© 2013 IBM Corporation
IBM Predictive Maintenance andQuality
Presenter Name
Presenter Job Title, IBM Organization Name
Date
© 2013 IBM Corporation
Poor Asset
Performance
LimitedProcessIntegration
•Lack of visibility ofpredictors acrossorganizationalsilos
•Difficultysynchronizingdemand andsupply
•Too many manualprocesses &disparateinformationsources
•Losses inprocesses havebecome norm
•Resourcecomplexity makeit harder torespond tochanging needs
Market forces are amplifying day-to-day issues
Customerdemands
Complexsupply chains
Raw materialprice volatility
Complianceand scrutiny
Leanoperations
Agingworkforce
•#1 Risk toOperations is assetfailure1
•Lack of visibilityinto asset health
•High costs ofunscheduledmaintenance
•Inability toaccurately forecastasset downtimeand costs
•Leads tounnecessaryprocessproliferation
•Aging assetspushed to limits tomeet consumerneeds
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© 2013 IBM Corporation
Analytics is a key enabler in maximizing asset productivity andprocess efficiency
Process Integration
Optimize operations andmaintenance
Enhance manufacturing andproduct quality
Asset Performance
Improve quality and reduce failuresand 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 datathey collect more effectively, and turn thatdata into actionable intelligence
Source: Aberdeen Group. Asset Management: Using Analytics to Drive PredictiveMaintenance. Mar 2013.
Fig. 2: Best-in-Class companiesleverage all technology enablersto enhance outcomes
83 percent of CIOs citedanalytics as the primarypath to competitiveness
Organizations that lead inanalytics outperform those thatare just beginning to adoptanalytics 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
oWashers, dryers, hot water heaters, furnaces, HVAC
Vending Machines
oFood, drinks, cigarettes, electrical products, videos, money
Connected Transportation
oPlanes, trains, ships, tanks, buses, passenger automobiles, fleets, electric vehicles, gaspowered autos, motorcycles, snow mobiles, lift trucks
Heavy Equipment Machinery
oEarth movers, mining equipment, cranes, wind/gas turbines, nuclear plants, solar panelarrays, oil drills, oil rigs
Networks
oElectrical grids, water/sewage infrastructure, IT systems, telecom lines/cables, securitysystems
Buildings
oProperty, 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-Value
AccelerateTime-to-Value
Real-time capabilities
Big data, predictive, and advancedanalytics
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 forbetter availability, utilization and performance
•Predict asset failure to optimize quality andsupply chain processes
•Remove guesswork from the decision-makingprocess
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
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© 2013 IBM Corporation
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Business Use Case
Business Value
Predictive Maintenance and Quality generates business value for
organizations
Predict Asset Failure/Extend Life
Determine failure based on usage andwear characteristics
Estimate and extend componentlife
Utilize individual component and/orenvironmental information
Increase return on assets
Identify conditions that lead to highfailure
Optimize maintenance, inventoryand resource schedules
Predict Part Quality
Detect anomalies within process
Improve quality and reducerecalls
Compare parts against master
Reduce time to identify issues
Conduct in-depth root cause analysis
Improve customer service
© 2013 IBM Corporation
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Case Studies
•A city government wanted to boost cityservices and address infrastructuresustainability
•IBM combines asset managementinnovations, predictive modeling, andgeospatial and business analytics tohelp the city improve planning,operations and services
Outcomes:
•Anticipates saving $100,000 per yearin staff time spent on capital planforecasting
•Expects to reduce costs related toproject coordination, operations andcapital expenditures
•A global petroleum companywanted to increase asset utilizationand reliability in a remoteenvironment
•IBM helps predict where and whenice presents a threat to existingdrilling platforms
Outcomes:
•Produces real-time visualization ofice floe positions and trajectorycone forecasts
•Predictions determine whether tomove platforms — providing costsavings
•A not-for-profit marine society dedicatedto ensuring safety and pollution
•IBM helps the company detectanomalies in vessel monitoring systemseven under dynamic changes of oceanconditions
Outcomes:
•Significant reduction of the cost fordetection rule construction (~1/10)
•Significant increase of detectioncoverage (~ x 2-3)
•Reduction of overall maintenance cost(demonstrated at least 10%)
Predict Asset Failure/Life:Environment
Predict Asset Failure/Life:Enterprise Asset Mgmt
Predict Part Quality:
Anomalies
© 2013 IBM Corporation
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Case Studies
•A global manufacturing companywanted to more quickly detect partdefects
•IBM implemented an early detectionmodel to detect part defects earlierand respond in the most optimalway
Outcomes:
•Early identification and mitigation ofenterprise component and qualityissues
•Provide insight to the health andprobability of failure for in-serviceequipment maximizing uptime
Global manufacturingcompany
Regional utility company
•A regional utility companyneeded to maintain an aginginfrastructure
