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IBM per Industry 4.0 - Asset Mngm - Performance Mngm – Predictive Analisys

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Situation awareness involves being aware of what is happening in the vicinity, in order to understand how information, events, and one's own actions will impact goals and objectives, both immediately and in the near future. One with an adept sense of situation awareness generally has a high degree of knowledge with respect to inputs and outputs of a system, i.e. an innate "feel" for situations, people, and events that play out due to variables the subject can control.

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MCM ottobre 2016 workshop

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Veronafiere 19-20 ottobre 2016 Gli atti dei convegni e più di 7.000 contenuti su www.verticale.net Cogenerazione Termotecnica Industriale Pompe di Calore 27 ottobre Cogenerazione Termotecnica Industriale Pompe di Calore Alimentare Alimentare Petrolchimico Alimentare 28 ottobre Alimentare Petrolchimico Alimentare Alimentare Petrolchimico Visione e Tracciabilità 28 ottobre Luce Energia Domotica LED Luce Energia Domotica LED IBM per Industry 4.0:
- Asset Management
- Performance Management
- Predictive Analysis Paolo L Bizzozero
Technical Sales & Solutions
Watson Internet of Things 2 https://en.wikipedia.org/wiki/Industry_
4.0 Industry 4.0 Industry 4.0, Industrie 4.0 or the
fourth industrial revolution, is the
current trend of automation and data
exchange in manufacturing
technologies. It includes cyber-
physical systems, the Internet of
things and cloud computing.
The term "Industrie 4.0" originates
from a project in the high-tech
strategy of the German government,
which promotes the computerization
of manufacturing. La rivoluzione industriale promessa da Industry 4.0 deve rivedere sia l'intera catena del valore (filiera) dai
fornitori di materie prime fino al consumatore finale, sia la modalità di produzione, distribuzione e vendita dei
prodotti introducendo una propensione continua al cambiamento al fine di immettere sul mercato
internazionale prodotti innovativi garantendo nel contempo la sostenibilità economica. Questo ambizioso programma individua nel a ''digitalizzazione' il filo conduttore e fattore abilitante principale,
basata pricipalmente su nuove ''tecnologie'. 3 Internet of Things A term invented by Kevin Ashton in 1999 (MIT) IBM Simon Personal Communicator - 1992 prototype - 1994 marketplace Network of physical objects or "things'' embedded with electronics, software, sensors and connectivity to exchange data and other business processes. 2006/2007: - Nokia E90 Communicator business - Nokia N95 multimedia entertainement - iPhone Apple A smartphone or smart phone is a mobile phone with an advanced mobile operating system which combines features of a personal computer operating system with other features useful for mobile or handheld use. They typically combine the features of a cell phone with those of other popular mobile devices. Most smartphones can access the Internet and have high-speed mobile broadband. Technology
' Device ' Connectivity Applications People behavior Costs Smartphone - 1992 4 Source: Gartner Maintenance: the evolution . . . 5 Asset Management Maturity Maintenance is an expense Maintenance is an investment P er fo rm a nc e Asset value & Business Impact Calendar based Usage based Prescriptive Condition based B us in e ss Im pa ct Instrumented Interconnected Intel igent ' Ever increasing range of sensors
' Volume, velocity, variety
' Event driven information ' Agility and Mobility
' Highly Connected Systems
' Cross Col aboration ' From data to actionable intel igence
' From reactive to proactive
' Whole lifecycle system optimization Maintenance: the evolution . . . Sensor data
Real time and
Historical System
Asset Information Asset Health Condition data is enhanced when combined with contextual information to give a more perfect picture of Asset Health ' Real time sensor data from the equipment via individual sensors (add-on or embedded) ' Real time sensor data or alerts from SCADA systems
' Historical trends of sensor data from historian or other data repository
' Inspection data that might include measurements, observations, photos gathered manual y or from mobile devices ' Maintenance history of the asset
' Related information: environmental (temp, humidity, etc.), weather, usage, output Understanding current condition alone, is not enough' Weather
