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Business Development Expert Manufacturing und Industry 4.0October 27, 2014
Predictive Maintenance and ServiceAn Overview Presentation
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Agenda
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Trends
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The World is Connected
devices connectedby 2020*
50 billion 40-50%CAGR for M2Mmarket until 2020*
price of sensors,microprocessors &wireless technologiestoday vs. 4 years ago**
1/5
*Source: Gartner – “Top 10 Tech Trends for 2013” – 2012
**Source: Economist Intelligence Unit – ”The Rise of the Machines” – 2012
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Predictive Maintenance and Service – Business
Dealers and Service Providers:Add-on services for asset owners or on behalf ofOEMs.
• Optimize services delivery
• Improve service efficiency
Owners and Operators:Asset owners optimizing asset performance bymonitoring asset health e.g. condition based orpredictive maintenance, predictive quality, etc.
• Increase asset availability
• Reduce unplanned downtimes
• Improve overall quality and safety
OEMs:Manufacturer of digitally empowered equipmentproviding new service business models to assetowners e.g. selling performance, remote service,etc.
• Higher margin service offerings
• Improve product quality
• Reduce warranty costs
• Enabling of new business modelsaround the asset
Players Value
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Challenges
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Predictive Maintenance and Service – What it is about…
“Predictive maintenancetechniques help determine thecondition of in-service equipment<by also using sensor/telemetrydata and alerts> in order to predictwhen maintenance should beperformed. This approach offerscost savings over routine or time-based preventive maintenance,because tasks are performed onlywhen warranted.
The main value of PredictedMaintenance is to allow convenientscheduling of correctivemaintenance, and to preventunexpected equipment failures.The key is ‘the right information inthe right time’.” (Wikipedia)
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Valuable Insight Lost in Disparate Information Flows& Disconnected Databases
Business & ProductData
Technical & OperationalData
Unstructured Data
OEM
Dealer
Customer
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Predictive Maintenance and Service
OEM Customer / Owner / OperatorServiceDealer
Sales ServiceR&D Warranty
“How can I improvemy product’sreliability and up-time?”
“Which service leveldo we need toprovide?”
“How can I improvemy customerssatisfaction andloyalty?”
“How can I providethe best service atthe right time?”
Fleet
“How can I reduceservice andoperational cost?”
Driver/Operator
“How can I improvemy driving style, drivesave and reduce fuelconsumption?”
Emerging IssuesPredictive Analytics
What-if Analysis
Liquidity
Product Reliability360° Transparency
Product Improvement Spare Parts
Profitability
Machine Health Prediction
Customer Service
Ad hoc data mining and exploration,analyze warranty claims, determinespare part stocks, optimize design andmanufacturing…
Add-on services for asset owners,optimize services delivery, maximizeuptime, raise service efficiency…
Analyze fleet behavior, minimizeunplanned downtime, manage assetrelated risks, align between operationsand maintenance,…
Information and Analysis Tools
Common Objective for Customer, Dealer & OEMMaximum Equipment Uptime and Minimum of Maintenance Costs
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Solution
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Predictive Maintenance and ServiceA key building block for improved asset performance
Predict Act
Sensor Data
Business Data
Environmental Data
Patternand Root
CauseAnalysis Pr
edic
tions
Create work order
Change product specs
Alter maintenanceschedule
Propose spare parts
…
Sense
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Traditional Service vs. Optimized ServiceOperator
TechnicianOEM
SupportOEM
TechnicianSpare parts
& tools
Remote ServiceEngineer
Real-time condition monitoring
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End-to-End Process for Maintenance & Service
Asset HealthPrediction
Increaseeffectiveness
CreateMaintenance
or Service Order
Execute Orderon Mobile
DeviceVisual SupportSAP solution for
maintenance/service
Schedule Order
ConditionMonitoring
Remote Service
Fault PatternRecognition
IT/OTConnectivity
RemoteMaintenanceand Service
Increaseefficiency
Watch: https://www.youtube.com/watch?v=UlpGDrSmg38
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Predictive Maintenance and Service – Vision
SAP HANA
Benchmarking
