Harness The Power Of IoT For Condition Based And Predictive Maintenance

Did you know

  • 82% of asset failures occur randomly and do not have an age-related failure pattern[1]
  • On an average, 18%-30% of every dollar spent on maintenance is wasted[2]

Age-related failure is the basis for Preventive Maintenance. The older the asset, the higher the frequency of maintenance – this kind of time-based cycle has always been the accepted industry practice. But when time-based maintenance activity is not effective, the question becomes whether the money spent is really worth the investment.

Preventive Maintenance costs Versus Asset Reliability
ARC Advisory Group’s Enterprise Asset Management and Field Service Management Market Study finds that an average company can reduce its maintenance costs up to 50%. ARC identifies the primary KPIs for asset performance as higher uptime and asset longevity.[3] The argument is that sometimes over- maintaining may do more harm than good, increasing costs and squandering precious maintenance resources (time, tools, parts and labor).

A study by Oniqua Enterprise Analytics, found that 30% of preventive maintenance activities were carried out too frequently, while 19% of preventive maintenance activities were a waste of time.[4] With more than three-fourths of your assets having a random (and not age-related) failure pattern, your preventive maintenance activities may not be effective. Companies are challenged to balance maintenance investments versus asset reliability.

Condition-based Monitoring
Rather than executing maintenance based on a set interval, listening to your assets can provide valuable insight. Monitoring temperature, pressure, vibration, voltage imbalances and other measures can be strong indicators. If any of these conditions are outside of acceptable parameters, then it signals the need for maintenance investigation. This kind of condition-based maintenance is predictive in nature and can help increase asset uptime and reduce asset life cycle costs.

How can an EAM solution help
Management and/or mitigation of risk due to failure of critical assets is the foundation of asset management. Identifying risk and establishing controls is essential to transform an organization’s asset management approach from reactive to predictive. Predictive Asset Analytics can proactively address potential safety risks and compliance issues by analyzing both historical and current data from multiple sources like SCADA (Supervisory Control and Data Acquisition), online monitoring systems, and non-operational data (industry standards, operational practices) to build predictive models. One can use these models to generate risk scores which, in turn, can help you understand the implications of events and the necessary action.

Choosing the right asset management software is the key to maximize value and efficiency. IBM Maximo Asset Health Insights, for instance, can access multiple data sources in real time to predict asset failure, which can help mitigate downtime and reduce your maintenance costs. Use Maximo to detect anomalies and failure patterns and identify assets or processes that are at the highest risk for failure.

Technological advancements like the Internet of Things (IoT) also makes it easier for Predictive Maintenance activities like Condition-based Monitoring since it eliminates the need for human-to-human or human-to-computer interaction. IoT can be integrated with work management to create closed loop reporting, alerts and work requests.  Motors@Work IoT application, for instance, associates near real-time energy data with motor system design plus operational and DoE metrics  as the basis for condition monitoring alerts.

As a long standing and trusted partner of IBM, ValuD (through AME, our Maximo services company) has been providing implementation and support services for IBM Maximo since 4.0. Motors@Work is a scalable, cloud based solution that provides the information and intelligence that will save you energy, reduce maintenance costs, and improve motor-driven system asset performance. The out-of-the-box solution integrates seamlessly with existing asset management systems like IBM Maximo, leveraging current technology investments.

To learn more on how ValuD can help leverage Maximo and IoT for your asset management strategy, contact us at info@valudconsulting.com.

[1] Optimize Asset Performance with Industrial IoT and Analytics By Ralph Rio. ARC View, August 6, 2015

[2] Bever K, Enterprise Systems Integration: Opportunities & Obstacles Developing Plant Asset Management Systems March 13, 2000 (Presented at National Manufacturing Week, Chicago, Illinois)

[3] Optimize Asset Performance with Industrial IoT and Analytics By Ralph Rio. ARC View, August 6, 2015

[4] Oniqua Enterprise Analytics: Reducing the cost of Preventive Maintenance

Why you should upgrade to Maximo Version 7.6

Are you on the fence on whether your company should upgrade to Maximo Version 7.6?  Let’s walk through what you should consider.

Do I need an upgrade

Ask yourself the following questions.

  • Are you on version 7.5 or earlier?
  • Are the customizations in your current version of the software now available in the out-of-the-box version?

If the answer to either one of the above mentioned questions is “Yes”, then you will definitely need to consider upgrading to 7.6.  While, IBM has already discontinued their support for Maximo 7.1 and other earlier versions, they have announced that they will be discontinuing the support for Maximo 7.5, effective 30th Apri 2018.