Data Reliability - Affidabilità 7 Asset ' 8 Asset ' - Costo Valore - Prodotto - Business Quale' - 3 I 9 Internet of Things . . . - Gestione
connessione
- Gestione dispositivi
- Analisi dati
- Applicazioni dedicate
- . . . . Connettività Dispositivi Applicazioni - Dati - Stato - Eventi - Comandi Comunicazione
a due vie 10 Equipment(s) System Realtime Data
Exchange Maintenance Data
' Basic asset info
(locations, model, age,
etc.) ' Maintenance-related
outcomes Inspection &
Repair history ' Preventive & Unscheduled Equipment (sensor) time-series
' Vibrations, temperature, pressure,
''speed' variables (rotational,
translational, '), etc. ' Positional and/or motion data ' ''Point process' / event data '' e.g., when
an accelerator is triggered; when gear is
shifted ' ''Alerts' (thresholds breached, etc.) ' Relevant gauge data Offline data
' Fluids analysis, etc. Financial & Customer
' Order/commitment
pipeline ' Production history detail Environment / Site Data
' Weather conditions (e.g., wind, precipitation,
temperatures, humidity,
barometric pressures'
' Particulate levels ' Terrain-type info (for mobile assets) 10+ years of
historical data INSIGHTS Operating ''things' 'Inappropriate operation alert 'Sub-assembly / component lifetime wear indicators 'Leading failure indicators 'Engine speed alerts 'Overload / over speed alerts 'Suspension cylinder alerts 'Transmission oil level alerts IoT Illustrative use case for Industry 4.0
Reducing Maintenance Costs 11 Pre''. Maintenance Prescriptive Maintenance Provides a real-time analytical assessment of an asset's health,
the probable window of failure, and helps prescribe actions to
resolve the problem. It offers asset insight and analytics
capabilities to help manufacturers predict degradation and failure
of critical manufacturing equipment issues earlier than traditional
condition-based maintenance methods. Prescriptive
recommendations can be generated to help optimize
maintenance planning schedules.
The Prescriptive Maintenance solution complements Predictive
Maintenance. Prescriptive analytics
Asking ''What should we do'', prescriptive analytics explores a
set of possible actions and suggests actions based on
descriptive and predictive analyses of complex data. Though the
final decision is up to the facilities and asset manager,
prescriptive analyt-cs solutions can provide a reliable path to an
optimal solution for business needs or resolution of operational
problems. Predictive Maintenance Provides access to multiple data sources in real time to predict
asset failure or quality issues so your organization can avoid
costly downtime and reduce maintenance costs. Driven by
predictive analytics, these solutions detect even minor
anomalies and failure patterns to determine the assets and
operational processes that are at the greatest risk of problems
or failure. This early identification of potential concerns helps
you deploy limited resources more cost effectively, maximize
equipment uptime and enhance quality and supply chain
processes, ultimately improving customer satisfaction. Predictive analytics
Asking ''What could happen'', predictive analytics provides
answers that move beyond using historical data as the principal
basis for decisions. Instead, it helps managers anticipate likely
scenario, so they can plan ahead, rather than reacting to what
has already happened. Descriptive, which uses business intel igence and data
mining to ask: ''What has happened''
Predictive, which uses statistical models and forecasts
to ask: ''What could happen''
Prescriptive, which uses optimization and simulation to
ask: ''What should we do'' Maintenance: Chal enges to Gaining Meaningful Insights from Assets 40% of preventive maintenance costs are spent
on assets with negligible affect on uptime 1 Knowing status of critical business assets
''I need to monitor device behaviors in real-time to understand assets that aren''t working as expected.' Optimizing maintenance schedules based on early
warnings from assets
''I need to detect that something is wrong and schedule maintenance before failure.' Avoid unplanned downtime
''Can I prevent problems before they occur by forecasting imminent
issues and initiate appropriate responses to avoid run to failure'' Minimize unnecessary repairs
''I need insights from devices in the field to schedule repair only when needed.' Identify economic outcomes and risks associated
with your asset strategy
''Should I repair, replace, or shift load on my asset to extend it''s life'' Reliability Engineers
are caught in the middle ' Contextualizes device data
