Intelligent Maintenance: Mapping the #IIoT Process
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A presentation about Industrial IoT, the value chain and real-world use cases; how to create value with IoT at your organization with an emphasis on predictive maintenance (bearing fault detection).
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Intelligent Maintenance: Mapping the #IIoT Process
- 2. Agenda • Introduction • Forecasts and Value Gaps • IIoT Real-World Context • IIoT Program Design for Intelligent Maintenance Confidential and Private 2
- 3. Dan Yarmoluk • Business Development, ATEK AssetScan • 15 years of Global Experience in Industrial Instrumentation • MBA • MS Data Science Confidential and Private 3
- 4. ATEK Access Technologies Welcome to the world of ATEK Access Technologies. Access to superior efficiencies and savings. Access to essential data and systems. Access to improved safety and control. Access to expert solutions and support. Access the power of technology. Confidential and Private 4 Innovation Vision
- 5. Finding Meaning and Mindset • Ideas From Billionaire Mindsets and Where You Fit In – Agility trumps size • Kodak went bankrupt in 2012 and Instagram was bought by Facebook for $1 billion with only 13 employees • Disrupt Yourself, or Someone Else Will – Estimated that 40% of the Fortune 500 companies will be gone in 10 years – Digitizing a service (think AirBnB and Uber) – Digitizing maintenance that leads to efficiency gains, savings on breakdowns and costly downtime ~ if maximized = competitive advantage Confidential and Private 5
- 6. Exponential and Enabling Technologies • Technology to Change the World and Create the Next Billion- Dollar Organizations – Computational systems/infinite and cloud computing – Networks and sensors – Artificial intelligence – Robotics – Digital Manufacturing – Medical technology/nanodiagnostics/digital health/biotechnology = DNA sequencing, genome mapping, CRISPR, preventative vs. reactive medicine and making 100 the new 60 Confidential and Private 6
- 7. Global Innovation driving demand for smart systems or “Fourth Industrial Revolution” Industry 4.0 Big Data Contextual Computing senseMaking Cognitive Computing •Climate •Oil Exploration •Asset/Supply Chain •Tsunami/Earthquake warning •Smart Grid/Smart Cities •Structural monitoring CeNSE – trillion nano sensors Internet of Things Agricultural Technology Robotics Digital Health Nanodiagnostics Industrial IoT “IIoT” Wearables
- 8. Technology Adoption Drag… Confidential and Private 8
- 9. Technology Adoption Drag…presents opportunity Confidential and Private 9
- 10. The Internet of Things is Everywhere Confidential and Private 10
- 11. Trillion Dollar “Mega-Trend” Confidential and Private 11 2015: $500 Billion Projected Spending on IoT 2019: $1.3 Trillion Source: Machina Research, other estimates
- 12. IoT: Explosive Growth Occurring Confidential and Private 12
- 13. IOT is Creating New Space for Value Creation Confidential and Private 13
- 14. Example: GoodYear Tire Confidential and Private 14 • ServiTIZE the Product • Service-led Competitive Strategy • Participate in a Larger Value Chain/Stream • Value-based Pricing in an Otherwise Commodity, Cost- Plus Environment • Must Understand the Customer’s Business Process and Determine the Right Business Model Extended Value Chain Opportunities Advanced Services Intermediate Services Integrated Products/Systems Augmented Product Use information to Move Beyond the Product Use Information to Sell The Product as a Service Use Information to Improve The Product in Use Use Information to Improve The Product Product Monitoring Services Supporting Customers Services Supporting Products Categories of Value Creation from IoT Source: Goodyear Global Innovation Dept.