OOTB functionalities can streamline your business processes and minimize customization and configuration issues. Also consider integration complexity and the end user training needs in your decision process.

Benefits of the upgrade

Maximo 7.6  comes loaded with multiple capabilities which will help achieve greater efficiency in resource management. IBM has also introduced the ‘continuous delivery’ model which ensures that Maximo users get quicker access to all the fixes, enhancements, features and functions versus waiting for a full scale upgrade.

Here are the major features to consider when making your upgrade decision:

Installation Considerations

  • Single interface for installation and updates
  • Support for multi-tenancy environments
  • Improved Workflow designer that minimizes conflicts with other applications

Technical Considerations:

  • Process Content Packs (PCPs) containing best practices data to minimize configuration efforts
  • In-session or thread based logging to ease debugging process
  • Automated scripting enhancements to simplify data entry process

Functional Enhancements:

  • Result set portlet – Enables viewing information related to main record of the result set
  • “Lock edit” mode – Allows edits to be made only by a single user at any point in time.
  • Crew Management- Crew types and Crew application
  • Ability to add service addresses for assets and locations
  • Public map API and application designer for map control – Easier access to Google and Bing Maps
  • Log tab for Quick Reporting, Purchase orders and Purchase Requests
  • Mobility – Embedded mobile access with the inclusion of Maximo Everyplace in the core product at no additional licencing cost

Business Intelligence:

  • Perform calculations, create summaries for selected attributes and restrict record access in ad-hoc reports
  • New BIRT Reporting engine allows for enhanced performance and flexibility
  • Streamlined KPI creation and management
  • Cognos report creation

UI Considerations:

  • Configurable Dashboards
  • Customizable fields
  • Collapsible side menu to simplify navigation
  • Hover Capabilities – Hover over a field to view more record-related information

Possible Obstacles
While considering an upgrade, keep in mind that Maximo 7.6 does not support

  • Operating Systems – 32 bit Linux & Windows 2008
  • Browsers – Internet Explorer 7 & Mozilla Firefox 24
  • Application Servers – IBM Websphere 7 & Oracle WebLogic Server 10.3.3

With a wealth of new features and capabilities, Maximo 7.6 can positively impact your asset management needs through improved visibility, resource utilization and cost savings. As a long standing and trusted partner of IBM, ValuD (through AME, our Maximo services company) has been providing upgrade, implementation and support services for IBM Maximo. To learn more on how ValuD can help you upgrade to Maximo 7.6, contact us at sales@valudconsulting.com.

Benefits of connecting smart meters with assets

What if your equipment ‘senses’ changes in bearing friction, creates a lubrication work request, and sends the data to your asset management system automatically?

Internet of Things (IoT) technology makes machine-to-machine interaction possible. By assigning an IP address to your assets (both physical and digital), you can achieve data exchange between devices. But for the machine to sense and track changes in temperature or pressure, it needs a metering device.

A smart meter is an electronic device that tracks changes in temperature, pressure, airflow, sound, vibrations or motion and uses two-way communication to facilitate data exchange. The meter can record real-time measurements of energy consumption, detect and prevent outages and improve operational efficiency.

Smart Meters, Cloud and Asset Management
Smart meters when used in conjunction with cloud technology allows you to maximize benefits from asset condition monitoring. You can set a pre-determined schedule (hourly, daily, weekly etc.) for the smart meter (which is attached to your asset) to take meter readings. These readings are passed in real-time to the asset management system. IoT applications, like Motors@Work, can help by acting as a “gatekeeper” between the Smart Meter and the Asset Management system. Motors@Work analyzes the smart meter readings and translates them into meaningful energy management actions. For instance, if any of the reading levels are outside the “safe” zone, then the application raises an alert and transmits the information to the asset management system which may generate a work request.

Under on-going condition monitoring, you can schedule maintenance only when it is required versus maintenance activities that are carried out with a pre-determined schedule, regardless of the need. This proactive approach can help detect failures, reduce maintenance costs and increase the lifespan of your assets by avoiding unnecessary replacement of machinery.

Need for Smart Meters
A failure to detect the non-performance of a boiler was the primary reason behind the Bhopal gas tragedy, the world’s worst industrial disaster. With the boiler repair unattended, the increase in pressure remained undetected till it was too late causing the safety valve to burst and the gas to leak. Smart meters and IoT applications could have detected such anomalies and negated the human negligence aspect.

Other advantages of using smart meters for asset management include enhanced asset utilization, decreased maintenance costs, improved energy efficiency, and better regulatory compliance.

