The Science of Predictive Maintenance: IBM's Predictive Analytics Solution
IntegrityPRO-introduction
1. 10 North Silver Street I Aberdeen I Scotland I AB10 1RL
t:+44 (0)1224 984400 I info@enkelt.co.uk I www.enkelt.co.uk
enkelt is an innovative management and software consultancy, established in 2005 & based
in Scotland. Our services are a powerful hybrid of performance improvement SaaS Solutions,
mobile technology & consulting expertise aimed at equipment intensive assets and complex
infrastructure.
A mature asset had not produced for over 2 years and struggled to sustain stable
production after restart. With IntegrityPRO®
in place within a year crew the crew were
transformed from reactive to proactive. Awareness of vulnerabilities is quicker and failures
have been reduced allowing more time for preventative maintenance. Priorities are clearly
understood, IntegrityPRO®
became a single source of direction to deliver:
● Greater stability of production with increased availability
● Reduction in failures allowing more time for preventative maintenance
maintenance backlog reduction
Dec ‘14 Dec ‘15
production efficiency
IntegrityPRO® is fully customisable. It can be implemented quickly to deliver an immediate
& positive impact. Configuration is six weeks & minimum system requirements are listed
in the table below. Once the asset team is familiar with the benefits of the system they will
be better placed to further enhance the system with additional customisation.
Minimum System Data Requirements
QHSE & Verification People Equipment
Asset Overview Usernames Systems & Sub Systems
Risk Matrix Roles Equipment Codes
Safety Case incl. MAH’s Competency Matrix Main Equipment List
Barrier Model & ORA form Production Critical Equipment Lists
Performance Standards Plant & Process Overview General Arrangement Dwg’s.
Policies System P&IDs KPI’s
Golden Rules Metering Overview HSEQ & Competence
Leadership Values Chemicals Production
Policy Statements Oils & Greases Maintenance
IntegrityPRO®, protect your assets against the ever present
challenges of the ageing process with an integrated solution for:
● Process Safety
● Risk Management
● Defect Elimination
● Operational Excellence
Deterioration in performance & condition causes disruption, while adding risk & complexity to
operations. It increases the demand on budgets & personnel. If your organisation does not
have the right tools & processes to learn, adapt & improve through the ageing process then
safety, integrity, reliability & profits should not be taken for granted.
Our intuitive solution introduces a new dimension to asset management. With a fully integrated
proactive workflow process, data collection, reporting & planning system we have made it
easier to learn, adapt & improve. Making the use of your resources more effective and efficient,
protecting integrity, reliability & profits in a single affordable application.
fingertip precision by
OPERATE, MONITOR
& MAINTAIN
Critical Equipment
Verification
Process Safety
Production Efficiency
Operational Availability
Security
NDT Inspections
ATEX
Operator Rounds
PLAN, ADAPT
& IMPROVE
Cost Benefit Analysis
Lessons Learned
Management of Change
Shutdown Management
Obsolescence
Strategic Planning
Performance Assurance
Budget Modelling
Continuous Improvement
LEARN, EVALUATE &
PRIORITISE
Failure Reporting
Data Analytics
Accumulative Risk
Risk Analysis
Categorisation
Prioritisation
Risk Owner
Mitigation
Barrier Management
maximum return make the invisible visible minimal risk
2. Step 04 Organisational Learning
share lessons learned across assets &
Step 01 Monitoring Performance
record & trend the performance
of plant process & people, report
deterioration
learn & adapt, understand the root cause of the
event, define the corrective actions to prevent
Step 02 Failure Reporting
report failures or deterioration in
condition or performance,
A fully integrated system to ensure assets are managed in a safe, effective, proactive
& efficient manner to drive performance improvements, reduce downtime & costs.
With so many moving parts, managing the
safety & performance of an asset becomes a
balancing act of ever changing priorities, &
when you are trying to manage an asset with
a mixture systems, spreadsheets, checklists &
emails it’s not easy.
Relying on systems & processes that don’t talk
to each other can often make a difficult task
feel like an impossible task.
When an asset is suffering from deterioration,
equipment failures & process trips the
organisation need systems that work, that
allow them to react quickly, understand the
cause of unwanted events, prevent
recurrence, reduce risk & stop obvious
mistakes being made again & again. An
organisation need systems & processes that
make it easy to learn, adapt & improve.
IntegrityPRO® pulls all the moving parts of
asset management together into a single
integrated solution making it easier to protect
an organisation & the performance of their
assets throughout their entire life.
By delivering a disciplined & proactive
approach we make it easier to make the right
decisions first time around, increasing the
effectiveness & efficiency of the asset team
and reducing the demand on resources.
IntegrityPRO® is fully customisable & includes
intrinsic mobile functionality, enabling
technicians, inspectors & surveyors to collect
data without compromising safety.
It can help an organisation achieve
compliance with ISO55000 and can be
deployed quickly to provide an immediate
and positive impact within;
●
●
●
●
LEARN : ADAPT : IMPROVE
treat every event as an opportunity to
learn, consider the potential for
recurrence or escalation
escalation & recurrence. Ensure mitigation is
peers, prevent failures elsewhere,
search for proven solutions in similar
events
Step 06 Cost, Benefit Analysis
evaluate the benefits and explore
options, approve budget, schedule
improvement & forward planning
Step 05 Corrective Action System
learn & adapt, understand the root cause of the
event, define the corrective actions to prevent
Step 07 Performance Assurance Plan
direct resources & investment, manage
shutdowns, life extension & prioritise the
Step 02 Failure Reporting
report failures or deterioration in
condition or performance,
Step 03 Risk Analysis
analyse and categorise the risk, review
risk register, understand asset priorities
A fully integrated system to ensure assets are managed in a safe, effective, proactive
& efficient manner to drive performance improvements, reduce downtime & costs.
LEARN : ADAPT : IMPROVE
treat every event as an opportunity to
learn, consider the potential for
recurrence or escalation
& allocate responsible person to
identify mitigation & adapt
escalation & recurrence. Ensure mitigation is
technically feasible & financially viable
corrective backlog in a single point of
reference that supports & promotes the
needs of the business