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Prevent asset failure, detect quality issues and improve operational processes Predictive Maintenance & Quality Hendrik Leddin Client Technical Specialist Predictive Maintenance & Quality IBM Deutschland GmbH
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Jan 09, 2017

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Page 1: 20160217 ll pmq kopie

Prevent asset failure, detect quality issues and improve operational processesPredictive Maintenance & QualityHendrik LeddinClient Technical SpecialistPredictive Maintenance & QualityIBM Deutschland GmbH

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© 2015 IBM Corporation 17 February 20162

Predictive Maintenance & QualityPredictive maintenance is what its name implies: Maintaining resources and machines, whether large or small, according to fact-based expectations for when they will fail or require service. A predictive maintenance and quality solution can also detect anomalies within processes, compare parts against their master, and conduct in-depth root cause analysis.

Predict part quality- Improve quality and reduce recalls -

- Reduce time to identify issues -- Improve customer satisfaction -

Predict asset failure- Estimate and extend component life -

- Increase return on assets -- Optimize maintenance schedule -

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© 2015 IBM Corporation 17 February 20163

Leverage the full potential of your processesVariation in production or maintenance processes is unavoidable. Even state-of-the-art machines cannot hold perfectly the target setting. Achieving consistent quality requires understanding, monitoring, and analyzing variation of parameters.Using mathematical techniques to determine the stability and predictability of a production or maintenance process.

Statistical Process Controlas a method of quality control to monitor

and analyze machine data

Quality Early Warning Systemdetection of developing quality

problems at a low rate of false alarms

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© 2015 IBM Corporation 17 February 20164

Find deeper insights and drive real-time actionsTurn data into deeper insight, confident decisions and faster, in-time actions, with extensive analytics capabilities from IBM. With extensive analytics capabilities, you can understand what happened, what will happen and what should happen. Easily engage both business and technical users to uncover opportunities and address big issues.

Predictive Analyticsempowers you to analyze trends, patterns

and relationships in yourstructured and unstructured data

Optimizationenables for improving efficiency,

reducing costs, and increasing profitability

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© 2015 IBM Corporation 17 February 20165

Make the right production adjustments and meet tight tolerancesEach day, production-quality analysts run the more than 500 production-line variables they track through predictive models that tell them which specific parts of the line need to be adjusted to ensure that products remain within their tight tolerances. The solution also provides predictive insights on which production assets should be preventively maintained to avoid future problems.

25% increasein the overall productivity of the

customers production line

>50% reduction in the time required to ramp up the

process to target levels

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© 2015 IBM Corporation 17 February 20166

Data analytics solution optimizes and reduce energy costsA supermarket group conducted a feasibility study that found there was a huge variation across stores in the way refrigerator temperatures were managed. By acquiring and harvesting the readily available data from one store and applying big data statistical approaches such as predictive analytics to a large data set, the supermarket group was able to validate refrigeration performance and identity case anomalies against standard policies

20% reductionin energy costs by helping ensure that

refrigerators operate at optimal temperature

USD25 millionannual savings that could be realizedthrough energy analytics applied to

wider store chain

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© 2015 IBM Corporation 17 February 20167

Predict equipment malfunctions and avoid product defectsThe optimisation of plant production is the key to profitability. Some of the main parameters include throughput, product quality, machine availability and efficiency. Small flaws, such as temperature imbalances in a furnace or the wrong tension setting on a steel roller, can lead to defective products, customer dissatisfaction and costly delays. The IBM solution analyzes large volumes of production data to seek patterns in equipment operations, product quality, failure patterns.

USD2 Millionreduction of costs for every 0.1% improvement

in production efficiency

Boost skills transferby embedding process knowledge into equipment and process optimization

algorithms

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© 2015 IBM Corporation 17 February 20168

Demonstration: IBM Predictive Maintenance & QualityThe IBM Predictive Maintenance and Quality solution helps you monitor, analyze, and report on information gathered from devices and recommend maintenance and quality activities for those devices. With this integrated solution, you can accomplish various tasks to gain efficiency and save costs.

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© 2015 IBM Corporation 17 February 20169

Next Steps – Become a data-driven organization now!A five-segment methodology spans a predictive analytics discovery workshop with desired outcomes. Together we will narrow down different use cases in order to find and discuss the right advanced analytics approaches in the right areas and outline the business impact and benefits when applying advanced analytics to your organization.

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Hendrik LeddinClient Technical SpecialistPredictive Maintenance& QualityIBM Deutschland GmbH

IBM-Allee 1D-71139 EhningenMail: D-71137 EhningenMobile [email protected]