Assessment of Predictive Maintenance Systems: Technology Market Penetration and Road Mapping (Technical Insights) D2B4-TI ...
Table of Contents  <ul><li>Executive Summary </li></ul><ul><li>Research Scope </li></ul><ul><li>Research Methodology </li>...
Table of Contents  <ul><li>Opportunity Evaluation and Roadmapping  </li></ul><ul><ul><li>Emerging Opportunities </li></ul>...
Key Findings  1 The key technology trends in the PdM industry is characterized by development of intelligent sensors, rese...
Key Findings (Contd...) 5 Among the key developments in sensors for PdM are the tri-axial MEMS based accelerometers used i...
Technology Value Chain Predictive Maintenance Systems (PdM) <ul><li>Vibration sensors </li></ul><ul><li>Pressure sensors <...
Key Business Drivers Automated corrective measures through software are constantly being included in PDM systems, resultin...
Key Business Drivers (Contd…) On-field data collectors are being improvised to be able to connect to the data analyzers ov...
Key Business Challenges PDM software has seen significant advances of late, and compared to the rate of newer developments...
Key Business Challenges (Contd…) Online monitoring systems are being upgraded with new advances in the internet technologi...
Technology Life Cycle of   Predictive Maintenance Systems Lifecycle Assessment of PMS Decline Maturity Research &  Develop...
Opportunities for Predictive Maintenance Systems Probability of Success Low High Low High Impact/Market Attraction Opportu...
Potential Applications – Opportunity Analysis Probability of Success   Level of Attractiveness  Source: Frost & Sullivan M...
Technology Management Strategies Analysis <ul><li>Downtime Minimization  </li></ul><ul><li>Reduction in maintenance costs ...
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Technical Insights: Assessment of Predictive Maintenance Systems - Technology Market Penetration and Road Mapping

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  • http://www.hindawi.com/journals/js/2009/312053.html
  • Technical Insights: Assessment of Predictive Maintenance Systems - Technology Market Penetration and Road Mapping

    1. 1. Assessment of Predictive Maintenance Systems: Technology Market Penetration and Road Mapping (Technical Insights) D2B4-TI March 2011
    2. 2. Table of Contents <ul><li>Executive Summary </li></ul><ul><li>Research Scope </li></ul><ul><li>Research Methodology </li></ul><ul><li> Overview </li></ul><ul><li>Key Findings </li></ul><ul><li>Technology Snapshot and Trends </li></ul><ul><ul><li>Technology Capability </li></ul></ul><ul><ul><li>Technology Value Chain </li></ul></ul><ul><li>Impact Assessment and Analysis </li></ul><ul><ul><li>Market Impact of Existing and Emerging Technologies </li></ul></ul><ul><ul><li>Market Impact of Technology/Drivers and Challenges </li></ul></ul><ul><li>Diffusion of Innovations and Needs Assessment </li></ul><ul><ul><li>Technology Adoption Cycle </li></ul></ul><ul><ul><li>Demand Side Analysis </li></ul></ul>
    3. 3. Table of Contents <ul><li>Opportunity Evaluation and Roadmapping </li></ul><ul><ul><li>Emerging Opportunities </li></ul></ul><ul><ul><li>Potential Application – Available Market </li></ul></ul><ul><ul><li>Technology Roadmap </li></ul></ul><ul><ul><li>Technology Management Strategies </li></ul></ul><ul><li>Appendix </li></ul><ul><li>Key Contacts and Patents </li></ul><ul><li>About Frost & Sullivan </li></ul>
    4. 4. Key Findings 1 The key technology trends in the PdM industry is characterized by development of intelligent sensors, research on improved analyzing algorithms, integration of data collectors with analyzing software., development of integrated hardware systems specific to PdM, and improved communication channels with wireless sensor networks. 4 Some of these challenges are being solved by the following emerging technologies: a) MEMS based sensors being used in wireless sensor networks e.g. WSN products by MEMSIC, USA b) Improved algorithms based on Fast Fourier Transform and Pattern recognition e.g. products by Ivara, USA and research by IMS Center, USA c) Integrated systems for lower complexity e.g. products from Mettler Toledo, USA, Mistras Group, USA, etc. d) PdM software compatible with smart phones and PDAs e.g. portable system from Prosig, UK, e) Web-based PdM systems with wireless communication capabilities e.g. products from iSagacity, USA. 2 The main business accelerator for the PdM industry is the need for near zero downtime and demand for automated corrective measures for plant equipment. The industry requires low cost and easy to install PdM systems, that are portable. The increasing use of wireless monitoring systems, need for prediction of trends in equipment performance, streamlining and prioritizing data on equipment condition, and improved reliability management needs are driving technology in this domain. 3 The key challenges in the PdM industry include slower rate of advancements in core sensor technology used in PdM, and drawbacks of MEMS sensors used in PdM. Slower rate of adoption of PdM software is also a significant restraint. The industry faces some obstacles in the near future because of lack of diversification in monitoring parameters of PdM, and low short term Return on Investment (ROI) for PdM. Installation barriers of web based PdM systems may lead to slower adoption rate for advanced PdM systems.
