Advanced Maintenance Management.
Through APM 4.0's predictive and prescriptive analytics, which use sensor data to make better decisions, enormous opportunities are presented to improve the performance of your assets
Within the Asset Performance Management 4.0 (APM 4.0) solutions portfolio, there is proactive asset performance management based on predictive alerts and prescriptive analysis. This type of maintenance management can reduce costs, reduce unplanned downtime, and optimize the use of labor and equipment performance. Through predictive and prescriptive analysis, companies will be able to implement advanced asset strategies to avoid unplanned downtime for their most critical assets, while deciding which preventive or corrective asset strategy is most optimal for their less vital equipment.
As automation becomes more prevalent in all industries and infrastructures, mechanical devices are being replaced by electronic components in manufacturing, industrial, and infrastructure environments. This evolution means that more sensors are being used to capture data and use it for our maintenance management. The more equipment data we are able to capture through these sensors, the greater the visibility and knowledge acquired for owner-operators.
I Digital Transformation and APM 4.0
True digital transformation requires improving the asset-oriented APM approach into a system that comprehensively connects engineering, operations, and performance, and therefore enables a quantum leap in asset performance. Through the APM 4.0 Portfolio, a single, integrated digital thread is created throughout the asset lifecycle. Two key factors play a fundamental role in the successful operation of this new digital thread. First, there must be connectivity between assets and workers/operators. Second, decisions informed by sensors and intelligent data must be able to be executed in real time. While APM 4.0 maintains the asset-oriented approach, it focuses on delivering results by achieving asset excellence by improving safety, profitability, and sustainability.
An essential part of APM 4.0 is sensor-based decision making with true performance indicators: a variety of sensors and mobile devices provide decision makers with real-time data on the condition, performance, and safety of their assets, enabling more accurate decisions. APM 4.0 Management based on monitoring the working conditions of our equipment (CBM), artificial intelligence, and expert engineering systems based on the data provided by the sensors to predict performance degradations and component failures before they happen.
It is clear that APM 4.0 management contrasts with the widely used and generally lagging indicators that report failures only after they occur, and that have become technologically obsolete.
Industrial equipment needs planned shutdowns and scheduled maintenance times for its satisfactory operation. Because of this, APM 4.0 management is not about maintaining assets in a perpetual online state; rather, APM 4.0 allows you to maximize your return on investment (ROI) by allowing you to make the most of sensor data so you know exactly how each individual asset is, from the most critical to the least vital, and how it should be managed and maintained to best mitigate risk and capitalize on opportunities.
Based on this, through APM 4.0’s predictive and prescriptive analytics, which use sensor data to make better decisions, there are enormous opportunities to improve the performance of your assets. However, it is important to realize that it is not feasible in all cases to implement predictive asset strategies to mitigate or reduce the risks of your assets and optimize their performance.
- First, from an engineering perspective, it may not be possible with current sensor technology to measure the failure of an asset or measure some type of failure mechanism variable that allows us to predict the failure in advance.
- Second, for some assets it may not be financially feasible to apply predictive strategies because the cost (sensors, infrastructure, analysis, contingencies) could be more expensive than the value of the benefit (e.g., planned downtime instead of breakdown).
To create a complete APM solution, the owner/operator must complement their predictive and prescriptive analysis with a solid approach to asset risk management, as shown in the following figure. In addition, the owner/operator must assess the asset context and define its criticality based on the impact on its context if it fails. For the company’s most critical assets (critical A), it will be simple. The owner/operator will maximize all opportunities to monitor and control their condition and performance. But for critical assets B and C, this will require a more structured asset strategy optimization approach.
I APM 4.0 Management and Predictive Analysis
APM management focuses on reliability engineering methods (e.g., –Reliability Centered Maintenance (RCM), Root Cause Analysis (RCA), Criticality and Failure Mode Effects Analysis (FMECA) and Information Technology (IT) such as Computerized Maintenance Management System (CMMS), Enterprise Assets Management (EAM), Enterprise Resource Planning (ERP) and Business Intelligence (BI)-). APM 4.0 management takes a step forward, where it integrates IT with operational technology (OT) and connects the asset with the person in the different stages of the asset lifecycle (engineering, operations and performance) through various layers of technologies.
APM 4.0 lays the foundation for predictive analysis, data science, and transforms sensor data into powerful predictive indicators. This enables owners/operators to avoid asset failures and optimize asset performance.
Shareholders invest in assets because they expect to obtain a reasonable return on investment (ROI). ROI is primarily defined by the operating profit that can be achieved with an asset. However, ROI also depends on the owner/operator’s ability to operate. If the integrity of the asset is threatened and does not comply with safety, quality or environmental standards, the owner/operator runs the risk of the responsible authorities closing the asset.
In APM 4.0 a direct link is established between the sensor and the ROI. It creates key performance indicators from sensors and, therefore, allows those responsible to make correct decisions in Real Time about asset performance. For the first time in history, these performance indicators are truly “leading” in the sense that they can change the outcome before it happens. To date, systems have been based primarily on “lagging” indicators (e.g., cost, availability, number of security incidents). These indicators only reported on post-fact issues.
APM 4.0 and its sensor-based decision making, impact our understanding of asset performance. Our Benefit is the turnover generated by the asset less the conversion costs of producing the product that results from the operation of the equipment; the turnover is directly related to the indicator of overall equipment effectiveness (OEE) of an asset, and the cost consists of the conversion / production costs and the maintenance costs of the equipment. APM decisions have a direct impact on the OEE and operating costs of that equipment and, therefore, on the final profitability of the asset (ROI).
In summary, APM 4.0 technology uses sensors and indicators to monitor, control and optimize the performance of the production process and its machines, seeking the optimum for its processes and economic results.
If you want to know more or resolve any questions about advanced maintenance management, do not hesitate to contact our specialists.