•IBM delivered an industry-specific solution to detectpotential problems before theyoccur
Outcomes:
•Improved asset maintenanceidentification
•20% productivity gains forservice trucks
•Up to 20% reduction of fuelcosts due to fewer truck rolls
Global auto manufacturer
•A vehicle manufacturer wanted toimprove its production quality
•IBM’s solution helped use real-timedata to monitor the productionquality and more quickly identifyand resolve issues
Outcomes:
•Reduced the defect rate by 50% in16 weeks in the production ofcylinder heads
•Increased customer satisfaction
Predict Asset Failure/Life:Extend Life
Predict Production Quality
Predict Part Quality
© 2013 IBM Corporation
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Predictive Maintenance and Quality analyzes data from multiplesources and provides recommended actions, enabling informeddecisions
Asset Maintenance
Asset Performance
Process Integration
Collect & Integrate Data
Structured, Unstructured,Streaming
Generate Predictive& Statistical Models
Conduct Root CauseAnalysis
Display Alerts andRecommended Actions
Act upon Insights
PredictiveMaintenance andQuality
•Data agnostic
•User-friendlymodel creation
•Interactivedashboards
•Quickly makedecisions
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© 2013 IBM Corporation
A proven architecture based on best practices underlies PredictiveMaintenance and Quality
Integration Bus
(Message Broker)
Integration Bus
(Message Broker)
End User Reports,Dashboards, DrillDowns
High volume streamingdata
High volume streamingdata
Telematics, ManufacturingExecution Systems,
Legacy Databases,Distributed ControlSystems
Telematics, ManufacturingExecution Systems,
Legacy Databases,Distributed ControlSystems
Enterprise AssetManagement Systems
Enterprise AssetManagement 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)
PredictiveAnalytics
PredictiveAnalytics
DecisionManagement
DecisionManagement
BusinessIntelligence
BusinessIntelligence
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Advanced analyticspowered by IBM SPSSand Cognos
Data integrationprovided by WebsphereMessage Broker andInfosphere Master DataManagementCollaborative Edition,which feeds a pre-built,DB2-based data schema
Process Integration withMaximo – automaticwork order generation
Includes data models,message flows, reports,dashboards, businessrules, adapters, andKPIs
© 2013 IBM Corporation
Predictive Maintenance and Quality provides several key features
Accelerated
Time-to-Value
Big Data, Predictive andAdvanced Analytics
Open Architecture
BusinessIntelligence
Real-timecapabilities
Quick and AccurateDecisioning
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Maximo
integration
© 2013 IBM Corporation
Real-time Capabilities
Features
Conduct real-time monitoring ofassets and processes
Collect, integrate, analyze, andreport streaming information
Orchestration of events andservices for efficient processing
Connect to sensors, PLCs,SCADA systems, databases,maintenance logs, Big Datastreaming sources
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© 2013 IBM Corporation
Big Data, Predictive and Advanced Analytics
Features
Leverage descriptive, predictive, andprescriptive analytics, as well as dataand text mining
Utilize menu-driven interfaceswithout the need for anyprogramming to create predictivemodels
Asset health modeling based onreal-time event data –measurements, logs, alarms, repairhistory
Product anomaly detection detectsproduct uniformity issues, and outliersproviding lot inspectionrecommendations
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© 2013 IBM Corporation
Quick and Accurate Decisioning
Features
Utilize the Decision Managementmethodology and optimizedecisions at the point of impact,balancing resource and costsconstraints
Combine asset and processbusiness rules of the organizationto enhance decisions
Conduct “what-if” simulations toaccommodate changing operationalconditions
Provide optimized decisions directlyto decision-makers
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© 2013 IBM Corporation
Maximo Integration
Features
Integrate directly with EnterpriseAsset Management systemssuch as IBM Maximo
PMQ leverages asset masterdata from Maximo
Master data is synchronizedbetween Maximo and PMQ
PMQ generates work ordersbased on analytic insight andbusiness rules
Act upon predictive insights
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© 2013 IBM Corporation
Open Architecture
Features
Stream data from many sourcesfor data aggregation
APIs for integration andcustomization
Quickly expand included contentfor specific industry and businessapplications
Integrate directly with EnterpriseAsset Management systemsBusiness Process Managementor other services
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© 2013 IBM Corporation
Business Intelligence
Features
Monitor status and quickly addressareas of concern
Conduct self-service query,reporting and analysis from virtuallyany data source
Leverage the drag-and-drop studioenvironment to provide real-timeviews
Experience insight wherever neededwith mobile capabilities
Drill-down into data for additionalinsight
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© 2013 IBM Corporation
Accelerated Time-to-Value
Features
Business user interface for master dataentry and modification
Leverage easy-to-install, pre-configuredsoftware and content stack
Utilize out-of-the-box data sourceconnectors and models, dashboards,and reports to reduce the need foradditional services
