Advanced Analytics for

Asset Management with IBM

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ABOUT PERFICIENT

Perficient is a leading information technology and

management consulting firm serving clients

throughout North America.

We help clients implement digital experience, business optimization,

and industry solutions that cultivate and captivate customers, drive

efficiency and productivity, integrate business processes, improve

productivity, reduce costs, and create a more agile enterprise.

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PERFICIENT PROFILE

Founded in 1997

Public, NASDAQ: PRFT

2014 revenue $456.7 million

Major market locations:

Allentown, Atlanta, Ann Arbor, Boston, Charlotte, Chicago, Cincinnati,

Columbus, Dallas, Denver, Detroit, Fairfax, Houston, Indianapolis,

Lafayette, Milwaukee, Minneapolis, New York City, Northern

California, Oxford (UK), Southern California, St. Louis, Toronto

Global delivery centers in China and India

>2,600 colleagues

Dedicated solution practices

~90% repeat business rate

Alliance partnerships with major technology vendors

Multiple vendor/industry technology and growth awards

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ABOUT THE SPEAKERS

Greg Crist, IBM

Technical Sales Specialist, Predictive Maintenance & Quality Solutions

Greg has over eight years of experience working with customers to utilize predictive analytics to solve

business problems and gain early warning of impending events. For the past three years he has focused

on applying predictive analytics to various business segments within the industrial space.

Kevin Clark, Perficient

Practice Director, IBM Asset Management

Kevin leads Perficient’s asset management practice and brings over a decade of experience in industry

leadership roles in engineering and manufacturing. Prior to joining Perficient, Kevin was the Global Maximo

& Maintenance Excellence Leader at Johnson & Johnson. Kevin is also on the board and/or leader of

multiple asset management user groups and communities.

Dave Reiber, Perficient

Business Solutions Architect

Dave recently joined Perficient from General Motors, where he led predictive maintenance and global

training for Maximo. Dave is a co-leader, member and frequent speaker various maintenance and Maximo

user groups and conferences. He holds CMRP and CPMM certifications.

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MARKETPLACE FORCES ARE AMPLIFYING DAY-TO-DAY ISSUES

Poor asset performance

• Lack of visibility into

asset health

• High costs of

unscheduled

maintenance

• Inability to accurately

forecast asset downtime

and costs

• Resultant unnecessary

process proliferation

• Aging assets pushed to

limits to meet consumer

needs

Limited process integration

• Lack of visibility of

predictors across

organizational silos

• Difficulty synchronizing

demand and supply

• Too many manual

processes and information

sources

• Losses in processes have

become normal

• Resource complexity

makes it harder to

respond to changing

needs

Raw-material

price volatility

Compliance

and scrutiny

Aging

workforce

Complex

supply chains

Customer

demands

Lean operations

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THE IBM SOLUTION: IBM PREDICTIVE MAINTENANCE & QUALITY

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• Helps monitor, maintain and optimize assets for

better availability, utilization and performance

• Helps predict asset failure to better optimize

quality and supply chain processes

• Reduces guesswork during the

decision-making process

Combined with out-of-the-box models,

dashboards, reports and source connectors

BETTER BUSINESS OUTCOMES WITH PMQ

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GAIN GREATER VALUE FROM DATA GENERATED BY ASSETS

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MAKE IT EASY TO UNDERSTAND & MODEL ASSET PERFORMANCE unstr

uctu

red

str

uctu

red

• maintenance logs

• inspection reports

• repair invoices

• customer complaints

• warranty claims

• operator profiles

• test results

• Frequent types of failures

• Locations and product usage details

• (In)effective repair methods

• Top warranty issues

Capture, integrate, verify,

classify, correlate, model Automated retraining

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EXCERPT FROM UPTIME MAGAZINE ARTICLE – WHY PMQ?

Why PMQ? In my words:

Is this the right time to bring Big Data analytics to the asset

management world? YES

Many tools enhance the maintenance process

Few existing tools provide the total picture

Large quantities of data exist from a lot of sources, but it’s tough

to get the best results

What’s the real goal of a maintenance team?

