Innovation in maintenance - Accenture


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Most industries are embracing Digital as core component of their growth strategies

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Innovation in maintenance - Accenture

  1. 1. Let’s Talk Operations “Innovation in maintenance” 20 March 2014
  2. 2. 2 Most industries are embracing Digital as core component of their growth strategies Copyright © 2014 Accenture All rights reserved.
  3. 3. 3 There is an estimated $14.4 Trillion of value at stake between now and 2022 for ALL companies to realize through Digital Businesses Copyright © 2014 Accenture All rights reserved. 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 will migrate 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
  4. 4. 4 Digital Plant Vision Copyright © 2014 Accenture All rights reserved. 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
  5. 5. 5 Key technology trends Copyright © 2014 Accenture All rights reserved. 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 decision making 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 automated and personal interaction. Mobile devices impact all areas of business and personal live by transforming how people interact, consume information and services, collaborate, and work.
  6. 6. 6 The Digital Plant is integrating processes and solutions to build, operate and maintain the plant more efficient and safe Copyright © 2014 Accenture All rights reserved. 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
  7. 7. 7 Accenture Digital Plant solutions for Asset Management helps companies address asset and operational performance challenges Copyright © 2014 Accenture All rights reserved. Services Capital Projects Improves portfolio and projects “time to value” and capital efficiency Operations Optimization Optimizes plant and supply chain operations to increase margins and production performance Asset Optimization Optimizes asset performance, balancing cost and risk and enabling operational efficiency Commercial Optimization Optimizes 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
  8. 8. 9 Digital Plant Apps Copyright © 2014 Accenture All rights reserved.
  9. 9. 10 The Digital Plant will be enabled by technology solutions that are connected, capable, collaborative and contextual Copyright © 2014 Accenture All rights reserved. The “Digital Plant” of the future is: Connected Ubiquitous wireless infrastructure supports digital connectivity of equipment. Sites will be connected to each other and to remote optimization centers User Solutions will be: Collaborative Connecting people and teams across the plant and enterprise, bringing together skills to solve problems and optimise operations Capable The plant will be developed with in built digital predictive capability for process and asset optimisation. Contextual Integrating information at the point of interaction to bring context and insight to operators and engineers.
  10. 10. 11 Connected: Plant wide connectivity Copyright © 2014 Accenture All rights reserved.
  11. 11. 12 Connected: Leading Mobile Devices by Environment Copyright © 2014 Accenture All rights reserved. XCIEL (I-Pad) Apple I-Pad XCIEL (I-Pad) Panasonic (CF19 – CF29) Apple I-Phone Samsung Galaxy Phone Getac (B300) Motororla (ET1 pad) Ecom (Handy 07 IS 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 Motorola Smart 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) Ecom Iroc. (CI70-ex PDA) 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
  12. 12. 13 Capable: New Application Architectures Copyright © 2014 Accenture All rights reserved. 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
  13. 13. 14 Capable: Better use of analytics Copyright © 2014 Accenture All rights reserved. Dashboards Drill down functionality Advanced 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
  14. 14. 15 Capable: Digital plant workforce Copyright © 2014 Accenture All rights reserved. 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
  15. 15. 16 Collaborative: Video Collaboration – technical support Copyright © 2014 Accenture All rights reserved. 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.
  16. 16. 17 Contextual: Augmented Reality for O&M Mobility Copyright © 2014 Accenture All rights reserved. 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
  17. 17. 18 Contextual: Update drawings in the field Copyright © 2014 Accenture All rights reserved. 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
  18. 18. 19 Contextual: Virtual Operations Environment Copyright © 2014 Accenture All rights reserved. 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
  19. 19. LET’s Talk Operations Copyright © 2014 Accenture All rights reserved. 20 More information on: