Maximo Asset Health Overview (Watson IoT)

Jim Crosskey

Senior Offering Manager

February 16, 2016

Optimizing Preventive Maintenance

with Asset Health Insights

21 Source: T.A. Cook, Maintenance Efficiency Report 2013, August 2013. http://uk.tacook.com/fileadmin/files/3_Studies/Studies/2013/T.A._Cook_Maintenance_Efficiency_Report_2013_En.pdf?tracked=1

2 Source: Oniqua Enterprise Analytics, Reducing the Cost of Preventative Maintenance, http://www.plant-maintenance.com/articles/PMCostReduction.pdf

A time-based approach is

embraced by a traditional

preventive maintenance program.

Problems that arise:

• Consuming expensive resources

• Potentially introducing failure by

disrupting stable systems

40% of preventive maintenance costs are spend

on assets with negligible affect on uptime 1

45% of all maintenance efforts are ineffective 2

30% of preventive maintenance activities are

carried out too frequently 2

Watson IoT / Insights into Asset Health

Preventive Maintenance programs effectively improve reliability, however…

• Many organizations have more PMs than they have staff to execute

• Optimization and Prioritization of PMs is becoming necessary

• Effort needs to be based on the health of the asset

http://uk.tacook.com/fileadmin/files/3_Studies/Studies/2013/T.A._Cook_Maintenance_Efficiency_Report_2013_En.pdf?tracked=1

http://www.plant-maintenance.com/articles/PMCostReduction.pdf

Watson IoT / Insights into Asset Health4

Condition based maintenance uses IoT data to assess asset health

40% of preventive maintenance costs are spent

on assets with negligible affect on uptime 1

The results speak for themselves

Reduce

maintenance

costs by up

to 25%

Eliminate up

to 70% of

breakdowns

Reduce

downtime by

up to 50%

Cut

unplanned

outages by

up to 50%

Reduce

scheduled

repairs by up

to 12%

Reduce

capital

investment

by 3-5%

Monitor and analyze asset health data, both historical and real-time

Intervene at the right time, before assets go down

Prioritize and optimize resources


Maximo Condition Monitoring Today

• Some sample use cases:

− When a tank is low, initiate work to fill it

− When pressure differential on a filter is above x, replace the filter

− When output pressure drops for a pump, schedule an inspection

• Readings exceeding user defined values trigger a PM Work Order

CharacteristicGaugeContinuousContinuous

Numeric Range

Thermometer

They fluctuate

Counters

Odometer

They aggregate

Observations

Level of Service

Discrete values


Sensor data

Real time and

Historical

Maximo

Asset Information Asset Health

Condition data is enhanced when combined with contextual information to give a more perfect picture of Asset Health

• Real time sensor data from the equipment via individual sensors (add-on or

embedded)

• Real time sensor data or alerts from SCADA systems

• Historical trends of sensor data from historian or other data repository

• Inspection data that might include measurements, observations, photos gathered

manually or from mobile devices

• Maintenance history of the asset

• Related information: environmental (temp, humidity, etc.), weather, usage, output

Understanding current condition alone, is not enough…

Weather

Data


SCADA Enterprise (Homegrown System)

Maximo RPM (Renewal Planning Model – 3rd party))

Today there are multiple sources and systems for assessing asset health

IBM Maximo Asset Health Insights

Designed with Reliability Engineers/Asset Owners

in mind

Subscribe to warnings and notifications for

response to Asset issues prior to failure

Define Asset Health using data from many

sources including Maximo and Real-timeRemaining useful life

Maintenance and failure history

Asset Condition based on real time and historical information

Leverage Historical Weather as a Key Element in

determining Asset Health

Minimize unnecessary maintenance based on

Asset Health score

Insights to determine repair vs. replace


Available

now

• Contextualizes device data

• Monitors streaming data to

detect situations

• Filters the data for analysis by

Maximo Users

• Stores data for further analysis

IBM Watson

IoT Platform

3 Historical sensor data

Real time filtered datafrom automation systems2

4 Historical weather data

IBM Maximo Asset Health Insights

• Enables Immediate action and/or

• Provides engineers with rich set of sensor and asset data to determine proper course of action

• Visibility into asset condition, from

asset lifecycle perspective

• Consolidates Asset data, historical and

real-time, including data from external

data systems, weather data, etc.