' Monitors streaming data to detect situations ' Filters the data for analysis by Users ' Stores data for further analysis Collect
Asset information 3 Historical sensor
and weather data Real time filtered data from automation systems 2 4 Machine Learning Asset Health Insights ' Enables Immediate action and/or ' Provides engineers with rich set of sensor and asset data to determine proper course of action ' Visibility into asset condition, from
asset lifecycle perspective ' Consolidates Asset data, historical
and real-time, including data from
external data systems, weather data,
etc. ' Advanced dashboard view enables
proactive asset and maintenance
decisions 1 Real Time data from low cost add-on sensors How IoT information is used within Asset Management System Informazione
Dato
Notifica
Avviso
Notizia
Indicazione
. . . A complete Asset Health solution Data and Device Management Connection aggregation, curation, data persistence for real-time analytics Analytics Machine learning
Physics-based modeling
Ful range of predictive algorithms
Streaming
Cognitive Weather Historical weather helps determine asset health, forecast help with maintenance
planning Design Asset Health: purpose built solution for reliability engineers Filtering, Rules and Advanced Analytics Collect data platform 16 Reduce Costs '' Smart Maintenance Smart detection to reduce disruption from downtime Truck publishes data from hundred of on- board sensors Data indicates fault developing in critical component Predictive analysis reveals component failure is imminent Warns driver and instructs him to make a stop at services Services Ahead 100 yds Identify and dispatch best skilled repairer with right components Truck is rapidly and completely repaired on site Truck is back en route to client site in full working order Manufacturers sent aggregated component performance analysis Alert! 17 A condition monitoring system that will: Combine multiple data sources associated with a piece of equipment Apply predictive analytics to highlight possible problems Utilize interpretive expertise to confirm the problem and identify a solution Predictive Asset Optimization for Heavy Equipment View 5 CM Elements and make Maintenance and Repair Recommendations 1. Machine Data 2. Fluid Analysis 3. Inspections 4. Site Conditions 5. Repair History Condition Monitoring Elements Dealer Condition Monitoring Analyst Wired or Wireless Machine Data Off-board Analytics To Detect Slower Moving Problems Recommendations Fed into Maintenance & Repair (M&R) Process Analysts Validate Recommendation Effectiveness Work
Orders Inspections and
Fluid Samples Events /
Trends /
Payloads 18 transform asset performance data into action 19 acquire data to gain understanding of asset performance What is an IoT Platform' IoT Foundation Sensors &
Networks Other Data Sources Weather Map 01
0110
0010
001001 Devices Platform Applications Other IoT platforms 21 desirable capabilities to operationalize asset data 22 Overview: PMQ analyzes data from multiple sources
and provides recommended actions, enabling informed decisions Business Outcomes ' Safety ' Reliability ' Performance ' Capex ' Opex Operations Action ' Work Scheduling ' Planning ' Operations ' Supply Chain Optimization Demand Environment Weather/season Economic factors Correlation Exogenous Conditions Operations Control actions Maintenance Construction actions Measurements Equipment failures Training actions Crew experience Maintenance resources Optimization Decision Equipment supplier Equipment supplier Equipment supplier Equipment supplier Asset Attributes 'Asset Maintenance
'Product Warranty
'Process Quality PMQ Use Cases PMQ Use Case 23 23 IoT Platform, PMQ and Maximo provide ful featured asset
management 23 Sensors on the monitors provide device information IoT C: Device registration, event mngmt PMQ and/or IoT C: Ingesting event data from devices IoT Connect/RTI Realtime analytics PMQ on Cloud PMQ''s scores drive response such as a service request SCADA, historians Event data Drive highest levels of reliability by uncovering hidden patterns that can predict failure well in advance and take pro-active action Maximo 3 4 5 1 2 Each asset''s event data is profiled in PMQ based on master data from Maximo, then continuously scored and visualized 24 Predictive Maintenance: improve asset availability, reduce
maintenance costs, and increase process throughput ' maintenance logs
' inspection reports
