Download - © 2013 IBM Corporation IBM Predictive Maintenance and Quality Presenter Name Presenter Job Title, IBM Organization Name Date

© 2013 IBM Corporation

IBM Predictive Maintenance and Quality

Presenter Name

Presenter Job Title, IBM Organization Name

Date


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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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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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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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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• 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


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


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


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


Quality

• Data agnostic• User-friendly

model creation

• Interactive dashboards

• Quickly make decisions

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2

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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


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


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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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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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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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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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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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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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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Predictive Maintenance and Quality converges Enterprise Asset Management (EAM) and Analytics capabilities

Enterprise Asset Management Better Outcomes


Quality


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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+ =


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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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


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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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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Download - © 2013 IBM Corporation IBM Predictive Maintenance and Quality Presenter Name Presenter Job Title, IBM Organization Name Date

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