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Bridging the Divide Between Maintenance and Operations: Moving From Data to Action Brian Charles, Account Executive
Bridging the Divide Between Maintenance and Operations: Moving From Data to Action
Brian Charles, Account Executive
Machine health is a
$1.4 trillion* blind spot.
Source: American Manufacturing Association 2016
Reliability Overwhelmed by data
OperationsPlagued by unplanned downtime
MaintenanceConstantly firefighting
Unexpected Failures
This is Not Just a Maintenance Problem
Machine Health Data is the Foundation of:
● Plant Health● Business Health● Digital Transformation
Company-level Costs
Plant-level Costs
Production Line-level Costs
Machine Health Data is Plant and Business HealthWhat is the cost of failure to your organization?
Avoided Cost of Failure
Contract Compliance
Costs
Supply Chain Costs
Waste and Scrap Costs
Repair and Replacement Costs
Labor Costs
Part Costs
Downtime Reduction
Cost of Lost Product/Hour of Downtime
Time to Repair
Inventory Optimization
Asset Care Optimization
Maintenance Optimization
Risk Exposure
Safety Compliance
Service Vendor Costs
Part Delivery Costs
Dilution of plant labor
SCALE
CO
MPL
EXIT
Y
Customer Service
Quality Compliance
Environm. Compliance
Safety Performance
Org.Health Brand Promise
Employee Morale
Full Goods
Inventory
Warranty Costs
Workforce Productivity Excessive PartsInventory
Machine Health Data is Digital TransformationWhat is the impact of Machine Health on your total digital opportunity?
Source: McKinsey Global Institute 2015Machine Health Impact: Medium LowHigh
Costs for qualityreduced by 10-20%
Forecasting accuracyincreased to 85+%
20-50% reductionin time to market
10-40% reduction ofmaintenance costs
Productivity increaseby 3-5%
30-50% reductionof total machine
downtime
45-55% increase ofproductivity in technical
professions via automationof knowledge work
Costs for inventory holdingdecreased by 20-50%
Process Productivity
Quality
Time to Market
Supply/Demand Match
Maintenance& Service
Inventories
Labor
Asset Utilization
Actionable Insights Drive Health & Performance
ReactiveMaintenance
Some scheduled & mostly reactive
fix what’s broken
PreventiveMaintenance
reduce breakdowns
Time based asset care & reporting
Predictive Maintenance
reduce surprises
Periodic data & sensor analysis
Digital Machine Performance
optimize production outcomes & flexibility
Integrated asset diagnostics & performance
analysis
Digital Machine Health
Fully automated continuous asset
monitoring& diagnostics
avoid cost of failure & optimize asset care
Solving Maintenance & Reliability Challenges
Solving Business, Operations &
Reliability Challenges
Foundational Elements
Single Source of Truth
Driven by AI, Cloud and IIoT
Real-Time and Continuous
How Data Moves to Actionable Insights
Algorithms DiagnoseDiagnoses of malfunctions and provide alerts and recommendations
VisualizeYou get full visibility of machine health across your facility
Connect
Smart sensors monitor your machines 24/7
continuous monitoring of all critical line and utility componentsFull Facility Coverage
Filling systems
Supply systems
Washing systems
Conveying systems
Packaging systemsUtility equipment
Algorithm in Action
June 14, 2018 9:29 AMBR450
Centrifugal Pump 11450
uncover root causes and get actionable maintenance suggestionsHow to visualize results
see how real-life events correlate with mechanical dataGet the full history of your machine’s health
The Standard Manufacturing Company
Milwaukee facilities | Milwaukee machinesMilwaukee
Detroit
Chicago
71 Machines
86 Machines
full visibility into equipment condition across single or multiple facilities Executive View
Data FlowCloud & Diagnostic
AlgorithmsBLE
CELLULAR/ETHERNET/WiFi
Business Info (CMMS)
Machine Raw Data
Data Historian
Big DataAnalytics - PLC
systems
Desktop
Mobile
Vibration, Temperature, Magnetic
Repair, work order data
Customer Success Team
- Reliability support
- Actionable outreach
- Trainings
- Custom notifications
Maintenance / Operators
CMMS/APM Workflow
1 2 3 4
5 6
Issues identified by solution
Funnel into work order request
Work order Approved
Action performed with confirmation upon completion
Feedback Loop: Input additional observations or repairs made
Machine health status and history update
Track results and business value
Everything is tracked in both systems
Higher level of detail on Machine Health always available in Augury
Work Order Workflow Example
Centrifugal Pump 11450
June 14, 2018 9:29 AMBR450
Work Order Workflow
HEALTH METRICS
PERFORMANCE METRICS
BUSINESS METRICS
-OEE, TEEP
-Production KPIs, Savings, Growth and Optimization
-Health Trend & Status
The Power of AI at Scale
Impact on Your Bottom Line
BaselinePeriod Urgent Actions
PlannedImprovement
New State of Reliability
10-40% reduction ofmaintenance costs
30-50% reductionof mechanical downtime
20-50% decrease in costs for inventory holding
Avoided safety and environmental risks
Mac
hine
s C
over
ed
OEE
Moving From Data to ActionCase Study
Data Leading to Actionable Insights
Global Manufacturer of Lumber Products
● Previously relied on an outside contractor to perform vibration/data collection on a monthly basis
● Augury program deployed December 2018
● Initial results revealed about 30% of critical equipment in an unacceptable condition
● Corporate deemed the Augury program a must haveand is being standardized to additional plants
$470KCost
Avoidance
Quick Time-to-Value
BRIAN CHARLESEnterprise Account Executive
Data, Not Opinions, Drives Impactful Actions
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