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1 1 Source: T.A. Cook, Maintenance Efficiency Report 2013, August 2013. http://uk.tacook.com/fileadmin/files/3_Studies/Studies/2013/T.A._Cook_Maintenance_Efficiency_Report_2013_En.pdf?tracked=1 2 Source: Oniqua Enterprise Analytics, Reducing the Cost of Preventative Maintenance, http://www.plant-maintenance.com/articles/PMCostReduction.pdf
A time-based approach is embraced by a traditional preventive maintenance program. Problems that arise:
• Consuming expensive resources
• Potentially introducing failure by disrupting stable systems
40% of preventive maintenance costs are spend on assets with negligible affect on uptime 1
45% of all maintenance efforts are ineffective 2
30% of preventive maintenance activities are carried out too frequently 2
Watson IoT / Insights into Asset Health
Preventive Maintenance programs effectively improve reliability, however…
• Manyorganiza+onshavemorePMsthantheyhavestafftoexecute• Op+miza+onandPriori+za+onofPMsisbecomingnecessary• Effortneedstobebasedonthehealthoftheasset
Watson IoT / Insights into Asset Health 2
Condition based maintenance uses IoT data to assess asset health
40% of preventive maintenance costs are spent on assets with negligible affect on uptime 1
The results speak for themselves
Reduce maintenance costs by up
to 25%
Eliminate up to 70% of
breakdowns
Reduce downtime by
up to 50%
Cut unplanned outages by up to 50%
Reduce scheduled
repairs by up to 12%
Reduce capital
investment by 3-5%
Monitor and analyze asset health data, both historical and real-time
Intervene at the right time, before assets go down
Prioritize and optimize resources
Watson IoT / Insights into Asset Health 3
Sensor data Real time and Historical
Maximo Asset Information Asset Health
Condition data is enhanced when combined with contextual information to give a more perfect picture of Asset Health
• Real time sensor data from the equipment via individual sensors (add-on or embedded)
• Real time sensor data or alerts from SCADA systems • Historical trends of sensor data from historian or other data repository • Inspection data that might include measurements, observations, photos gathered
manually or from mobile devices • Maintenance history of the asset • Related information: environmental (temp, humidity, etc.), weather, usage, output
Understanding current condition alone, is not enough…
IBM Maximo Asset Health Insights
Designed with Reliability Engineers in mind Subscribe to warnings and notifications for response to Asset issues prior to failure Define Asset Health using data from many sources including Maximo and Real-time
Remaining useful life Maintenance and failure history Asset Condition based on real time and historical information
Leverage Historical Weather as a Key Element in determining Asset Health Minimize unnecessary maintenance based on Asset Health score Insights to determine repair vs. replace
Watson IoT / Insights into Asset Health 4
Available now
• Contextualizes device data • Monitors streaming data to
detect situations • Filters the data for analysis by
Maximo Users • Stores data for further analysis
IBM Watson IoT Platform
3 Historical sensor data
Real time filtered data from automation systems 2
4 Historical weather data
IBM Maximo Asset Health Insights
• Enables Immediate action and/or
• Provides engineers with rich set of sensor and asset data to determine proper course of action
• Visibility into asset condition, from asset lifecycle perspective
• Consolidates Asset data, historical and real-time, including data from external data systems, weather data, etc.
• Advanced dashboard view enables proactive asset and maintenance decisions
1 Real Time data from low cost add-on sensors
Watson IoT / Insights into Asset Health 5
How IoT information is used within Maximo Asset Health Insights
Customizable Work Center for Reliability Engineers
Watson IoT / Insights into Asset Health 6
Consistent look and interface with Maximo 7.6
Drill into Specific Contextual Data for Assets
Watson IoT / Insights into Asset Health 7
MeterReadings
Asset detail
Weather can be an important element for Asset Health
Transmission line sag is a key factor in determining power line health. Temperature and humidity can significantly affect sag. Understanding sag in the context of historical weather for that location, engineers can more effectively determine asset health.
Correlation of high temperature readings from a pump with current weather can be used to determine a potential problem vs. normal operation given ambient temperature.
The number of times an asset has operated in weather outside its recommended operating parameters (i.e. over 90 degrees F.) can be a driver in determining overall asset health
Watson IoT / Insights into Asset Health 9
Why Consider Leveraging Asset Health?
Reduce the cost and frequency of asset failures
• Perform maintenance while the asset is working to reduce disruptions to operations
• Improves overall equipment reliability
1
• Optimizes time spent on maintenance
• Reduces overtime costs by scheduling the activities
• Decreases requirement for emergency spare parts
Minimize unscheduled downtime due to catastrophic failure 2
• Defer unneeded maintenance
• Prioritize PM workload based on condition
2 Reduce maintenance workload and costs with PM optimization 3
Watson IoT / Insights into Asset Health 10
Take-aways from today
Maximo Asset Health Insights lets businesses capture knowledge about the true health of valuable assets and maximize the value of your maintenance investment.
Understand what data your organization is using to make Preventive Maintenance decisions. Where can you start to unlock value quickly?
1
2
Maximo Asset Health Insights represents a new way of maintaining equipment - one based not only on current condition-based readings coming from the equipment, but also informed by other influences like age, maintenance history, weather incidents and historical context of subcomponents.
Your next steps
1
2 Schedule a demo of Asset Health Insights to discover how a consolidated view of asset data improves reliability. Check out the details at IBM.co/asset-mgt. Then contact your IBM solution seller to get started!
11
Thank you
Visit ibm.com/iot Watson IoT / Insights into Asset Health