• Advanced dashboard view enables

proactive asset and maintenance

decisions

1 Real Time data from low cost add-on sensors


How IoT information is used within Maximo Asset Health Insights


Maximo and IBM IoT Platform integration with Automation Systems:

Partnership with Schad Automation

• Automatic Meter Reading - software product that provides connectivity to automation systems

• Integrates with (SCADA, PLC, BMS) via a wide range of industry standard protocols such as OPC, BacNet, etc.

• Enables mapping of sensors to assets in Maximo

• Allows data from control systems to be sent to Maximo’s Condition Monitoring module

• Includes Integration with the IBM Watson IoT

Platform

• Ability to define simple rules for notifications or for

creating Maximo work orders/service requests

Reduces need for physical inspections or meter

readings

Rapid connection of SCADA information into

Maximo

Data can be used for trend analysis to optimize

preventive maintenance

Highly scalable, capable of measuring millions of

data points across multiple sites

Consistent look and

interface with

Maximo 7.6

Drill into Specific Contextual Data for Assets


Meter Readings

Asset detail


Asset Health in action

If the diagnostic data is available in real

time for a locomotive, I can decide whether

I need to hit the reset button, saving 1,000

euro’s per train, or take it out of service to

bring it to the maintenance center for repair.

Understanding the vibration and

temperature of a pump, along with the

maintenance history will indicate whether I

should inspect, perform routine maintenance

or schedule the asset for replacement. The

least cost option or optimal timing can then

be assessed.

Weather can be an important element for Asset Health

Transmission line sag is a key factor in determining power line

health. Temperature and humidity can significantly affect sag.

Understanding sag in the context of historical weather for that

location, engineers can more effectively determine asset health.

Correlation of high temperature readings from a pump with

current weather can be used to determine a potential problem

vs. normal operation given ambient temperature.

The number of times an asset has operated in weather outside

its recommended operating parameters (i.e. over 90 degrees F.)

can be a driver in determining overall asset health

…In addition, IBM can provide enhanced accuracy and optimization

with Predictive Maintenance on Cloud

Additional tools for Reliability Engineers

accessible along with Maximo Asset Health

Insights

Predictive models which determine likelihood

of asset failure and time to failure based on

statistical modeling

Identify top failure modes

Recommended optimal maintenance

schedules and maintenance procedures

Ongoing optimization through machine

learning and physics based models


Overv

iew

Drill-

dow

n

Com

parison


Why Consider Leveraging Asset Health?

Reduce the cost and frequency of asset failures

• Perform maintenance while the asset is working to reduce disruptions to operations

• Improves overall equipment reliability

1

• Optimizes time spent on maintenance

• Reduces overtime costs by scheduling the activities

• Decreases requirement for emergency spare parts

Minimize unscheduled downtime due to catastrophic failure2

• Defer unneeded maintenance

• Prioritize PM workload based on condition

2 Reduce maintenance workload and costs with PM optimization3


Take-aways from today

Maximo Asset Health Insights lets businesses capture knowledge about the

true health of valuable assets and maximize the value of your maintenance

investment.

Understand what data your organization is using to make Preventive

Maintenance decisions. Where can you start to unlock value quickly?

1

2

Maximo Asset Health Insights represents a new way of maintaining equipment

- one based not only on current condition-based readings coming from the

equipment, but also informed by other influences like age, maintenance history,

weather incidents and historical context of subcomponents.

Your next steps

1

2Schedule a demo of Asset Health Insights to discover how a consolidated view

of asset data improves reliability. Check out the details at IBM.co/asset-mgt.

Then contact your IBM solution seller to get started!

18

Thank you

Visit ibm.com/iotWatson IoT / Insights into Asset Health

Business

Maximo Asset Health Overview (Watson IoT)