Leverage IIoT to improve asset performance

As organizations recognize the significance of asset maintenance and its impact on the bottom line, companies are increasingly incorporating asset management in their strategic initiatives. The shift from a reactive culture has asset managers seeking opportunities to proactively contribute to the operational and strategic goals of the business.

Asset Maintenance and Industrial IoT
The maintenance maturity model[1] proposed by the ARC advisory group shows how maintenance strategies can yield higher business benefits as one progresses further along the maintenance continuum. Ralph Rio says that users who moved from preventive to predictive to prescriptive maintenance have reported 50 percent savings in maintenance labor and MRO materials.[2] Better and effective maintenance strategies help improve operational efficiency, prevent equipment downtime, and extend the life of the asset. The ripple effect of such maintenance strategies also has other intangible benefits like improved quality, customer satisfaction and safety. For instance, if the frequency of breakdown in certain machinery is high, then this could also turn out to be a safety issue and would necessitate precautionary measures.

Industrial IoT (IIoT) combined with analytics is the key to maximizing asset productivity and process efficiency. Analytics convert raw machine data into actionable intelligence enabling proactive maintenance execution and increased asset reliability. The number and variety of parameters that is monitored increases dramatically with no compromise on data quality. The IoT sensors monitor asset performance continuously and when this data is combined with today’s advanced analytics, it helps managers make better asset management decisions. You can schedule maintenance only when it is needed and optimize your resources.

But just implementing hundreds of sensors to every asset in the organization will not drive IIoT benefits. Instead, you will need to focus on the specific instances which best fit your industry and your organization. For instance, if your focus is on improving the operating health of the asset, parameters such as vibration and temperature become more critical as compared to other criteria.

Asset Maintenance Maturity Model and IIoT
Use the AMM Model to understand how best to use IIoT effectively for asset maintenance. For instance, reactive maintenance may work for non-critical assets as their preventive maintenance costs might outweigh their asset failure costs.

When asset fail randomly, tracking various trends and parameters is essential to identify root cause. You can use sensor data to set up user-defined rules to monitor and perform asset maintenance activities. Any of the set conditions can trigger work orders requests and assignments. McKinsey says that this type of Condition-based maintenance can not only reduce maintenance costs by up to 25% but also cut unplanned outages by up to 50%, thus contributing to asset longevity.[3] Critical asset failure can have a significant business impact. Using a combination of condition-based maintenance, Advanced Pattern Recognition and machine learning can provide robust analytics which can identify performance issues and predict impending asset failures.

But to reach the top of the pyramid (Prescriptive Maintenance), your asset management strategy needs to incorporate predictive maintenance analytics and machine learning to provide diagnostics and guidance for asset repair. Also, you will need the necessary information to determine the timing and impact of failure to help assess asset priority and urgency.

How we can help
ValuD, together with Motors@Work and IBM Maximo can assist you on your journey to predictive maintenance. Combine the best of what IIoT, Analytics and Cognitive Intelligence has to offer and make informed asset management decisions. Our Maximo experts will assist in upgrading your instance to 7.6 and taking advantage of the benefits. Leverage Motors@Work’s analytics to collect and analyze condition monitoring alerts to improve reliability and asset utilization. You can also:

  • Leverage Motors@Work’s patent-pending analytics and proprietary motor catalog to plan, prioritize, initiate, and execute capital replacement recommendations.
  • Use IBM Maximo together with Maximo Asset Health Insights (MAHI) and Motors@Work’s pre-configured Energy and Reliability score cards to monitor motor health and to support better asset management decisions.
  • Take advantage of Watson IoT’s predictive analytics solution and Motors@Work’s learning algorithms to monitor motor health, build a life-cycle model that predicts asset end-of-life, and trigger maintenance alerts.

For more information, contact us at info@valudconsulting.com.

[1] https://www.arcweb.com/industry-concepts/asset-performance-management-maturity-model

[2] https://industrial-iot.com/2017/02/iiot-expands-the-maintenance-maturity-model/

[3] http://fortune.com/2015/07/22/mckinsey-internet-of-things/

Benefits of a Maximo Version 7.6 upgrade

In our earlier blog, we reviewed considerations for upgrading to Maximo 7.6.  Now that IBM has announced End of Support for Maximo 7.5, now is the time to  upgrade to the latest version.