    5. 5. Key Findings (Contd...) 5 Among the key developments in sensors for PdM are the tri-axial MEMS based accelerometers used in a PdM system developed by Analog Devices, Intelligent high-temperature sensors by IMI Sensors, and Smart compressed air sensors by IFM Efector. 9 Predictive maintenance systems are used predominantly in the manufacturing and process industry. Other important application areas include oil and gas, aerospace and marine defense systems, and electric power generation. 6 Among the key innovations in PdM software are the ‘Dynamic Inspection Routes’ based algorithm from Ivara USA, advanced data collectors for ultrasonic monitoring by CTRL systems, USA, and RPM based sampling enabled analyzer from SPM Instruments, Sweden 8 Collaboration and partnership strategies among PdM manufacturers will accelerate wider usage of web based PdM systems, thereby enabling more efficient maintenance management. R&D strategies that include researching on better algorithms and low cost smart sensor systems are required. 7 Developments in PdM software is seen to be more rapid compared to developments in sensor technologies for PdM. PdM manufacturers are also increasingly producing integrated PMS solutions in the market. The key innovations in integrated systems are ‘Peakvue’ embedded technology based systems from Coservices, USA, and Multi array electrochemical sensor based PdM systems by Aginova, USA.
    6. 6. Technology Value Chain Predictive Maintenance Systems (PdM) <ul><li>Vibration sensors </li></ul><ul><li>Pressure sensors </li></ul><ul><li>Temperature sensors </li></ul><ul><li>Position sensors </li></ul><ul><li>Key players: Analog Devices, </li></ul><ul><li>Honeywell, BEI sensors, etc. </li></ul>End Users <ul><li>PdM Management </li></ul><ul><li>Downtime Minimization </li></ul><ul><li>Reduction in maintenance </li></ul><ul><li>costs </li></ul><ul><li>Preventing catastrophic </li></ul><ul><li>equipment failure </li></ul><ul><li>Reduction in maintenance </li></ul><ul><li>staff </li></ul><ul><li>Energy conservation </li></ul><ul><li>Key players: DLI, SKF, </li></ul><ul><li>SPM, Mistras, Mettler </li></ul><ul><li>Toledo, etc. </li></ul><ul><li>Sectors: </li></ul><ul><li>Manufacturing and </li></ul><ul><li>process </li></ul><ul><li>Oil and gas </li></ul><ul><li>Aerospace and Defence </li></ul><ul><li>Nuclear plants </li></ul><ul><li>Marine equipments </li></ul><ul><li>Wind farms </li></ul><ul><li>Key Players: Masonite, </li></ul><ul><li>Novartis, Irish Cement, </li></ul><ul><li>Pfizer, GE, ELI </li></ul><ul><li>Engineering, Pepsi, </li></ul><ul><li>Marathon petroleum, </li></ul><ul><li>etc. </li></ul>Source: Frost & Sullivan <ul><li>Data analysis software </li></ul><ul><li>Diagnosis software </li></ul><ul><li>Corrective measures and </li></ul><ul><li>tools </li></ul><ul><li>Key players: Ivara, SKF, SPM, </li></ul><ul><li>iSagacity, Emaint, etc. </li></ul><ul><li>Local detecting devices </li></ul><ul><li>Central PdM devices </li></ul><ul><li>Data collection devices </li></ul><ul><li>Data storage devices </li></ul><ul><li>Communication channels </li></ul><ul><li>Key players: CSI, Entek, SKF, </li></ul><ul><li>Commtest, etc. </li></ul>
    7. 7. Key Business Drivers Automated corrective measures through software are constantly being included in PDM systems, resulting in the development of advanced PDM software. Demands for automated corrective measures Constant need for miniaturization is a factor for the increased use of advanced MEMS based sensors and wireless sensors in PDM. Integration of PdM systems with handheld devices is also being rapidly adopted by maintenance personnel. Need for portability and miniaturization Factors Description Near zero downtime requirements for plant equipment Most plant managers are opting for better PdM analysis software with newer algorithms owing to their capabilities of better analysis of the collected data that leads to a lesser downtime of the machines. Low cost and easy to install PdM systems. Integration of entire PDM systems provides easy installation solutions to many PdM end users. This demand has led to the development of smart sensors. Smart sensors include a sensor (vibration/pressure/temperature etc.), a probe, and a data collector, that can be connected to a computer or a PDA analyze the data using a software.
