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© 2013 IBM Corporation
IBM Predictive Maintenance and Quality
Presenter Name
Presenter Job Title, IBM Organization Name
Date
© 2013 IBM Corporation
Poor AssetPerformancePoor Asset
Performance
Limited Process
Integration
Limited Process
Integration
• Lack of visibility of predictors across organizational silos
• Difficulty synchronizing demand and supply
• Too many manual processes & disparate information sources
• Losses in processes have become norm
• Resource complexity make it harder to respond to changing needs
• Lack of visibility of predictors across organizational silos
• Difficulty synchronizing demand and supply
• Too many manual processes & disparate information sources
• Losses in processes have become norm
• Resource complexity make it harder to respond to changing needs
Market forces are amplifying day-to-day issues
Customer demands
Complex supply chains
Raw material price volatility
Compliance and scrutiny
Lean operations
Aging workforce
• #1 Risk to Operations is asset failure1
• Lack of visibility into asset health
• High costs of unscheduled maintenance
• Inability to accurately forecast asset downtime and costs
• Leads to unnecessary process proliferation
• Aging assets pushed to limits to meet consumer needs
• #1 Risk to Operations is asset failure1
• Lack of visibility into asset health
• High costs of unscheduled maintenance
• Inability to accurately forecast asset downtime and costs
• Leads to unnecessary process proliferation
• Aging assets pushed to limits to meet consumer needs
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© 2013 IBM Corporation
Analytics is a key enabler in maximizing asset productivity and process efficiency
Process Integration
Optimize operations and maintenance
Enhance manufacturing and product quality
Asset Performance
Improve quality and reduce failures and outages
Optimize service and support
Source: IBM CIO Study, "The Essential CIO" Source: IBM Institute for Business Value and MIT Sloan Management Review, “Analytics: The New Path to Value”
Fig.1: Best-in-Class companies use the data they collect more effectively, and turn that
data into actionable intelligence
Fig.1: Best-in-Class companies use the data they collect more effectively, and turn that
data into actionable intelligence
Source: Aberdeen Group. Asset Management: Using Analytics to Drive Predictive Maintenance. Mar 2013.
Fig. 2: Best-in-Class companies leverage all technology enablers
to enhance outcomes
Fig. 2: Best-in-Class companies leverage all technology enablers
to enhance outcomes83 percent of CIOs cited analytics as the primary path to competitiveness
83 percent of CIOs cited analytics as the primary path to competitiveness
Organizations that lead in analytics outperform those that
are just beginning to adopt analytics by 3 times
Organizations that lead in analytics outperform those that
are just beginning to adopt analytics by 3 times
3x
83%
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© 2013 IBM Corporation
Assets are more than just manufacturing machinery
1. Manufacturing process Manufacturing machinery utilized to create a product
2. Field-level assets Consumer Appliances
o Washers, dryers, hot water heaters, furnaces, HVAC Vending Machines
o Food, drinks, cigarettes, electrical products, videos, money Connected Transportation
o Planes, trains, ships, tanks, buses, passenger automobiles, fleets, electric vehicles, gas powered autos, motorcycles, snow mobiles, lift trucks
Heavy Equipment Machinery o Earth movers, mining equipment, cranes, wind/gas turbines, nuclear plants, solar panel
arrays, oil drills, oil rigs Networks
o Electrical grids, water/sewage infrastructure, IT systems, telecom lines/cables, security systems
Buildingso Property, real estate, universities, stadiums, corporate offices, headquarters, field offices
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© 2013 IBM Corporation
New Offering!
IBM Predictive Maintenance and Quality•Reduce operational costs•Improve asset productivity •Increase process efficiency
AccelerateTime-to-ValueAccelerateTime-to-Value
Real-time capabilities Big data, predictive, and advanced
analytics Quick and accurate decisioning Maximo integration Open architecture Business intelligence
2012
Q1 2013
TODAY!