Let’s delve into the benefits.

Benefits of Maximo 7.6 upgrade

  1. Reduced need for Customizations: Maximo 7.6 comes with improved OOTB capabilities which greatly reduce the need for customization. Feature pack enhancements include
    1. Support for Maximo Integration Framework (MIF) scripting
    2. General scripting enhancements (including support for real-time logging, library scripts)
    3. More script points for Maximo Business Objects (MBO) and MBO attributes
    4. Support for mathematical formulas
    5. Federated MBOs which facilitate ease of integration with external REST APIs. This allows external REST APIs to be treated as Maximo MBOs enabling them to be used in Maximo UI, workflows, conditions, escalations, integrations, scripting etc.
    6. Enhanced REST APIs to support end-to-end JSON format and accessibility to more Maximo functionalities.
    7. Improved troubleshooting capabilities including user-scoped logging support and Maximo Management Interface (MMI).
  2. IBM Watson Analytics Integration: Maximo 7.6 comes equipped with seven preconfigured data sets and seamless export to Watson Analytics. Take advantage of Watson’s cognitive intelligence to identify and analyze asset issues and trends within your Maximo system.
  3. Leverage IoT Platform: McKinsey says companies can reduce their maintenance costs by up to 25% and cut outages by up to 50% just by monitoring and analyzing asset health data – both historical and real-time[1]. Internet of Things (IoT) can help you gain insights to real-time asset health data. Perform your condition-based maintenance leveraging the wealth of data provided by the IoT platform. Learn more on how IoT can help with Preventive Maintenance here.
  4. Expanded list of Add-Ons like AHI and Industry Solutions: Maximo Asset Health Insights (MAHI), an add-on solution offered by IBM with Maximo 7.6, helps determine repair versus replace opportunities by providing you insights on asset health. It leverages the Watson IoT platform together with historical weather and sensor (real-time and historical) data to enable condition-based asset maintenance. Similarly, industry solutions including Utilities, Oil & Gas and Aviation have been enriched with newer capabilities delivering an enhanced user experience.
  5. Better License Tracking: Maximo 7.6 includes new applications and reports to enable users to register and track usage of their entitlements that would help identify under or over utilization.
  6. Newer Capabilities:
    1. BIM: Integration with BIM (Building Information Modeling) has been enhanced due to the addition of new apps for COBie data import, BIM project management and commissioning of 3-dimensional building views.
    2. Maps & Service Addresses: You can now add service addresses for assets and locations and take advantage of Esri, Google and Bing maps for increased resource utilization and usability.
  7. Work Centers: Role-based, data-driven, interactive work centers will be made available with 7.6 to drive an intuitive and better user experience.
  8. Automation Testing: Maximo 7.6 offers automation testing support using the Selenium Automation Framework facilitating quicker deployment of newer features.

How ValuD can help
ValuD has deep asset management and Maximo technical knowledge with twenty years of Maximo upgrade experience beginning at Maximo 4.2. Our team of Maximo consultants will solve your Maximo upgrade challenges quickly and deliver cost effective solutions. Specific Maximo upgrade services that we provide include

  1. Data Cleansing to detect and remove/correct inaccurate records making the system easier to use.
  2. Integration with external and internal legacy systems to enable transmission and exchange of asset data.
  3. Standard and Custom Report creation for better insights on asset health and facilitate condition-based asset monitoring
  4. Industry Expertise and best practices to implement a seamless transition to the latest version.
  5. Implement the Maximo Bridge to Cloud program to move your on-premise license to a SaaS Model. Use this option to experiment the SaaS model for your Maximo subscription at no extra charge, retaining your support for the on-premise option at the same time.
  6. Minimal downtime during implementation: We will perform the upgrade offline in a Development/Test environment and solve the issues. These changes will then be deployed to the production environment over a weekend to minimize downtime.

To learn more on how ValuD can help you upgrade to Maximo 7.6, contact us at sales@valudconsulting.com.

[1] http://fortune.com/2015/07/22/mckinsey-internet-of-things/

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.