- 15. The IIoT is Many Things I EnergyBuildings Government & Smart Cities Medical Industrial Digital Oil Field Smart Meters Solar & Wind Electric Vehicle Charging Stations Tank Monitoring Public Safety Vehicles Water Treatment Parking Street LightsSecurity Traffic Medical Devices Pharma Safety Patient Monitoring Manufacturing Automation Heavy Machinery Smart Agriculture Asset Monitoring HVAC Security Lighting Public Transit Transportation Fleet Management Smart Railways Asset Tracking Automation 15Confidential and Private
- 16. What is the Industrial Internet of Things Value? Confidential and Private 16 • IIoT is creating a universe of sensors, detectors, automation, software and other “Big Data” analytics tools, which enable an accelerated, deep learning of existing operations • These new hardware and software tools allow for rapid contextualization, visualization, computation, and automatic pattern and trend detection • Furthering this of manufacturing operations will finally allow for true quantitative capture of what oftentimes qualitative, ‘tribal’ or ‘expert’ human experiences running manufacturing operations
- 17. IIoT Business Drivers • Compliance with New Regulations – FDA’s FSMA (food safety), DOT’s FCSMA (driver e-logs), EPA, OSHA • Cost Reduction / Avoidance – Field service, predictive maintenance, logistics, supply chain • Product Differentiation – Adjunct offering, avoid commoditization, reliability/uptime, new premium SLAs, better roadmaps • New Revenue Streams / Models – Managed Hardware-as-a-Service offering, recurring revenue Confidential and Private 17
- 18. Challenge: Lots of Pieces and Parts 18 1 2 3 4 5 6 7 People and Process Connectivity/Edge Computing Things Global Infrastructure Data Ingestion Data Analysis Applications Transformational Decision Making Based on “Thing” Apps and Data Custom Apps Built Using “Thing” Data Reporting, Mining, Machine Learning Big Data, Harvest and Storage of “Thing” Data Cloud Infrastructure (public, private, hybrid, managed) Communications, Protocols, Networks, M2M, Wi-Fi, Telecom, HW Kits Devices, Sensors, Controllers 7 Layers of the Internet of Things (IoT)
- 19. Cost Improvements Seen as Most Value Confidential and Private
- 20. Manufacturing is leader in IoT spending Confidential and Private 20
- 22. Value in Service, Applications & Analytics Confidential and Private 22
- 23. Barriers to analytics Confidential and Private 23
- 24. Data not being utilized Confidential and Private 24
- 25. Value requires interoperability Confidential and Private 25
- 26. Transformation lies in people and workflow Confidential and Private 26
- 28. Suppliers and organizations need to think about processes… Confidential and Private 28
- 29. IIoT Success Requirements Value 1 2 3 4 5 Domain Expertise Business Analysis Instrumentation Expertise Mechanical Engineering Electrical Engineering
- 30. Today is a break-fix world… Confidential and Private 30
- 31. Or today is a scheduled maintenance world… Confidential and Private 31
- 32. Moving to an IoT-enabled world for prediction… Confidential and Private 32
- 33. Need to Process Map Confidential and Private 33
- 34. Value Proposition • Essential Asset Monitoring vs. Critical Asset only • Continuous Asset Monitoring vs. Monthly Diagnostics • Automated Alerting to Various User Groups • Dashboards and Analytics to Visually Explore; Root Cause • Reduce Unplanned Maintenance – 30, 60 or 90 days in advance • Reduced Planned Maintenance on Healthy Assets • Operator Confidence Up and Less Operator Error • Reduction in Expedited Logistics and Premium Pricing • Integration into Workflow and Repair • OPEX Pricing Model Confidential and Private 34
- 35. Value Proposition vs. Constraints • Extremely Lean Staff: Break-fix or periodic maintenance -- putting fires out • Legacy Systems have Critical (not Essential) Assets integrated with SCADA or PLC systems • Cannot utilize current reports nonetheless new automated alerting nor reporting – no expertise or no time or do not trust • Budgetary constraints anything above a maintenance budget Confidential and Private 35
- 36. IIoT Predictive Maintenance Today Confidential and Private 36
- 37. Value Proposition vs. Constraints Confidential and Private 37 • No Time • No Expertise • No Budget • Not Enough People • Primitive Diagnostics • Users of machines are different than repair technicians • Has enough problems • Does not to need to be informed of another problem but rather having a solution for the issue scheduled to be fixed
- 38. Real Value Proposition • Periodic blood pressure check • Continuous blood pressure monitoring • Radiologist (domain expert) to read results • ALERT! Signs of a heart attack • Sound alarm; schedule and perform surgery • The real prescription is HOW to deliver the value in a business MODEL Confidential and Private 38
- 39. Human Interjection to Maximize Automation Confidential and Private 39
- 40. Human Interjection to Maximize Automation Confidential and Private 40
- 41. IIoT Predictive Maintenance Model Should Include • Technology Solution that has easy “bolt on” connectivity outside SCADA or IIoT • Automated Alerting and Dashboard Reporting • People and Process to Interject with Alerting • People and Process with Domain Experience to Diagnose and offer Prescriptive Solution • People and Process to Schedule Maintenance • People and Process to Repair Equipment Confidential and Private 41
- 42. Condition Monitoring - Vibration Example • Monitoring solution with accelerometer, thermistor, etc. with gateway, cloud and dashboard • Combined with MSO Reliability Team and Technology • Accelerometer actionable output split into two 4-20mA instrument loops; 1 loop is 0-50g peak acceleration of bearing (state of bearing health) measured historically; 2nd loop is representation of overall vibration level, scaled in 0-1 in/sec – combined with domain, valuable insight into the health of the bearing • Reliability team that has account access, maintenance contract • Reliability and Maintenance team that constantly maintains equipment and interjects with alerts over time • Reliability and Maintenance team to perform equipment diagnostics, root cause and repairs • Delivered in monthly subscription model Confidential and Private 42
- 43. Conclusion • Technology Solution that has easy “bolt on” connectivity outside SCADA or IIoT • Automated Alerting and Dashboard Reporting • People and Process to Interject with Alerting • People and Process with Domain Experience to Diagnose and offer Prescriptive Solution • People and Process to Schedule Maintenance • People and Process to Repair Equipment Confidential and Private 43