“On a flight path of continuous improvement, always striving to achieve

precision maintenance”

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WHAT IS PRECISION MAINTENANCE?

Making more precise

calls around predictive

failure probability

You found an anomaly – How

long before it fails?

Do I need another tool to

validate what I found?

Do I need to call in outside help?

Can we get by until the

weekend? End of month? Etc.

Live health scores of my

most critical assets

Trending data from many sources

Patterning data from many

sources

Aggregating multiple data

sources, in any format

System getting smarter every day

Automated actions direct

from the PMQ system

Auto generated work orders

Auto generated communication

templates

Auto-generated texts, voice

messages, etc.

“Maintenance teams are a vital part of the manufacturing process as long as we focus on

throughput and quality. We must continuously deliver uptime and equipment reliability.”

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WHAT DOES A PMQ DASHBOARD LOOK LIKE?

Why PMQ?

The ability to make a

more precision call on

equipment failure

probability

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GOALS & BENEFITS OF PRECISION MAINTENANCE Source: Gartner

GOAL Precision Maintenance

High Costs Lower Costs Lowest Costs

Predictive capabilities can significantly improve

maintenance strategy and ability to anticipate

pending performance issues

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Predictive maintenance tools

identify failing assets early,

by monitoring certain

conditions.

By baselining and trending,

they identify the probability of

failure.

Objective:

Precision Maintenance

Find early failure signals with Vibration / IR / EMD / Ultrasound / Oil Analysis

When we can hear the problem or feel the heat,

it’s too late. Failure is imminent.

Example: Fixing misalignment early saves $

We are picking up failures earlier minimizing

the degradation curve

HOW PREDICTIVE MAINTENANCE MAXIMIZES BUSINESS VALUE

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We can no longer only

worry about our cost silo.

Pushing burden to another

area of the business is not

acceptable.

What if we could

effectively process

data from

everywhere? – PMQ?

ALL BUSINESS DECISIONS AFFECT ALL PARTS OF THE BUSINESS

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MAINTENANCE ORGS MUST SHOW RETURN ON INVESTMENT CAPITAL

If we spend capital expense

dollars, we must show a

positive return on those dollars

in a specific timeline.

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… AND COMPANIES THAT INVEST IN ANALYTICS CONSISTENTLY

OUTPERFORM THOSE THAT DO NOT

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Hi-Critical Critical Normal Run to

Failure

Systems

failure

hi-impact

Process

throughput

equipment

Mobile

equipment

Small motors

Electrical Large pumps Failure low

impact

Small pumps

Air Large motors Things easily

or quickly

changed

Steam Electrical

switchgear

Examples of Critical Assets

PLANNING IN A RELIABILITY-CENTERED MAINTENANCE ENVIRONMENT (RCM)

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DECIDING WHAT DATA TO COLLECT

Begin with the end in mind – What data will be needed for analysis?

Decide which reports are used in each level of the organization (SPQRC)

Look at system requirements & your business process requirements

When training your users and leadership, make the relationship between data collection and the finished reports

When they see WIIFM, you will get buy-in

MAXIMO or Other EAM

What is required data, and where does it come from?

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EXAMPLE: MAXIMO START CENTER WITH KPI’S

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EXAMPLE: PRODUCTION MONITORING & CONTROL SYSTEMS

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Problem: Most technologies use their own

software systems. It is hard to aggregate

the data with your other systems.

PMQ does this for you!

• Vibration Analysis

• Infrared Thermography

• Ultrasound / Shaft Ultrasound

• Electrical Motor Diagnostics

• Oil Analysis / Lube Training

• Laser Alignment

• Hi-speed Video

• Video Probes

• Chain Wear Monitoring

MANY INDEPENDENT PREDICTIVE TECHNOLOGIES ARE AVAILABLE

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EXAMPLE: VIBRATION SOFTWARE REPORTING

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EXAMPLE: INFRARED SOFTWARE REPORTING

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EXAMPLE: ULTRASOUND SOFTWARE REPORTING

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PM&C (Production Monitoring and

Control) & Complicity/CMore - DATA

EAM - DATA

Predictive Maintenance

Tools - DATA

Collecting real-time continuous

data around asset uptime.