Quickly expand included content forspecific industry and businessapplications
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© 2013 IBM Corporation
Predictive Maintenance and Quality converges Enterprise AssetManagement (EAM) and Analytics capabilities
Enterprise AssetManagement
Better Outcomes
PredictiveMaintenance andQuality
Optimized maintenancewindows to reduce operatingexpense
Efficient assignment of laborresources
Enhanced capital forecastingplans
Optimized spare parts inventory
Automated analyticaltechniques, including anomalydetection for assets and sensors
Improved reliability and uptimeof assets
Asset maintenance history
Condition monitoring andhistorical meter readings
Inventory and purchasingtransactions
Labor, craft, skills, certificationsand calendars
Safety and regulatoryRequirements
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© 2013 IBM Corporation
Specialized Skills
Program and ProjectManagement
Setup / installation
Hardware
Software
Specialists
Hosting
Analytical Activities
Infrastructure Activities
Solution ImpactAssessment
Business CaseDevelopment
Use Case Definition
Data Integration
Information Modeling
Predictive Modeling
Integration Skills
Business Consulting
Industry Skills
Maintenance Experts
Maximo Specialists
Industry Expertise
Scientists andMathematicians
IBM offers a comprehensive end-to-end solution with PredictiveMaintenance and Quality
IBMSoftware
IBMResearch
IBMServices
ClientValue
=
IBM Systems and Technology
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© 2013 IBM Corporation
For example, IBM has specific accelerators for the Natural ResourcesIndustry
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Predictive Asset Maintenance forHigh Value Assets (PAM)
Business Drivers
Ensuring Production Line Continuity in Mining(Oil & Gas in roadmap)
Improvements & Warranty Claim CostReduction
Allowing SLA models for major OEM's
Achieving operational efficiencies in FieldOperations
Solution
Industry standards based (CCOM)
Provides a customized information modelrelevant to the industry, that will be used forreporting and analytics
Provides a base library of advanced analyticsspecific to the industry equipment types
Provides extension services for dataonboarding from input data sources
Benefits
Reduced machine/appliance/asset downtimedue to (parts) failure
Improved productivity of maintenanceresources
Avoid costs of machine/appliance/assetfailure
Improved customer satisfaction due toimproved service levels
Reduced environmental impact of productionfailures resulting in lower potential regulatoryfees
Predictive Operations Performance(POP)
Business Drivers
Significant new constraints and operationalchallenges
Optimizing production ;Complying with regulations
Managing HSE risks, people skills and environmentissues
Solution
Industry standards based (PPDM)
Aggregates key performance criteria to optimizeoperations for Oil & Gas production environments
Leverages performance information forprocess/product quality based on SPC/SQC criteria
Provides Event and Incident managementcapabilities
Benefits
Drive optimal performance with knowledgemanagement and control that comes from effectiveinformation capture ,analysis and alerting
Support better decision making with data miningand trend analysis
Maximize uptime and lifting capabilities with near-real-time monitoring and analysis of reservoirdrilling and production information
Optimize field force efficiency by providingcollaboration automation tools
Unify company systems for integrated upstreamoperational information across the extendedenterprise
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 systemincluding energy generation & consumptionmonitoring, prediction, forecast demand &supply, and plan & schedule for optimizedenergy use
Provides energy optimization models based ondemand forecast from production domain
Provides energy monitoring forgeneration/usage/consumption of different typesof energy.
Provides energy prediction based on historical
trends allowing for optimal generation
Benefits
Provides an understanding of energy loadprofiles ; Improves the management of usage,leading to reduced costs
Facilitates lower rate negotiations with energysuppliers & Improves forecasting of futureenergy usage and costs
Provide business intelligence that drives phasesof energy efficiency program
Built on Predictive Maintenance and Quality Platform utilizing its core product suite and programming model
© 2013 IBM Corporation
Talent
A resource pool of highly talented analytic SubjectMatter Experts and Industry experts with predictivemaintenance experience
Industry Expertise
Predictive models for a number of specificindustry use cases
Accelerators
Pre-configured dashboard and visualizationtemplates
Pre-integrated software tools, with connectors to avariety of asset management solutions
Big Data, Predictive & Advanced Analytics
An enhanced advanced analytics methodology,tailored to the needs of the predictiveasset/maintenance space
Why Choose IBM Predictive Maintenance and Quality?
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© 2013 IBM Corporation
Identify which business problems areripe for asset optimization and costcontainment
Determine capability gaps regardinginfrastructure, information, anddecision-makers
Map a course for rapid value creation
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Next Steps
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