intelligent maintenance: mapping the iiot process
TRANSCRIPT
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Agenda
• Introduction
• Forecasts and Value Gaps
• IIoT Real-World Context
• IIoT Program Design for Intelligent Maintenance
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Dan Yarmoluk
• Business Development, ATEK AssetScan
• 15 years of Global Experience in Industrial Instrumentation
• MBA
• MS Data Science
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ATEK Access Technologies
Welcome to the world of ATEK Access Technologies. Access to superior efficiencies and savings.
Access to essential data and systems.
Access to improved safety and control.
Access to expert solutions and support.
Access the power of technology.
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Innovation Vision
Finding Meaning and Mindset
• Ideas From Billionaire Mindsets and Where You Fit In
– Agility trumps size • Kodak went bankrupt in 2012 and Instagram was
bought by Facebook for $1 billion with only 13 employees
• Disrupt Yourself, or Someone Else Will – Estimated that 40% of the Fortune 500 companies
will be gone in 10 years
– Digitizing a service (think AirBnB and Uber)
– Digitizing maintenance that leads to efficiency gains, savings on breakdowns and costly downtime ~ if maximized = competitive advantage
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Exponential and Enabling Technologies
• Technology to Change the World and Create the Next Billion-
Dollar Organizations
– Computational systems/infinite and cloud computing
– Networks and sensors
– Artificial intelligence
– Robotics
– Digital Manufacturing
– Medical technology/nanodiagnostics/digital health/biotechnology = DNA
sequencing, genome mapping, CRISPR, preventative vs. reactive
medicine and making 100 the new 60
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Global Innovation driving demand for smart systems or
“Fourth Industrial Revolution” Industry 4.0
Big Data
Contextual Computing
senseMaking
Cognitive Computing
•Climate
•Oil Exploration
•Asset/Supply Chain
•Tsunami/Earthquake warning
•Smart Grid/Smart Cities
•Structural monitoring
CeNSE – trillion nano sensors
Internet of Things
Agricultural
Technology
Robotics
Digital Health
Nanodiagnostics
Industrial IoT “IIoT”
Wearables
Technology Adoption Drag…
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Technology Adoption Drag…presents opportunity
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The Internet of Things is Everywhere
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Trillion Dollar “Mega-Trend”
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2015:
$500Billion
Projected Spending on IoT
2019:
$1.3Trillion
Source: Machina Research, other estimates
IoT: Explosive Growth Occurring
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IOT is Creating New Space for Value Creation
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Example: GoodYear Tire
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• ServiTIZE the Product
• Service-led Competitive
Strategy
• Participate in a Larger Value
Chain/Stream
• Value-based Pricing in an
Otherwise Commodity, Cost-
Plus Environment
• Must Understand the
Customer’s Business Process
and Determine the Right
Business Model
Extended Value Chain Opportunities
Advanced Services
Intermediate Services
Integrated Products/Systems
AugmentedProduct
Use information to MoveBeyond the Product
Use Information to SellThe Product as a Service
Use Information to ImproveThe Product in Use
Use Information to ImproveThe Product
Product Monitoring
ServicesSupportingCustomers
ServicesSupporting
Products
Categories of Value Creation from IoT
Source: Goodyear Global Innovation Dept.
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The IIoT is Many Things
I
EnergyBuildings
Government & Smart Cities Medical
Industrial
Digital Oil Field
Smart Meters
Solar & Wind
Electric Vehicle Charging StationsTank Monitoring
Public Safety Vehicles
Water Treatment
Parking
Street LightsSecurityTraffic
Medical Devices
Pharma Safety
Patient Monitoring
Manufacturing Automation
Heavy Machinery
Smart Agriculture
Asset Monitoring
HVAC Security
Lighting
Public Transit
Transportation
Fleet ManagementSmart Railways
Asset Tracking
Automation
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What is the Industrial Internet of Things Value?
