

ve M

aintenance

(TPM) in

itiativ

e

Industr

y 4.0

or s

imila

r initia

tive to

get m

ore in

terco

nnected

Other (

please sp

ecify)

0

10

20

30

40

50

Value Percent

RCM initiative under Reliability Department 33.3%

RCM initiative under Maintenance Department 50 .0 %

RCM initiative under Eng ineering Department 23.3%

As part of a Lean Manufacturing initiative or under Operations 21.7%

As part of a T otal Productive Maintenance (T PM) initiative 28.3%

Industry 4.0 or similar initiative to g et more interconnected 5.0 %

Other (please specify) 5.0 %