Integrating Smart Meters with Maximo
Using smart meters to manage your assets can provide transformative levels of information and control but deploying and managing smart meters in an asset-intensive organization is a task in itself. The data generated will be significant and the location of your assets can create coordination issues. Using a separate point solution to manage your smart meters could be expensive, time-consuming and inefficient.

Choosing the right asset management software is the key to maximize value and efficiency. Maximo provides a holistic picture by providing greater visibility, control and automation over smart meter deployments. Some of the benefits include

  • Role-based dashboards that help manage smart meters from a central location
  • Support for related business processes like supply chain management, routing deployment, and regulatory compliance.
  • Master data management of Smart Meters such as location, work orders, scheduling and contracts
  • Integration with the organization’s legacy systems including Enterprise Resource Planning (ERP), Geographic Information System (GIS), Finance and billing.
  • Workflow automation, mobility integration and detailed reporting capabilities

As a long standing and trusted partner of IBM, ValuD (through AME, our Maximo services company) has been providing implementation and support services for IBM Maximo. Motors@Work is a scalable, cloud based solution that provides the information and intelligence that will save your energy, reduce maintenance costs, optimize operations and improve motor-driven system asset performance. The out-of-the-box solution integrates seamlessly with existing asset management systems like Maximo by leveraging current technology investments. To know more on how ValuD can help harness the power of cloud and IoT for your asset management strategy, contact us at info@valudconsulting.com.

Five reasons why mobility in the IWMS workplace matters

Let’s face it, we are pretty attached to our mobile devices these days. Chances are you are even reading this post from your smart phone or tablet. This cultural shift has slowly inched its way into the corporate world so that now it’s considered normal for employees to be mobile. Systems that were once only accessed when an employee was sitting at their desktop are bringing to light new capabilities that allow workers to take their work on the go. In fact, it’s predicted that mobile technologies will assist businesses the most as compared to any other technology over the next five years. Is it any wonder then that introduction of mobile capabilities in the workplace has become so critical for businesses? In this post, we’ve analyzed the various reasons behind the rapid proliferation of mobility and its significance in today’s work environment.

1

Mobility is everywhere. About 10 years ago, the mobile phone went from being a luxury to what most would consider a necessity. With more than five billion mobile subscribers in the world today, it goes without saying that mobility has indeed transformed the concept of connectivity by leaps and bounds making this world a much smaller place. It has opened a new window of opportunity for businesses to provide valuable customer service to unchartered markets.

2

Increased workforce efficiency. The workplace, as we know it, is progressing and traditional jobs that once required a clipboard and manual data entry are quickly evolving. By allowing employees to access systems through a mobile device, whether it be cell phone or tablet, the systems reach a new level of efficiency.

Entering findings is no longer a multi-step process. Take a maintenance worker going out to do a facilities condition assessment, for instance. Instead of jotting down his findings on a multitude of aspects in quick scribble and scratch that he will need to decipher later, he can simply log on to an application on his mobile device and enter all of the data that he needs to collect. This data will appear in real time and will be accessible to others within the organization as long as he has a reliable internet connection. Similarly, the supervisors too can assign additional work tasks to their technicians depending upon their location, availability and their skill-sets. This also saves up on the waiting time that would be required for the various technicians to return to their posts, update on their assigned work tasks and then get a new task assigned to them.

3

Advanced Capabilities. Mobile technology has improved dramatically over the past few years so much so that it would not be wrong to say that smartphones have become almost as powerful as desktops and laptops. It wouldn’t be a crazy assumption to say the mobile phone might even replace personal computers and laptops in a few years from now.

Faster access to data is always a good thing

4

Ease of Use. Because mobile platforms are typically forced to slim down into an app format, users can ensure that only those areas that they will really need to work on – will appear in the mobile application. You can remove the nonessential aspects that are present in the desktop version and keep only what you would really need to be more efficient and productive on the field. As a matter of fact, the mobile applications created today are more user friendly and accessible than ever. Their inherent simplicity and usability allows for greater user adoption and maximizes product satisfaction.

5

Savings in time and effort. With mobility bringing about increased efficiency, users have the freedom to devote more time on their actual tasks instead of getting stuck in the peripheries. Those working in maintenance, for example, will no longer have to spend time filling out tedious paperwork and sorting through files before they solve problems. They can simply enter in the information wherever they are and get down to business.  This reduction in paperwork can save invaluable time and allow for more work orders to be completed and help lessen the pile up of tasks to be completed.

There is no getting past it – mobility is making a big splash in today’s digital workplace. It’s never been more important for organizations to be on the front end to reap the maximum benefits. To know more about how mobility can help in the IWMS space, please reach out to us at sales@valudconsulting.com.