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• IIoT is creating a universe of sensors, detectors, automation,
software and other “Big Data” analytics tools, which enable an
accelerated, deep learning of existing operations
• These new hardware and software tools allow for rapid
contextualization, visualization, computation, and automatic
pattern and trend detection
• Furthering this of manufacturing operations will finally allow for
true quantitative capture of what oftentimes qualitative, ‘tribal’ or
‘expert’ human experiences running manufacturing operations
IIoT Business Drivers
• Compliance with New Regulations
– FDA’s FSMA (food safety), DOT’s FCSMA (driver e-logs), EPA, OSHA
• Cost Reduction / Avoidance
– Field service, predictive maintenance, logistics, supply chain
• Product Differentiation
– Adjunct offering, avoid commoditization, reliability/uptime, new premium
SLAs, better roadmaps
• New Revenue Streams / Models
– Managed Hardware-as-a-Service offering, recurring revenue
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Challenge: Lots of Pieces and Parts
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5
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7 People and Process
Connectivity/Edge Computing
Things
Global Infrastructure
Data Ingestion
Data Analysis
Applications
Transformational Decision Making Based on “Thing” Apps and Data
Custom Apps Built Using “Thing” Data
Reporting, Mining, Machine Learning
Big Data, Harvest and Storage of “Thing” Data
Cloud Infrastructure (public, private, hybrid, managed)
Communications, Protocols, Networks, M2M, Wi-Fi, Telecom, HW Kits
Devices, Sensors, Controllers
7 Layers of the Internet of Things (IoT)
Cost Improvements Seen as Most Value
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Manufacturing is leader in IoT spending
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Value in Service, Applications & Analytics
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Barriers to analytics
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Data not being utilized
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Value requires interoperability
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Transformation lies in people and workflow
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Suppliers and organizations need to think about processes…
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IIoT Success Requirements
Value
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4
5
Domain Expertise
Business Analysis
Instrumentation Expertise
Mechanical Engineering
Electrical Engineering
Today is a break-fix world…
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Or today is a scheduled maintenance world…
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Moving to an IoT-enabled world for prediction…
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Need to Process Map
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Value Proposition
• Essential Asset Monitoring vs. Critical Asset only
• Continuous Asset Monitoring vs. Monthly Diagnostics
• Automated Alerting to Various User Groups
• Dashboards and Analytics to Visually Explore; Root Cause
• Reduce Unplanned Maintenance – 30, 60 or 90 days in advance
• Reduced Planned Maintenance on Healthy Assets
• Operator Confidence Up and Less Operator Error
• Reduction in Expedited Logistics and Premium Pricing
• Integration into Workflow and Repair
• OPEX Pricing Model
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Value Proposition vs. Constraints
• Extremely Lean Staff: Break-fix or periodic maintenance --
putting fires out
• Legacy Systems have Critical (not Essential) Assets
integrated with SCADA or PLC systems
• Cannot utilize current reports nonetheless new automated
alerting nor reporting – no expertise or no time or do not trust
• Budgetary constraints anything above a maintenance budget
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IIoT Predictive Maintenance Today
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Value Proposition vs. Constraints
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• No Time• No Expertise• No Budget• Not Enough People• Primitive Diagnostics• Users of machines are different than repair
technicians• Has enough problems• Does not to need to be informed of
another problem but rather having a solution for the issue scheduled to be fixed
Real Value Proposition
• Periodic blood pressure check
• Continuous blood pressure monitoring
• Radiologist (domain expert) to read results
• ALERT! Signs of a heart attack
• Sound alarm; schedule and perform surgery
• The real prescription is HOW to deliver the value in a
business MODEL
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Human Interjection to Maximize Automation
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Human Interjection to Maximize Automation
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IIoT Predictive Maintenance Model Should Include
• Technology Solution that has easy “bolt on” connectivity
outside SCADA or IIoT
• Automated Alerting and Dashboard Reporting
• People and Process to Interject with Alerting
• People and Process with Domain Experience to Diagnose
and offer Prescriptive Solution
• People and Process to Schedule Maintenance
• People and Process to Repair Equipment
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Condition Monitoring - Vibration Example
• Monitoring solution with accelerometer, thermistor, etc. with gateway, cloud and dashboard
• Combined with MSO Reliability Team and Technology
• Accelerometer actionable output split into two 4-20mA instrument loops; 1 loop is 0-50g peak acceleration of bearing (state of bearing health) measured historically; 2nd loop is representation of overall vibration level, scaled in 0-1 in/sec – combined with domain, valuable insight into the health of the bearing
• Reliability team that has account access, maintenance contract
• Reliability and Maintenance team that constantly maintains equipment and interjects with alerts over time
• Reliability and Maintenance team to perform equipment diagnostics, root cause and repairs
• Delivered in monthly subscription model
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Conclusion
• Technology Solution that has easy “bolt on” connectivity
outside SCADA or IIoT
• Automated Alerting and Dashboard Reporting
• People and Process to Interject with Alerting
• People and Process with Domain Experience to Diagnose
and offer Prescriptive Solution
• People and Process to Schedule Maintenance
• People and Process to Repair Equipment
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