BCT-PTC Digital Webinar - IoT and Asset Analytics
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The document discusses the implementation of IoT and asset analytics in manufacturing and operations, highlighting the importance of predictive maintenance and the integration of various data sources. It outlines market trends, challenges, and the benefits of using advanced analytics for equipment performance and operational efficiency. Successful case studies demonstrate significant improvements in key performance indicators across various industries.
BCT-PTC Digital Webinar - IoT and Asset Analytics
- 1. © Bahwan CyberTek August 4, 2017 1www.bahwancybertek.com© Bahwan CyberTek August 4, 2017 IoT & Asset Analytics – Where do you start? BCT – PTC Webinar
- 2. © Bahwan CyberTek August 4, 2017 2 Agenda • About BCT & PTC • BCT’s IIoT Ecosystem • Asset data types and Analysis methods • Equipment data for predictive maintenance • Analytics Value creation • Success Stories • Discussions
- 3. © Bahwan CyberTek August 4, 2017 3 • Connect, federate, aggregate, and contextualize • Provide useful, timely, shareable information • Information from many disparate systems • SOA eliminating duplicated systems, functionality • Open integration with legacy and new technologies • Work process centric user interfaces • Role-based decision making, collaboration • Business process authoring and enforcement PTC and the Digital Thread LNS Research 2014
- 4. © Bahwan CyberTek August 4, 2017 4 Market trends - top IIoT use cases in the factory PTC FY16 customers (Corp. Strategy interviews) LNS Research (2016)McKinsey Global Institute (2015) Bain IIoT report (2016)
- 5. © Bahwan CyberTek August 4, 2017 5 • Digitization of processes • Connected assets and sensors • Interoperability • Cloud, mobile, augmented reality • Big data technology is transforming manufacturing And Operations
- 6. © Bahwan CyberTek August 4, 2017 6 Smart Manufacturing Industrie 4.0 a wave of transformation is coming to manufacturing Made in China 2025 33% (majority) of IoT economic value will come from the “Factories” setting McKinsey Global Institute
- 7. © Bahwan CyberTek August 4, 2017 7 CONVENTIONAL Manufacturing IT landscape – ISA S95 MODEL LNS Research 2015
- 8. © Bahwan CyberTek August 4, 2017 8 The manufacturing opportunity – With IoT Source: LNS Research, 2015 Suppliers EnvironmentalLogistics “Rip and replace” gives way to “wrap and extend” Role-based IoT applications
- 9. 9 • Many data sources, formats, types • Manufacturing process diversity • Lack of system interoperability, flexibility, visibility • Changing business, products, processes • Demands on IT resources • Deployment disruptions, risk, and cost TYPICAL CHALLENGES ERP ERP MES SCADA FleetVendorWeb Systems Assets People Line RobotTank Plant Office HQ
- 10. © Bahwan CyberTek August 4, 2017 10 • Open and extensible platform • Connecting systems, people, assets • Rapid application development • Easily create native mobile apps • Predictive and prescriptive analytics • Deploy: hosted, cloud, onsite, hybrid Next generation orchestration
- 11. © Bahwan CyberTek August 4, 2017 11 Desktop/Laptop TODAY Mobile AR/Wearables TOMORROW VR/Wearables Context Driven Physical/Digital orchestration Desktop/Laptop TODAY Mobile Analyze Business/IT Systems CAD & PLM AEC & BIM Digital Context AWS IOT Azure IOT Predix Edge/OT Environments Controllers Sensors Historians Model Digital Map Digitize via scan, photo, or video Simulate AR/Wearables TOMORROW VR/Wearables AWS IOT Azure IOT Predix Edge/OT Environments Controllers Sensors Historians CAD & PLM AEC & BIM Digital Context Business/IT Systems Analyze Simulate Model Digital Map Digitize via scan, photo, or video Computer Vision Computer Vision CONTEXTUALIZE (Map Data to Context) SYNTHESIZE ORCHESTRATE ENGAGE (Multi-Channel, In Context Role Based) SOURCE (Data & Context)
- 12. © Bahwan CyberTek August 4, 2017 12 We transform or enable transformation of businesses through innovative products and services Bahwan CyberTek Group Digital Mobility Analytics Cloud Connected Vehicle Predictive Analytics Digital Marketing Risk Analytics Outcome-based business models IP-led Products Solution Accelerators 2800+ Associates 1000+ Customers $ 242 M+ Revenue 20 countries 4 continents Bahwan CyberTek included in the Gartner Report on ‘Choosing the Right Vendor for Payment Modernization Initiatives Oil Telecom Power Government Banking SCM / Logistics Vertical Focus Predictive Analytics SJM & Connected VehiclesSocial & MobilityBCT’s Digital IP suite IOT Community
- 13. © Bahwan CyberTek August 4, 2017 13 BCT – Reliable Expert for your IoT Ecosystem Sensors Connectivity People Processes Business Value Integration || Dashboards || Contextualize || Analytics || Applications || Workflows Cloud to on-Premise Integration Devices & Plant Control Systems Integration SOA / FMW Application Integration Enterprise Apps / Portals BI and AnalyticsM2M
