maximo asset health overview (watson iot)
TRANSCRIPT
Jim Crosskey
Senior Offering Manager
February 16, 2016
Optimizing Preventive Maintenance
with Asset Health Insights
21 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…
• Many organizations have more PMs than they have staff to execute
• Optimization and Prioritization of PMs is becoming necessary
• Effort needs to be based on the health of the asset
Watson IoT / Insights into Asset Health4
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 Health5
Maximo Condition Monitoring Today
• Some sample use cases:
− When a tank is low, initiate work to fill it
− When pressure differential on a filter is above x, replace the filter
− When output pressure drops for a pump, schedule an inspection
• Readings exceeding user defined values trigger a PM Work Order
CharacteristicGaugeContinuousContinuous
Numeric Range
Thermometer
They fluctuate
Counters
Odometer
They aggregate
Observations
Level of Service
Discrete values
Watson IoT / Insights into Asset Health6
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…
Weather
Data
Watson IoT / Insights into Asset Health7
SCADA Enterprise (Homegrown System)
Maximo RPM (Renewal Planning Model – 3rd party))
Today there are multiple sources and systems for assessing asset health
IBM Maximo Asset Health Insights
Designed with Reliability Engineers/Asset Owners
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-timeRemaining 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 Health8
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 datafrom automation systems2
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 Health9
How IoT information is used within Maximo Asset Health Insights
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Maximo and IBM IoT Platform integration with Automation Systems:
Partnership with Schad Automation
• Automatic Meter Reading - software product that provides connectivity to automation systems
• Integrates with (SCADA, PLC, BMS) via a wide range of industry standard protocols such as OPC, BacNet, etc.
• Enables mapping of sensors to assets in Maximo
• Allows data from control systems to be sent to Maximo’s Condition Monitoring module
• Includes Integration with the IBM Watson IoT
Platform
• Ability to define simple rules for notifications or for
creating Maximo work orders/service requests
Reduces need for physical inspections or meter
readings
Rapid connection of SCADA information into
Maximo
Data can be used for trend analysis to optimize
preventive maintenance
Highly scalable, capable of measuring millions of
data points across multiple sites
Consistent look and
interface with
Maximo 7.6
Drill into Specific Contextual Data for Assets
Watson IoT / Insights into Asset Health12
Meter Readings
Asset detail
Watson IoT / Insights into Asset Health13
Asset Health in action
If the diagnostic data is available in real
time for a locomotive, I can decide whether
I need to hit the reset button, saving 1,000
euro’s per train, or take it out of service to
bring it to the maintenance center for repair.
Understanding the vibration and
temperature of a pump, along with the
maintenance history will indicate whether I
should inspect, perform routine maintenance
or schedule the asset for replacement. The
least cost option or optimal timing can then
be assessed.
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
…In addition, IBM can provide enhanced accuracy and optimization
with Predictive Maintenance on Cloud
Additional tools for Reliability Engineers
accessible along with Maximo Asset Health
Insights
Predictive models which determine likelihood
of asset failure and time to failure based on
statistical modeling
Identify top failure modes
Recommended optimal maintenance
schedules and maintenance procedures
Ongoing optimization through machine
learning and physics based models
Watson IoT / Insights into Asset Health15
Overv
iew
Drill-
dow
n
Com
parison
Watson IoT / Insights into Asset Health16
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 failure2
• Defer unneeded maintenance
• Prioritize PM workload based on condition
2 Reduce maintenance workload and costs with PM optimization3
Watson IoT / Insights into Asset Health17
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
2Schedule 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!
18
Thank you
Visit ibm.com/iotWatson IoT / Insights into Asset Health