    8. 8. Key Business Drivers (Contd…) On-field data collectors are being improvised to be able to connect to the data analyzers over wireless network connections. A few data collectors are even integrated into one device with the analyzer that is controlled remotely. These advancements let the maintenance personnel collect data and analyze it from different locations, thus improving reliability management. Improved reliability management The parameters that are used to monitor the condition of equipment are pre-determined by intelligent data collectors that in turn feed the collected data to high-end software. The interconnectivity between the various components of PdM is thus enhanced by manufacturing integrated solutions featuring all three components of the PdM value chain. Streamlining and prioritizing data on equipment condition Factors Description Wireless monitoring systems Adaption of wireless sensors networks are increasing due to the growing demands for un-tethered communication channels and wide area PDM coverage requirements. Wireless sensor networks involve collecting data from a large number of nodes, especially nodes placed in inaccessible or hazardous areas. More data collection provides the data analyzers with more information for more accurate results. Prediction of trends in equipment performance Analysis software is increasingly being equipped with pattern recognition algorithms in order to facilitate repetitive processes that could fully automate detection of performance trends based on historical data collected by the system.
    9. 9. Key Business Challenges PDM software has seen significant advances of late, and compared to the rate of newer developments in PdM software, the rate of adoption of such software is slower among the end users. Slower rate of adoption of PdM software Optical sensors are still used for very specific industries such as oil and gas pipeline monitoring. The advantages of fiber optic sensors are yet to be applied to industrial predictive maintenance, although research is on. Limited use of fiber optic sensors in PdM Factors Description Slower rate of advancements in core sensor technology used in PdM Advances in sensor architecture used for PdM are not as prominent as was a decade ago. The current trend among manufacturers of PdM systems is to integrate existing sensors with data collectors and communication channels to form smart sensors. Improvements in sensitivity and performance for sensors are required for the PdM market to grow. Drawbacks of MEMS sensors used in PdM Most advances in sensors used in PdM are MEMS based, and although adaption of these sensors have been growing, there are still certain drawbacks of MEMS when used for PdM systems. When compared to traditional piezoelectric sensors, MEMS sensors are more suitable for custom PdM solutions rather than standard systems.
    10. 10. Key Business Challenges (Contd…) Online monitoring systems are being upgraded with new advances in the internet technologies. However, complex issues are encountered by plant owners when it comes to setting up web based PdM systems. Most plants lack the communication infrastructure necessary to install, run, and maintain web based systems. Installation barriers of web based PdM With the advent of improved technology (specially advanced software that use technically advanced systems for operation), maintenance professionals need to be trained. Cost of training staff is often a barrier for plants to switch to predictive maintenance Dearth of trained professionals to use complex systems Factors Description Lack of diversification in measuring techniques of PdM Vibration analysis is still the most widely used method of PDM. The use of other methods such as pressure analysis, temperature analysis, ultrasound and infrared techniques, etc. have seen fewer recent developments Low short term Return on Investment (ROI) for PdM While plant managers are accepting the benefits of PdM systems with respect to downtime reduction, equipment efficiency improvement, and a good ROI in the long run, the initial cost of installing a PdM system is still a barrier for most plant owners
    11. 11. Technology Life Cycle of Predictive Maintenance Systems Lifecycle Assessment of PMS Decline Maturity Research & Development Growth Time Market Penetration Source: Frost & Sullivan 3 4 1 5 6 & 7 1 – Capacitance based sensor for PMS: 2 – MEMS based sensors for PMS: 3 - Piezoelectric sensor based PMS: 4 – Pattern recognition analysis for PMS: 5 – FFT based software for PMS: 6 – Self correcting software systems for PMS: 7 – Intelligent sensor based int-hardware for PMS : 8 – In-built self-assessment systems 9 – Wi-Fi enabled hardware systems for PMS: 10- MRAC algorithm based software for PMS: 2 9 Highlights 10 8
    12. 12. Opportunities for Predictive Maintenance Systems Probability of Success Low High Low High Impact/Market Attraction Opportunity Analysis Matrix for Component Technologies used in PdM Systems ( based on current R&D status ) Capacitance based sensor for PMS : Source: Frost & Sullivan Piezoelectric sensors: FFT based software based PMS: Self correcting and intelligent sensor based PMS: Highlights MRAC algorithm based software for PMS : Wi-Fi enabled hardware systems for PMS : Pattern recognition analysis: MEMS based sensors: Self correcting and intelligent sensor based PMS: In-built self assessment systems:
    13. 13. Potential Applications – Opportunity Analysis Probability of Success Level of Attractiveness Source: Frost & Sullivan Manufacturing Large scale Research facility Oil and Gas Power Generation Defence- marine and Aerospace Food processing and pharmaceutical
    14. 14. Technology Management Strategies Analysis <ul><li>Downtime Minimization </li></ul><ul><li>Reduction in maintenance costs </li></ul><ul><li>Preventing catastrophic equipment failure </li></ul><ul><li>Reduction in maintenance staff </li></ul><ul><li>Energy conservation </li></ul>Relevant Trends <ul><li>Zero downtime </li></ul><ul><li>Synchronization of data </li></ul><ul><li>flow </li></ul><ul><li>Streamlining and prioritizing </li></ul><ul><li>data </li></ul><ul><li>Reduction in installation costs </li></ul><ul><li>Intelligent self-assessment </li></ul>Unmet Needs <ul><li>Downtime Minimization </li></ul><ul><li>Reduction in maintenance costs </li></ul><ul><li>Preventing catastrophic equipment failure </li></ul><ul><li>Reduction in maintenance staff </li></ul><ul><li>Energy conservation </li></ul>Relevant Trends <ul><li>Web based PdM systems </li></ul><ul><li>Integrated data collectors </li></ul><ul><li>with analyzers </li></ul><ul><li>Advanced analysis algorithms </li></ul><ul><li>Advanced low cost sensors </li></ul><ul><li>Smart sensor systems used for </li></ul><ul><li>PdM </li></ul>Relevant Trends <ul><li>Collaboration Strategies: PdM solution provides could form collaborations with communication providers to enable plant owners install state-of-the-art network facilities in order to use web based PdM systems efficiently, thus further reducing downtime. </li></ul><ul><li>R&D Strategies: Research and development can be broken down into sensor technology and software algorithms. The recommended strategies in these two sectors are: </li></ul><ul><ul><li>Key players in the PdM market should invest on research of sensors that are more sensitive and cost efficient. The advantages of fiber optic sensors should be explored in a broader spectrum of predictive maintenance systems. </li></ul></ul><ul><ul><li>A few consortiums like the Center for Intelligent Maintenance Systems (IMS) are presently researching on advanced algorithms that would help prioritize the data collected from sensors based on baseline conditions. PdM software manufacturers should participate in such research and development activities. </li></ul></ul><ul><li>Partnership Strategies: Various PdM software developers and PdM sensor manufacturers should form partnerships with peers to achieve the need of fully automated data collection processes, and building intelligent equipment with built in self assessment capabilities </li></ul>Strategic Recommendations <ul><li>Collaboration Strategies: PdM solution provides could form collaborations with communication providers to enable plant owners install state-of-the-art network facilities in order to use web based PdM systems efficiently, thus further reducing downtime. </li></ul><ul><li>R&D Strategies: Research and development can be broken down into sensor technology and software algorithms. The recommended strategies in these two sectors are: </li></ul><ul><ul><li>Key players in the PdM market should invest on research of sensors that are more sensitive and cost efficient. The advantages of fiber optic sensors should be explored in a broader spectrum of predictive maintenance systems. </li></ul></ul><ul><ul><li>A few consortiums like the Center for Intelligent Maintenance Systems (IMS) are presently researching on advanced algorithms that would help prioritize the data collected from sensors based on baseline conditions. PdM software manufacturers should participate in such research and development activities. </li></ul></ul><ul><li>Partnership Strategies: Various PdM software developers and PdM sensor manufacturers should form partnerships with peers to achieve the need of fully automated data collection processes, and building intelligent equipment with built in self assessment capabilities. </li></ul>Strategic Recommendations <ul><li>R&D Strategi </li></ul><ul><li>R&D Strategies: The recommended strategies in sensor technology and software algorithms are: </li></ul><ul><ul><li>Key players in the PdM market should invest on research of sensors that are more sensitive and cost efficient. The </li></ul></ul><ul><ul><li>advantages of fiber optic sensors should be explored in a broader spectrum of predictive maintenance systems. </li></ul></ul><ul><ul><li>Consortiums such as the Center for Intelligent Maintenance Systems (IMS) are presently researching advanced </li></ul></ul><ul><ul><li>algorithms that would help prioritize the data collected from sensors based on baseline conditions. PdM software </li></ul></ul><ul><ul><li>manufacturers should participate in such research and development activities. </li></ul></ul><ul><li>Partnership Strategies: Various PdM software developers and PdM sensor manufacturers should form partnerships with peers to </li></ul><ul><li>achieve the needed fully automated data collection processes, and building intelligent equipment with built in self assessment </li></ul><ul><li>capabilities. </li></ul><ul><li>Collaboration Strategies: PdM solution providers could form collaborations with communication providers to enable plant </li></ul><ul><li>owners install state-of-the-art network facilities in order to use web based PdM systems efficiently, thereby reducing </li></ul><ul><li>downtime further. </li></ul>Strategic Recommendations

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