People and remote sensors

collecting DATA around vibration,

infrared, ultrasound, etc.

Collecting DATA from work orders, including :

Emergency – Class Failure + Problem, Cause, and

Remedy, Preventive, Predictive, and Projects.

PMQ Data AnalyticsTrending, patterning, learning, gaining intelligence around the data,

to help us be more predictive to failures.

The new term is called Precision Maintenance

Create work orders in the EAM system to

resolve predicted failures

Can notify through emails and other

mobile applications

Failures can be:

*Chronic

*Sporadic

*Catastrophic

Each need to be broken

down separately

Data can be

very intricate

and in separate

systems

onnected

Data SetsConnected

Data Systems

DATA AGGREGATION, ANALYSIS & PLAN FOR FAILURE PREVENTATION

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SUMMARY OF PMQ

PMQ is an advanced analytics solution that creates a

total view of the operational process, using the data

that you already have, and extends asset life through:

Monitoring process logs, structured and

unstructured data, component and

environmental data, and usage and wear

Analyzing patterns and trends

Identifying conditions to optimize inventory

management, alert for quality issues and

alert for warranty issues

Only company able to offer a suite of

tools comprehensive enough to

handle the task

Extensive expertise and talent

in the domain and industry

General Motors Example

Data Sources: PM&C, Maximo,

Predictive Tools, Quality

Results: All data trends, patterns and

scenarios aggregated to make

automated, actionable items. Better

precision decisions for predicting asset

failure probability.

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PMQ IN THE REGULATED INDUSTRIES: LIFE SCIENCES

“Product recall and defect reporting data demonstrate unacceptably high occurrences of problems

attributed to inherent defects in product and process design; these data further indicate failures in

the implementation of manufacturing process scale-up as well as routine production.”

“There have been alarming shortages of critical drugs over the past few years. Many of these

shortages were caused by the use of outdated equipment, reliance on aging facilities operating at

maximum production capacity, and lack of effective quality management systems.”

FDA Pharmaceutical Quality Oversight: One Quality Voice

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PMQ SUPPORT FOR FDA COMPLIANCE

Predictive Maintenance & Quality

Food & Drug Administration

Office of Pharmaceutical Quality (2015)

Quality Systems Regulations

Quality by Design

Process Analytical Tools

Current Good Manufacturing Practices

PMQ supports the FDA and the OPQ under QSR and through QbD

utilizing PAT while complying to cGMP

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PMQ DRIVES RELIABILITY: THE CURE

“Depending on inspection is like treating a symptom while the disease is killing you. The need for inspection

results from excessive variability in the process. The disease is variability…”

Innovation and Continuous Improvement in Pharmaceutical

Manufacturing: Pharmaceutical CGMPs for the 21st Century

PMQ is NOT:

• Operations

• Maintenance

• Facilities

• Quality

• Finance

• Etc.

PMQ is:

• A 3D asset lifecycle that encompasses

operations, maintenance, facilities,

quality, finance, etc.

• An exposure of variability leading to

products that are right the first time

• A high-level of predictable

manufacturing and quality

Predictive Maintenance &

Quality

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PMQ IN THE REGULATED INDUSTRIES: LIFE SCIENCES

Janet Woodcock, Director, FDA CDER (Center for Drug Evaluation and Research):

“…to shift [the FDA’s] focus to performance and away from compliance.”

• By its own admission, the heavy focus on compliance by the FDA and industry

has caused quality to suffer

• Performance (quality, throughput) drives compliance

• Quality metrics (analytics) and innovative technology/processes (predictability) are the future

PMQ is tipping the scales by exposing, eliminating or mitigating the risk

of failure and creating a culture of “knowns”

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GETTING STARTED WITH PMQ

Think PMQ Program

Feasibility assessment for predictive maintenance

and quality

Project options and deliverables

• Transformation storyboarding

• Data readiness evaluation

• Feasibility analysis

• User interface prototyping

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Next up:

Leverage Customer Data to Deliver a

Personalized Digital Experience

Thursday, August 20 | 1:00 PM CT

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