driving asset performance using real time...
TRANSCRIPT
REDUCE UNPLANNED DOWNTIMES BY 50%. IMPROVE RETURN ON ASSETS!
Enterprise Gateway (EG) is a real time Asset Intelligence Management solution. In other words, EG (a) connects production assets to enterprise asset management systems for automating information flows such as meter updates, machine failure root cause updates, manual work order generation, visualization of maintenance work order/status/performance data, etc.,
�nd
(b) improves asset availability by cutting down unplanned downtimes by roughly 80% and increasing proactive maintenance by the use of templated EG Business Rules, and (c) improves asset reliability using machine intelligence – in order to predict the probability of failure of assets and generate timely real time actions to prevent such failures.
RESEARCH FINDING
The top 20% (best in class manufacturers) generate a +24% Return on Assets (ROA) versus their corporate goal, see a 13% reduction in year-to-year maintenance costs, and have only 3% of unplanned downtimes by using predictive asset intelligence.
SCADA / HISTORIAN / MES / MES
Leveraging Mobility to Integrate Production and Maintenance Business Processes
UPDATE MACHINE USAGE
UPDATE ROOT CAUSE
ENTERPRISE ASSET MANAGEMENT SYSTEM (EAM)
PLANT FLOOR
SCADA / HISTORIAN / MES / MoMPLANT FLOOR
(Availability Improvement Achieved via Proactive Maintenance using EG Business Rules)
EG Rule Library: Templated real time business rules to actively eliminate unplanned downtimes and improve asset performance.
Work Orders Created by EG Rules in EAM System
SCADA / HISTORIAN / MES / MoMPLANT FLOOR
(Reliability Improvement achieved via Predictive Intelligence of Critical Assets’ Failures)
EG Rule: If probability of failure > x%, generate a predictive maintenance work order to prevent failure.
EG Intelligence : Machine Intelligence to predict
probability of failure of an asset
DRIVING ASSET PERFORMANCE USING REAL TIME
PREDICTIVE INTELLIGENCE
EG
XI
EG
AI
EG
RI
Do
wnt
ime
Co
st p
er H
our
, $
Company Size (Revenue), $ (millions)
Cost of Unplanned Downtime
500 1000 20001500
50,000
100,000
150,000
200,000
2500
CUSTOMER SAVINGS
A sudden increase in bearing temperature triggered a work order which allowed early identification of a coolant leak. Instant savings of $60K & no downtime! A traditional two week calendar-based PM every six months of 5300 hours annually was replaced by a 3-day shut down occurring six times (3500 hours)!
INTEGRATED MAINTENANCE AND ASSET REPORTS BASED ON PLANT AND EAM DATAUnified Visibility of Operational and Maintenance Intelligence
EG RULE EXAMPLEReal Time Predictive Monitoring Using Templated Rules
FOR EVERY PLANT ASSET:
> Track Average Cost per downtime, Average cost per failure.
> Track Average Cost per work order, number of Unplanned Downtimes Avoided
> Track Reduction in failure rate, probability of failure in a given future time.
HARDWARE REQUIREMENTSCurrent generation Server
with 2 CPUs: Min. 4 GB RAM, 50 GB HDD
SOFTWARE REQUIREMENTSWindows® 2008/2010/2012
SQL Server® 2008/2012IIS Server 6.0 or above
MSMQ.Net™ Framework 4.5 or above
5G Automatika Ltd.203 Colonnade RoadSuite 202, NepeanOntario K2E 7K3, CanadaE: [email protected]: +1-613-368-4809www.5gautomatika.com
PLEASE CALL US FOR A DEMO TODAY!
Bearing
Bearing
Bearing
PLANT SYSTEM EAM
EG RULE
ASSET 1
ASSET 2
ASSET 3
ASSET 10
ASSET 80
NO
YESRATE OF CHANGE OF
TEMPERATURE > THRESHOLD
CREATE PREDICTIVE
MAINTENANCE WORK ORDER
PREDICTIVE MAINTENANCE TO AVOID DOWNTIME COSTS