innovation in maintenance - accenture
TRANSCRIPT
Let’s Talk Operations “Innovation in maintenance”
20 March 2014
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Most industries are embracing Digital as core component of their growth strategies
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"We are uniquely positioned to give customers
anytime, anywhere access by combining the smartphone, online, and the physical stores“ - Walmart CEO Mike Duke
"By connecting intelligent machines to each other and ultimately to people, and by
combining software and big data analytics, we can push the boundaries of physical and
material sciences to change the way the world works“ - General Electric CEO Jeff Immelt
"The workplace of the future is going to be less centralized, more mobile, and more
flexible. Companies will have to work harder to attract the top talent, accommodating
more flexible hours and a more virtual workforce“ - Business Insider
BBVA applied artificial intelligence to the customer self service interface, creating a Virtual Personal Assistant capable to keep the context of the conversation, establishing a true
dialogue with the customer
Sales and CRM are seeing a big digitally-driven change. Hointer, for example, is
using robotic sales staff. You download an app, go to the showroom, and scan the
QR codes of the clothing you'd like to try. The clothes are delivered automatically
right to the fitting room. Customers swipe their card on the tablet, and walk out
Digital technology coupled with physical devices creates significantly new offerings and experiences. Nest, for example, is a smart set-it and forget-it thermostat that learns to change settings based on user behaviors, and allows remote access to temperature controls
According to Gartner, by 2014 >70% of G2000 organizations will have at least one gamified application. In Sweden, for example, they are using traffic cameras to fine speeders, and to identify those who follow limits to enter into a lottery to win a portion of the funds collected
Burberry's vision is "to be the first company who is fully digital…and to build a social enterprise” Today, Burberry is a leader in digital transformation….
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There is an estimated $14.4 Trillion of value at stake between now and 2022 for ALL companies to realize through Digital Businesses
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Value at stake as a result of disruption
$14.4 Trillion
2013 2022
This is the combination of increased revenues and lower costs that is created or willmigrate among companies and industries from 2013 to 2022, due to Digital Technologies.
Customer experience (addition of more customers)
Asset utilization (reduced costs)
Employee productivity (greater labor efficiencies)
Supply chain and logistics (eliminating waste)
Innovation (reduced time to market)
$3.7
$2.5
$2.5
$2.7
$3.0
Industries will be disrupted to the amount of:
Source: Cisco; Accenture Analysis
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Digital Plant Vision
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36% of the advantage of the best in class refineries is due to effective maintenance (Solomon)
Best in class have 40% less operating cost (non maintenance) than industry average (Solomon)
5% of annual production is lost for unplanned asset downtime and 80% of the losses are preventable and can be avoided as result there is a 4% production increase potential. (ARC)
1% increase in asset reliability reduce 10% of maintenance costs (Solomon)
The next generation of Intelligent Plant solutions will integrate real time information to deliver insight and foresight in operations performance and enables optimization of plant operation, availability, costs and safety
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Key technology trends
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Cloud
Social media/Collaboration
Analytics/ Big Data
Data Velocity
“Connected Everything”
Mobile
Infrastructure, platforms and applications as a service enable new levels of scalability, flexibility and responsiveness.
Social media and collaboration technologies drive new ways of interaction, personalization and relationship building within and beyond organizations.
Technologies such as in-memory computing enable real-time decisionmaking based on analytics.
Analytics and Big Data allow for use of rapidly increasing amount of data from multiple sources to generate new insights and decision making.
Connected devices and cheap sensors enables new ways of automatedand personal interaction.
Mobile devices impact all areas of business and personal live by transforming how people interact, consume information and services, collaborate, and work.
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The Digital Plant is integrating processes and solutions to build, operate and maintain the plant more efficient and safe
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For all the above boxes the market will provide a make or buy alternative offering end to end services through traditional and new players
Ability to integrate data, applications and processes which have been historically managed by horizontal silos becomes a key capability for each business willing to take advantage of the digital revolution in operations
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Accenture Digital Plant solutions for Asset Management helps companies address asset and operational performance challenges
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Services
Capital ProjectsImproves portfolio and projects “time to value” and capital efficiency
Operations OptimizationOptimizes plant and supply chain operations to increase margins and production performance
Asset OptimizationOptimizes asset performance, balancing cost and risk and enabling operational efficiency
Commercial OptimizationOptimizes entire value chain for asset-backed commodity traders
• Operating Model Consulting• Capital Projects Services Office • Engineering, Project and Data Services • Asset Data Management Services
• Operational Excellence Consulting• Application Services and Digital Solutions
– Operations Management– Production Supply Chain Optimization
• Remote Operations Managed Services
• Asset Performance Optimization Consulting• Application Services and Digital Solutions
– Asset Performance Monitoring and Analytics– Maintenance Execution
• Remote Maintenance Managed Services
• Trading, Investment and Commercial Optimization Consulting
• Application Services and Digital Solutions• Commodity Trading Managed Services
Area
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Digital Plant Apps
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The Digital Plant will be enabled by technology solutions that are connected, capable, collaborative and contextual
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The “Digital Plant” of the future is:
ConnectedUbiquitous wireless infrastructure supports digital connectivity of equipment. Sites will be connected to each other and to remote optimization centers
User Solutions will be:
CollaborativeConnecting people and teams across the plant and enterprise, bringing together skills to solve problems and optimise operations
CapableThe plant will be developed with in built digital predictive capability for process and asset optimisation.
