* Our Foresight: Your Decision *
| Predict Asset Reliability |
Equipment Reliability Prediction (MTBF)
Equipment’s have a lot of capital investment locked into them and they fundamental to day to day operations. Unplanned shutdown hurts companies in many ways. Asset life risk and premature investment. Maintenance cost, throughput loss, under utilization of overheads during such shutdowns, Revenue and customer service loss etc.
A vigil and disciplined maintenance team could maintain the assets as per OEM guidelines, but conditions under which equipment’s operate can deviate widely against OEM assumed conditions. Hence standard MTBF may not be enough.
To enable predictions of equipment failure, condition based monitoring is essential. In most large scale plants, equipment data is available (beyond just run hours), especially for critical equipment’s. condition monitoring, reliability studies and predictive maintenance modelling take Reliability Engineering to the next level. The benefits of predictive maintenance is believed to deliver following benefits-
- Return on investment: 10 times
- Reduction in maintenance costs: 25% to 30%
- Elimination of breakdowns: 70% to 75%
- Reduction in downtime: 35% to 45%
- Increase in production: 20% to 25%
Condition based Monitoring
Condition data gathering takes us into the world of sensors, controllers, the new age name collectively calls it IoT. Typical examples of such data are-
- Infra red sensor data
- Acoustic data
- Vibration data
- Humidity, temperature, pressure
- Corrosion
- Oil analysis
- Motor circuit analysis
- Thermal scan data
- Etc.
Your Predictive Maintenance Solution
Once data is collected the prediction models ranging widely in its complexity can be applied viz. simple regression model, supervised or unsupervised machine learning model.
It takes a team of
- functional experts (process champion) who understand the key condition data required for effective predictions, what determines its data quality
- Techno functional expert (data scientist) who can help with the right algorithm that predicts the outcome accurately and reliably.
- Technical expert (data engineer, DevOps and UI Expert) who helps to the data interfaces right and system management.
Our team brings the necessary know-how to execute you reliability function transformation.