Remote monitoring service for CAT diesel genset

1. WAE Generator Data Center
(Green belt certificate project)
Mr. Otgontugs U.
Sales engineer,
Power System Division

2. Agenda
 Condition Based Monitoring
 Remote monitoring Solution
 Six Sigma Approach
 Project implementation
 Project finance
 Conclusion

3.  Pressure to increase productivity
 Limited resources
 Assets are dispersed and not easily monitored
 Experts are not next to equipment
 Equipment is more complex
“Proactive analysis process using equipment and application data from
multiple sources to make informed maintenance, component
replacement, and repair decisions.”
Why Condition Based Monitoring

4. Performance
Weeks Days Hours
Customer Value
 Increased Planned Maintenance
 Lower Labor and Parts Cost
 Increased Availability
Failure
Machine
Alarm
Reactive
 Extensive Damage
 High Cost
 Most Downtime
Planned
Some Damage
Moderate Cost
Moderate Downtime
Predictive
Minimum Damage
Minimum Cost
Planned Downtime
Physical
Indicator
Wear
material
Operational
Change
Prognostic
deviation
Condition Monitoring
Equipment Management
Health Monitoring
Asset Management
Why Condition Based Monitoring

5. How it works
Data logging
and routing
Wired, cell or
satellite transmission
(can be disabled)
CAT secure server
Continuous data
archiving
Customer & Dealer
contacts for emergencies
CAT dealer Condition
Monitoring Specialists
24/7 support
Reports :
- Fleet analysis
- Issues
- Recommended actions
User network
User site
CAT Dealer
Control center CAT Data Centre
Non-CAT
data can be
acquired

6. 0.0%
0.1%
0.1%
0.0%
0.1%
74.2%
25.5%
0-750
750-800
800-850
850-900
900-950
950-1000
1000-1050
Speed
Speed Histogram
1.0%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
0.0%
0.2%
19.6%
59.9%
19.0%
0.1%
0-50
50-55
55-60
60-65
65-70
70-75
75-80
80-85
85-90
90-95
95-100
100-105
105-110
PercentRated Torque
Torque Histogram
Reporting

7. User Benefits
 Reduce unscheduled repairs
 Increase productivity
 Utilize data proactively – Not after failure
 Direct maintenance to high value work
 Provide visibility of asset performance & health across the enterprise
Condition Based Monitoring Summary

8. Agenda
 Condition Based Monitoring
 Remote monitoring Solution
 Six Sigma Approach
 Project implementation
 Project finance
 Conclusion

9. EMCP Monitoring Solution

10. Netbiter Monitoring Solution
• The Netbiter remote management solution
includes communication gateways, secure
hosting servers and a web user interface.

11. Bernini Design Solution

12. Comparison of Different Solution
Item EMCP / CAT Netbiter Bernini
Cost
Experience
Generator number
Modem
Distance
Server location
Support

13.  Condition Based Monitoring
 Remote monitoring Solution
 Six Sigma Approach
 Project implementation
 Project finance
 Conclusion
Agenda

14. What is Our Goal and Strategy
Our Goal: to build Mongolian first and only
Diesel Generator Data Center, to provide
Remote Monitoring service for Diesel
Generator Owner
Our Strategy: not to lose Our customer to
competitor, increase our customers by
Remote Monitoring Service

15. Turning Remote Control Solution into $$$
DEFINE – set the stage
Validate/Identify the remote control business opportunity
Establish scope of the project
Determine the goals of for this business development
MEASURE – collect Information
Quantify the remote control opportunity
Collect the voice of customer
Collect the voice of dealer
ANALYZE – determine the areas requiring improvement
Define customer critical requirement
Understand dealer capabilities
Identify the gap in performance and their causes
IMPROVE – move forward with a customer focused business strategy
Generate new solutions or improve processes to close performance gap
Develop Implementation plan
CONTROL – sustain the strategic improvement
Develop Control plan
A WELL PROVEN 5-STEP APPROACH

16. Team Selection
No Dept/Div Person responsibility
1 Black Belt Otgon SME
2 PowerSys Otgontugs Project leader
3 Tserenchunt Team member
4 Gantsetseg Team member
5 Janchiv Project Owner
8 Service Sergelenbat SME
9 Khishigbayar Team member
10 IT Bayarmagnai SME
11 Munkh-Orgil SME
12 RUN Batkhishig SME
13 Ariunbold / Andy Project Sponsor
14 Finance ? SME

17. Support Person from CAT

18. Agenda
 Condition Based Monitoring
 Remote monitoring Solution
 Six Sigma Approach
 Project implementation
 Project finance
 Conclusion

19. To do list Date (estimated)
Project kick-off meeting Feb 27 , 2015
Generator Data Center solution May 25, 2015
Introducing to Project Sponsor (RUN) June 15, 2015
Procurement of Hardware & Software July 31, 2015
Installation Generator Data Center Nov 30,2015
Training operator, technician Dec 2015
Pilot test Dec 2015
Official launch of Generator Data Center Jan 2016
Marketing campaign Jan – Mar, 2016
Providing remote monitoring service to End user Jan 2016 -
Project Implementation Schedule
Project team meeting held every Friday

20. Agenda
 Condition Based Monitoring
 Remote monitoring Solution
 Six Sigma Approach
 Project implementation
 Project finance
 Conclusion

21. Project Finance
- Cost Analysis
- Pugh Matrix
- Project Chart

22. Agenda
 Condition Based Monitoring
 Remote monitoring Solution
 Six Sigma Approach
 Project implementation
 Project finance
 Conclusion

23. Conclusion
- Project team meet every Friday
- Target customer: Diesel generator owner,
specially who bought from WAE
- Coverage area: UB
- Should have propose cost effective solution.
- In pilot stage better use WAE server, it need
to upgrade and add HDD.
- Need study Productlink solution from WAT.