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© 2013 IBM Corporation
• Monitor, maintain and optimize assets for better availability, utilization and performance
• Predict asset failure to optimize quality and supply chain processes
• Remove guesswork from the decision-making process
IBM Predictive Maintenance and Quality reduces operational costs, improves asset productivity and increases process efficiency
Combined with out-of-box models, dashboards, reports and source connectors Combined with out-of-box models, dashboards, reports and source connectors
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© 2013 IBM Corporation7
Business Use Case Business Value
Predictive Maintenance and Quality generates business value for organizations
Predict Asset Failure/Extend Life
Determine failure based on usage and wear characteristics
Estimate and extend component life
Utilize individual component and/or environmental information
Increase return on assets
Identify conditions that lead to high failure
Optimize maintenance, inventory and resource schedules
Predict Part Quality
Detect anomalies within process Improve quality and reduce recalls
Compare parts against master Reduce time to identify issues
Conduct in-depth root cause analysis Improve customer service
© 2013 IBM Corporation8
Case Studies
• A city government wanted to boost city services and address infrastructure sustainability
• IBM combines asset management innovations, predictive modeling, and geospatial and business analytics to help the city improve planning, operations and services
Outcomes: • Anticipates saving $100,000 per year
in staff time spent on capital plan forecasting
• Expects to reduce costs related to project coordination, operations and capital expenditures
• A global petroleum company wanted to increase asset utilization and reliability in a remote environment
• IBM helps predict where and when ice presents a threat to existing drilling platforms
Outcomes: • Produces real-time visualization of
ice floe positions and trajectory cone forecasts
• Predictions determine whether to move platforms — providing cost savings
• A not-for-profit marine society dedicated to ensuring safety and pollution
• IBM helps the company detect anomalies in vessel monitoring systems even under dynamic changes of ocean conditions
Outcomes: • Significant reduction of the cost for
detection rule construction (~1/10)• Significant increase of detection
coverage (~ x 2-3)• Reduction of overall maintenance cost
(demonstrated at least 10%)
Predict Asset Failure/Life: EnvironmentPredict Asset Failure/Life: Environment
Predict Asset Failure/Life: Enterprise Asset Mgmt
Predict Asset Failure/Life: Enterprise Asset Mgmt
Predict Part Quality:AnomaliesPredict Part Quality:Anomalies
© 2013 IBM Corporation9
Case Studies
• A global manufacturing company wanted to more quickly detect part defects
• IBM implemented an early detection model to detect part defects earlier and respond in the most optimal way
Outcomes: • Early identification and mitigation of
enterprise component and quality issues
• Provide insight to the health and probability of failure for in-service equipment maximizing uptime
Global manufacturing company
Global manufacturing company
Regional utility companyRegional utility company
• A regional utility company needed to maintain an aging infrastructure
• IBM delivered an industry-specific solution to detect potential problems before they occur
Outcomes: • Improved asset maintenance
identification • 20% productivity gains for service
trucks• Up to 20% reduction of fuel costs
due to fewer truck rolls
Global auto manufacturerGlobal auto manufacturer
• A vehicle manufacturer wanted to improve its production quality
• IBM’s solution helped use real-time data to monitor the production quality and more quickly identify and resolve issues
Outcomes: • Reduced the defect rate by 50% in
16 weeks in the production of cylinder heads
• Increased customer satisfaction
Predict Asset Failure/Life: Extend LifePredict Asset Failure/Life: Extend LifePredict Production
QualityPredict Production Quality
Predict Part QualityPredict Part Quality
© 2013 IBM Corporation10
Predictive Maintenance and Quality analyzes data from multiple sources and provides recommended actions, enabling informed decisions
Asset MaintenanceAsset Performance Process Integration
Collect & Integrate DataStructured, Unstructured,
Streaming
Generate Predictive & Statistical Models
Conduct Root Cause Analysis
Display Alerts and Recommended Actions
Act upon Insights
Predictive Maintenance and
Quality
Predictive Maintenance and
Quality
• Data agnostic• User-friendly
model creation
• Interactive dashboards
• Quickly make decisions
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© 2013 IBM Corporation
A proven architecture based on best practices underlies Predictive Maintenance and Quality
Integration Bus(Message Broker)
Integration Bus(Message Broker)
End User Reports, Dashboards, Drill Downs
High volume streaming data
High volume streaming data
Telematics, Manufacturing Execution Systems,
Legacy Databases, Distributed Control
Systems
Telematics, Manufacturing Execution Systems,
Legacy Databases, Distributed Control
Systems
Enterprise Asset Management Systems
Enterprise Asset Management Systems