' repair invoices identify top failure modes initiate or update work order modify maintenance schedule calculate failure probabilityrecommend repair procedures assess overal asset health assess individual asset health 25 Predictive Maintenance Capabilities 25 ' capture details about asset infrastructure, spare parts, performance, and work history ' support maintenance activities - initial service requests through planning, completion, recording of results ' prescribe lowest-cost, highest-utilization workforce schedules ' plan demand, streamline purchasing processes, ensure contract compliance ' reduce overal risk, comply with regulations ' develop predictive models to identify pending asset degradation or failure ' analyze maintenance records to identify top failure modes ' provide real-time asset health assessment ' recommend repair procedures based upon current asset condition ' recommend optimum maintenance schedule ' initiate or update work orders with asset repair recommendations Maximo Predictive Maintenance Enterprise Asset Management Enterprise Asset Management Enterprise Asse Managemen Advanced Enterprise Asset Management Advanced Enterprise Asset Managemen Advanced Enterpris Asset Managemen Predictive Maintenance ' Contextualizes device data
' Monitors streaming data to detect situations ' Filters the data for analysis by Maximo Users ' Stores data for further analysis IBM Watson
IoT Platform 3 Historical sensor
and weather data Real time filtered data from automation systems 2 4 PMQ Machine Learning IBM Maximo Asset Health Insights ' Enables Immediate action and/or ' Provides engineers with rich set of sensor and asset data to determine proper course of action ' Visibility into asset condition, from
asset lifecycle perspective ' Consolidates Asset data, historical
and real-time, including data from
external data systems, weather data,
etc. ' Advanced dashboard view enables
proactive asset and maintenance
decisions 1 Real Time data from low cost add-on sensors How IoT information is used within Maximo Asset Health Insights and
PMQ 27 Situational Awareness Situational awareness or situation awareness (SA) is the perception of environmental elements with respect to time or space, the comprehension of their meaning, and the projection of their status after some variable has changed,
such as time, or some other variable, such as a predetermined event. It is also a field of study concerned with
understanding of the environment critical to decision-makers in complex, dynamic areas from aviation, air traffic
control, ship navigation, power plant operations, military command and control, and emergency services such as
fire fighting and policing; to more ordinary but nevertheless complex tasks such as driving an automobile or riding
a bicycle.' Situation awareness involves being aware of what is happening in the vicinity, in order to understand how information, events, and one's own actions wil impact goals and objectives, both immediately and in the near future. One with
an adept sense of situation awareness general y has a high degree of knowledge with respect to inputs and
outputs of a system, i.e. an innate "feel" for situations, people, and events that play out due to variables the
subject can control. Lacking or inadequate situation awareness has been identified as one of the primary factors in
accidents attributed to human error. Thus, situation awareness is especial y important in work domains where the
information flow can be quite high and poor decisions may lead to serious consequences (e.g., piloting an
airplane, functioning as a soldier, or treating critical y ill or injured patients). https://en.wikipedia.org/wiki/Situation_awareness ' Baseline ' History ' Situational Awareness: use analytics engine 28 Continuous Engineering PLM & CLM & Dev. Ops. Embedded Analytics Engineered Offerings Enterprise Asset Management Preventative Maintenance Asset integration EAM System Predictive Maintenance & Quality Asset Optimization Process Improvement PMQ Watson IoT Platform Analytics A set of tools/building blocks'.not a solution Platform Connect Real-time Insights (SPSS) Real-Time, Predictive , Edge & Cognitive Analytics MessageSight Watson Explorer The Weather Company Bluemix Component Leverage Watson OfferingsC Watson Services & APIs SaaS/Cloud Softlayer On-Prem/Hybrid MQTT Language Translation Natural language Machine Learning Textural Analytics Data Management Value Chain Pattern Recognition Unstructured Data Soluzioni IBM Watson IoT Platform 29 Per approfondimenti: g.palagi@vargroup.it


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