- 14. © Bahwan CyberTek August 4, 2017 14 Asset Data types and Analysis Methods PLC, SCADA , Historian Process Data – Flow, Pressure, Temp, Level Vibration Solutions Vibration data with Outliers, Alarms and Conditions Pattern Analysis Outlier/Anomaly Relationships Contextualization Root Cause FindingsEAM/CMMS Asset Data – OEM, Model, Specs, Maintenance History, Fault codes, Spares Equipment Data – Current, Voltage, Ramp time VFD, Controller
- 15. © Bahwan CyberTek August 4, 2017 15 Equipment Data for Predictive Maintenance Calendar Calendar Time / Day / Month Equipment Conditions Parameters of the equipment Process Conditions Process Parameters related to Equipment Equipment Maintenance PMEffectiveness Manual Entry Manual Entry Auto Trigger in CMMS/EAM Existing Scenarios Condition Monitoring /Meters Preventive Maintenance Approval Asset Management Process Flow -------------------------------------------------------------------- Auto Trigger in CMMS/EAM Efficient Scenarios PLC , SCADA , Historian Integration Integration and Computation Engine Performance Efficiency / Predictive Analysis / Root Cause Analysis Work order Results Run Hours Running Hours of the equipment Interfaces PLC SCADA HISTORIAN MES • Reduces Unplanned Downtime • Avoids Deterioration of Equipment
- 16. © Bahwan CyberTek August 4, 2017 16 Predictive Solutions - Failure / Problem Predictions 0 1 2 3 4 5 0 5 10 15 20 25 30 Intelligent Alarm Capture Current Alarm Limit Benefits • Capture abnormal Behavior's • Operations info for decision making • Well informed Equipment Information • Avoid failures • Better prepared 0 5 10 15 20 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Applicable Scenarios • Process Improvements • Equipment Efficiency • Accurate Loss calculations Deviation Analysis
- 17. © Bahwan CyberTek August 4, 2017 17 • Run Hours • Counts – On/Off • Efficiency Calculations • Performance Indicators • Energy Calculations • 80-20 / Top 5 reasons • Parameter • Patterns / Clustering • Contextualization • Condition Logics • Failure intervals • Root Cause Analysis Analytics Report What happened? Analyze Why did it happen? Monitor What's happening now? Predict What might happen? Prescribe What should happen? Meters PLC, SCADA , Historian Enterprise Systems – EAM / ERP Vibration & Thermal Solutions Data Sources A n a l y t i c s Categories Analytics Examples • Asset Utilization • Operational Cost • Worker Productivity • Worker Safety • Sustainability • Customer Experience • New outcome model Value
- 18. © Bahwan CyberTek August 4, 2017 18 17 to 13 Value Proposition 2% Less 30,000 Hours 0.5 to 1 % 1 - 1.5 Years Less No. of Maintenance Visits (PM task Consolidation, Custom PM Plans) Less Downtime (Increased Availability & Revenue) Less Maintenance Labor Hours (Utilize it for Detailed, Quality Inspection) Less Spare Holding Cost (Better Spare Management) Higher Economic Life (Better Spare Ratio) Unified PM plan Customized Maintenance Fault Prediction
- 19. © Bahwan CyberTek August 4, 2017 19 Power Generation, T & D •Operations efficiency & Heat Rate Degradation Advisor •Asset Analytics •T&D Distribution Analytics •Renewables: TOMS & SOVA 15% Reduction in load Planning time 5% Improvement in Equipment Availability 1% Increase in production 20% Reduction in field visits Oil & Gas •E&P Monitoring •Predictive Maintenance and WO automation 7% - 10% Reduction of non productive time Verticals What we did for them VALUE Analytics – Value creation Minerals, Metals & Resources •Plant performance improvement •Quality Mgmt. •Enterprise Integration 3% Improvement in Productivity 4% Reduction in Energy Consumption 50% Improvement in Quality Adherence Discrete Manufacturing •Operations Management Platform •Predictive Maintenance and WO automation 5% Improvement in Equipment Availability 3% Operations Efficiency Building Energy Mgmt. •Analytics Platform •Predictive Maintenance •Energy Management 15% Reduction in Energy use $$$ Millions saved in Law Suits
- 20. © Bahwan CyberTek August 4, 2017 20 Top 5 Learnings on Asset Analytics Outcome Definition Data sufficiency Integration Scenario Definition How to Deliver?
- 21. © Bahwan CyberTek August 4, 2017 21
- 22. © Bahwan CyberTek August 4, 2017 22 BCT’s “Real Time Asset Optimization Model” – using Predictive Analytics Asset Optimization Model Condition Monitoring Performance Indicators Root Cause Analysis Cost of Operation Active Truth Table Optimization - to minimize the whole-life cost in Operation, Maintenance and Replacement or disposal Condition Monitoring To CMMS /EAM - Normal Operations - Needs Maintenance during next opportunity - Needs immediate Maintenance/Overhaul Performance & Sustainability Indicators / Intelligence Level 1 - 100% to 80% Level 2 - 50% to 79% Level 3 - < 50% Of Manufacturer Recommendations (or) Plant Best Practices Real Time Cost of Operation - Normal Cost - Higher than normal by 25% - Higher than normal by > 25% Truth Table Type of Failure Reasons Consequences Corrective Actions Equipment 1 Equipment 2 Root Cause Analysis • Immediate access to problem source • In Real Time • Forward Chaining