Analytic Datastore(Pre-built data schema for storing quality, select machine and prod data, configuration)
Analytic Datastore(Pre-built data schema for storing quality, select machine and prod data, configuration)
PredictiveAnalyticsPredictiveAnalytics
DecisionManagement
DecisionManagement
BusinessIntelligenceBusiness
Intelligence
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Advanced analytics powered by IBM SPSS and Cognos
Data integration provided by Websphere Message Broker and Infosphere Master Data Management Collaborative Edition, which feeds a pre-built, DB2-based data schema
Process Integration with Maximo – automatic work order generation
Includes data models, message flows, reports, dashboards, business rules, adapters, and KPIs
© 2013 IBM Corporation
Predictive Maintenance and Quality provides several key features
Accelerated Time-to-Value
Big Data, Predictive and Advanced Analytics
Open Architecture
Business Intelligence
Real-time capabilities
Quick and Accurate Decisioning
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Maximo integration
© 2013 IBM Corporation
Real-time Capabilities
Features
Conduct real-time monitoring of assets and processes
Collect, integrate, analyze, and report streaming information
Orchestration of events and services for efficient processing
Connect to sensors, PLCs, SCADA systems, databases, maintenance logs, Big Data streaming sources
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© 2013 IBM Corporation
Big Data, Predictive and Advanced Analytics
Features
Leverage descriptive, predictive, and prescriptive analytics, as well as data and text mining
Utilize menu-driven interfaces without the need for any programming to create predictive models
Asset health modeling based on real-time event data – measurements, logs, alarms, repair history
Product anomaly detection detects product uniformity issues, and outliers providing lot inspection recommendations
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© 2013 IBM Corporation
Quick and Accurate Decisioning
Features
Utilize the Decision Management methodology and optimize decisions at the point of impact, balancing resource and costs constraints
Combine asset and process business rules of the organization to enhance decisions
Conduct “what-if” simulations to accommodate changing operational conditions
Provide optimized decisions directly to decision-makers
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© 2013 IBM Corporation
Maximo Integration
Features
Integrate directly with Enterprise Asset Management systems such as IBM Maximo
PMQ leverages asset master data from Maximo
Master data is synchronized between Maximo and PMQ
PMQ generates work orders based on analytic insight and business rules
Act upon predictive insights
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© 2013 IBM Corporation
Open Architecture
Features
Stream data from many sources for data aggregation
APIs for integration and customization
Quickly expand included content for specific industry and business applications
Integrate directly with Enterprise Asset Management systems Business Process Management or other services
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© 2013 IBM Corporation
Business Intelligence
Features
Monitor status and quickly address areas of concern
Conduct self-service query, reporting and analysis from virtually any data source
Leverage the drag-and-drop studio environment to provide real-time views
Experience insight wherever needed with mobile capabilities
Drill-down into data for additional insight
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© 2013 IBM Corporation
Accelerated Time-to-Value
Features
Business user interface for master data entry and modification
Leverage easy-to-install, pre-configured software and content stack
Utilize out-of-the-box data source connectors and models, dashboards, and reports to reduce the need for additional services
Quickly expand included content for specific industry and business applications
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© 2013 IBM Corporation
Predictive Maintenance and Quality converges Enterprise Asset Management (EAM) and Analytics capabilities
Enterprise Asset Management Better Outcomes
Predictive Maintenance and
Quality
Predictive Maintenance and
Quality
Optimized maintenance windows to reduce operating expense
Efficient assignment of labor resources
Enhanced capital forecasting plans
Optimized spare parts inventory
Automated analytical techniques, including anomaly detection for assets and sensors
Improved reliability and uptime of assets
Asset maintenance history
Condition monitoring and historical meter readings
Inventory and purchasing transactions
Labor, craft, skills, certifications and calendars
Safety and regulatory Requirements
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© 2013 IBM Corporation
Specialized SkillsSpecialized Skills
Program and Project Management
Setup / installation Hardware Software Specialists Hosting
Program and Project Management
Setup / installation Hardware Software Specialists Hosting
Analytical ActivitiesAnalytical ActivitiesInfrastructure ActivitiesInfrastructure Activities
Solution Impact Assessment
Business Case Development
Use Case Definition Data Integration Information Modeling Predictive Modeling
Solution Impact Assessment