ContextualIntegrating information at the point of interaction to bring context and insight to operators and engineers.
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Connected: Plant wide connectivity
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Connected: Leading Mobile Devices by Environment
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XCIEL(I-Pad)
AppleI-PadXCIEL
(I-Pad)Panasonic (CF19 – CF29)
AppleI-Phone
Samsung GalaxyPhone
Getac (B300)
Motororla (ET1 pad)
Ecom(Handy 07IS Phone)
Intermec(CK32 -IS)
Getac (V100)
Apple Macbook
Windows 7 laptop
Intec(ExPC Terminal)
Xplore(iX104C4)
Selections based on: • Features• Form Factor• Ecosystem Support• Portability
MotorolaSmart phone (Defy+)
Atex Zone 0 Atex Zone1 Atex Zone2 Ruggedized High St
Class 1 Div 1 Class 1 Div 2
Dofero(Viz-iCARRY iPad)
Dec2012
Rampage6 (Android)
Intermec(CK32-IS)
EcomIroc.(CI70-exPDA) Bartec
(MC9090ex)
Mobility options are beginning to change with the introduction of Tablet Devices in the Ruggedized and Atex Zone 2, Class2 Div II environments
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Capable: New Application Architectures
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New technologies provide a more intuitive way to consume immense amount of data
Google-like search Links between content
4D+ planning and analysis Simulation for improved planning
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Capable: Better use of analytics
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Dashboards Drill down functionalityAdvanced Analytics
& Simulation
Balanced scorecards based on a clearly defined set of metrics.
Insurance that definitions are consistent across the scorecards and allow to further analyze the shown data and drill into details
Break through the time barrier: Instead of reviewing what happened, drive to see what will happen
Allowance to simulate potential outcomes and select the optimum
Drill down on bad actors to identify root causes in a few clicks
Integration of information across siloes
Real time data access and reporting facilities provide management information. Advanced Analytics builds models and scenarios to support operational decisions
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Capable: Digital plant workforce
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Smart equipment and digital control with wireless capabilities
Plant and fleet remote monitoring and control centers
Electronic work packages and mobile wireless
3D plant rendering
The digital workforce
Using digital technologies to drive performance improvements and resource efficiencies
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Collaborative: Video Collaboration – technical support
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The Future:Individuals can use wireless infrastructure and video camera to obtain remote support on the plant floor.
The Benefits:• Improving repair
decisions in the field and avoided costs
• Reduced asset downtime• More optimal use of
scarce deep experts – 1 to many model
• Enhanced supplier collaboration
Design type required:Location
For companies with operations spread across the globe, delays in equipment maintenance issues or production problems can result in significant costs. Often times the most skilled engineer is located somewhere other than the plant in need, and standard practice is to board a plane to go and try to solve the problem.
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Contextual: Augmented Reality for O&M Mobility
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Application of Wearable Displays for Maintenance
Source: Accenture Research 2014
O&M relevant Areas of application
Heavy Equipment Operator: assist in the operation of heavy equipment (cranes, shovels, and trucks) to improve execution, accuracy and safe working conditions
Over the Shoulder Coach: just-in-time training or coaching, connecting remotely with off-site control center to
Work Discrepancy Resolution: identify current status of equipment using red, green, yellow traffic light indicators and to drill down into contextual information
Emergency Evacuation Support: to alert personnel of an emergency situation by providing audible and visual indicators
Description
Computing devices with displays worn on the body for easy access , showing contextually relevant information
Wearable displays have the potential to support, augment, and optimize the physical workforce
Wearable displays will affect every industry: Innovative companies must be prepared to rethink their processes to
get the most out of wearable displays Gartner forecasts that Google Glass and other “smartglasses” will
help make employees more efficient, ultimately adding more than $1 billion per year to company profits by 2017.
• Improve efficiency• Reduce non-productive time• Reduce re-work• Reduce time to decision• Reduce exposure• Reduce travel • Enhance training experience• Positive identification• Reduce mechanical failures
BenefitsWearable Displays Augmented Reality
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Contextual: Update drawings in the field
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One of the hardest things to finalize after a project is complete is updating as built plant infrastructure and equipment drawings (e.g., P&IDs); however this is very important for compliance management.
Unit Plot Plan
PI&D
The Future:Update drawings real time in the field when standing/ inspecting the assets
The Benefits:• Close out Management of
Change (MOC) required documentation more efficiently
• Reduced compliance issues• Increased data management
integrity for maintenance
Design type required:Coverage
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Contextual: Virtual Operations Environment
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Characteristics
• Virtual plant environment that enables training and supports work execution - complementing high-resolution simulators
• Enable early visualization & walk-through prior to construction or MOC
• Validate safety procedures in virtual environments before rolling out the training
• Train & evaluate response to emergency situations
• Enable distance learning with multiple users accessing the same environment at the same time
• Promote virtual collaboration
Requires• 3D CAD designs to import as models
Benefits• Ability to reinforce Operations procedures and Emergency Response training
in a low cost manner• Ability to evaluate and improve TA planning• Ability to assess maintainability before finalizing designs
Virtual environment to simulate complex processes and train people
LET’s Talk Operations
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More information on: www.accenture.com/operational-excellence