Business Case Development
Use Case Definition Data Integration Information Modeling Predictive Modeling
Integration Skills Business Consulting Industry Skills Maintenance Experts Maximo Specialists Industry Expertise Scientists and
Mathematicians
Integration Skills Business Consulting Industry Skills Maintenance Experts Maximo Specialists Industry Expertise Scientists and
Mathematicians
IBM offers a comprehensive end-to-end solution with Predictive Maintenance and Quality
IBM Software
IBM Research
IBM Services
Client Value
=IBM Systems and Technology
+ + +
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© 2013 IBM Corporation
For example, IBM has specific accelerators for the Natural Resources Industry
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Predictive Asset Maintenance for High Value Assets (PAM)
Business Drivers Ensuring Production Line Continuity in
Mining (Oil & Gas in roadmap)
Improvements & Warranty Claim Cost Reduction
Allowing SLA models for major OEM's Achieving operational efficiencies in Field
Operations
Solution Industry standards based (CCOM) Provides a customized information model
relevant to the industry, that will be used for reporting and analytics
Provides a base library of advanced analytics specific to the industry equipment types
Provides extension services for data onboarding from input data sources
Benefits Reduced machine/appliance/asset downtime
due to (parts) failure Improved productivity of maintenance
resources Avoid costs of machine/appliance/asset
failure Improved customer satisfaction due to
improved service levels Reduced environmental impact of production
failures resulting in lower potential regulatory fees
Predictive Operations Performance (POP)
Business Drivers Significant new constraints and operational
challenges
Optimizing production ;Complying with regulations
Managing HSE risks, people skills and environment issues
Solution Industry standards based (PPDM) Aggregates key performance criteria to optimize
operations for Oil & Gas production environments Leverages performance information for
process/product quality based on SPC/SQC criteria
Provides Event and Incident management capabilities
Benefits Drive optimal performance with knowledge
management and control that comes from effective information capture ,analysis and alerting
Support better decision making with data mining and trend analysis
Maximize uptime and lifting capabilities with near-real-time monitoring and analysis of reservoir drilling and production information
Optimize field force efficiency by providing collaboration automation tools
Unify company systems for integrated upstream operational information across the extended enterprise
Predictive Energy Optimization (PEO)
Business Drivers Continual increase in Energy Consumption
Continual increase in Energy price trends
Pressures of global energy policies
Environment regulations
Solution Industry standards based (ISA SP95) Integrated energy management system
including energy generation & consumption monitoring, prediction, forecast demand & supply, and plan & schedule for optimized energy use
Provides energy optimization models based on demand forecast from production domain
Provides energy monitoring for generation/usage/consumption of different types of energy.
Provides energy prediction based on historical
trends allowing for optimal generation
Benefits Provides an understanding of energy load
profiles ; Improves the management of usage, leading to reduced costs
Facilitates lower rate negotiations with energy suppliers & Improves forecasting of future energy usage and costs
Provide business intelligence that drives phases of energy efficiency program
Built on Predictive Maintenance and Quality Platform utilizing its core product suite and programming model
© 2013 IBM Corporation
TalentA resource pool of highly talented analytic Subject Matter Experts and Industry experts with predictive maintenance experience
TalentA resource pool of highly talented analytic Subject Matter Experts and Industry experts with predictive maintenance experience
Industry ExpertisePredictive models for a number of specific industry use cases
Industry ExpertisePredictive models for a number of specific industry use cases
Accelerators Pre-configured dashboard and visualization templatesPre-integrated software tools, with connectors to a variety of asset management solutions
Accelerators Pre-configured dashboard and visualization templatesPre-integrated software tools, with connectors to a variety of asset management solutions
Big Data, Predictive & Advanced AnalyticsAn enhanced advanced analytics methodology, tailored to the needs of the predictive asset/maintenance space
Big Data, Predictive & Advanced AnalyticsAn enhanced advanced analytics methodology, tailored to the needs of the predictive asset/maintenance space
Why Choose IBM Predictive Maintenance and Quality?
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© 2013 IBM Corporation
Identify which business problems are ripe for asset optimization and cost containment
Determine capability gaps regarding infrastructure, information, and decision-makers
Map a course for rapid value creation
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Next Steps
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