Prioritize maintenanceand service activities
Early warningsto prevent downtimes
Designimprovements
Asset healthmonitoring
Optimized warrantyand spare parts mgmt
Telemetry Data
Business Data
Third party data …
• Sensor measurements• Geospatial data• Diagnostics• Events• Performance metrics• Battery status
• Sales contract• Warranty information• Maintenance/ Service history• Customer profile• Dealer events• Cost and risk
• Structured and unstructurede.g. weather forecast
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Data ModelsM2M Agent
Business Data
Mobile App
Web App
Equipment Data
Predictive Maintenance and Service on SAP HANA
Sales
Service
Engineering
createactionableinsights
predicthealth
monitorasset
Prediction Notification
FlexibleModeling
Visual RulesDesigner
PredictiveAnalysis
Recordings
Weather
Unstructured Data
Temperature
Voltage
ServiceCoordinator
R&DEngineer
AssetManager
WarrantyManager
UI
TelemetryData Import
Unified DataModel
PredictionEngine
NotificationServer
Analysis &Exploration
UserInterface
Business Data ImportBusiness Process
Integration
Any Text basedData Analysis
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SAP Predictive Maintenance and Service, Cloud EditionPlanned Capabilities
3rd Party Device Cloud
Communication Networks (by Telcos)
Devices
Connectivity Platforms (by Telcos)
SAP HANA IoT Edition
MachineMgmt
Rules &Alerting User Mgmt Vibration
Analysis …
Hot Cold
Integrationservices
Dashboards Lists Graphs &Charts …Maps
IoT Connector
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Scenarios
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Defect Pattern Identification
Identification and prioritization of machine failure pattern for product improvement
Based on claims, damage reports, business and configuration dataCombining in an iterative approach
Visualization (parallel coordinates, multi-dimensional scaling)Mapping of expert knowledge into HANA andStatistical analysis (text clustering, association analysis,decision trees)
Improved product quality at lower costsQuick identification of new defect patternsGuidance for root cause analysisReduction of manual work in quality managementCost reduction & increased customer satisfaction
IndustrialMachinery& Construction
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Machine Health Prediction
Sense & predict machine health supporting the solution provider transformation
Using machine dataPredict breakdowns via decision treesCalculate energy consumption pattern profiles with k-means clusteringModel domain expert knowledge in SAP HANA with decision tablesProvide 360° view on machines with real-time calculation of KPIsfrom ERP and telemetry data
Scale and improve service business byBetter transparency of current conditionMachine health prediction from historic dataOptimize field technicians scheduling, includingfailure predictions
Machine A
IndustrialMachinery& Construction
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Vehicle Health Prediction
Improve manufacturing quality, service planning and customer satisfaction
Single point of access to all related business and technical informationIntegration of SAP HANA and for reportingand predictive analyticsAssociation rule mining and regression tree learning tocorrelate production rework and customer satisfaction dataSAP HANA/R data mining and data visualization based onsurvey - and manufacturing data sets
Improved prediction of upcoming warranty cases80% accuracy based on vehicle diagnosis andprevious warranty claims
Automotive
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Emerging Issues
Faster product improvement and early failure prediction to reduce downtime
Single SAP HANA based platform that combines sensor and warranty dataAnalysis of equipment's telematics dataDetection of potential issues and relation to equipment's service and warranty data usingtext mining, association analysis and HANA database capabilitiesShorter detection-to-correction cycle
Reduced warranty costsQuick identification of potentially defective behavior of fleetCreation of evidence packages as input to root cause analysisMachine warranty cost reduction & improved up-time
IndustrialMachinery& Construction
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Vibration Analysis
Identification of health finger print based on vibration analysis
Monitoring of machine health using failure patternA 360 degree view of a machine by integrating technical machineand business data in a flexible data model in HANATrend analysis and pattern comparison onvibration and process data
Better machine utilization & reduction of warranty costsDetect emerging dangerous vibrationsChange from manual, reactive vibration analysis processto an automated, proactive processImprovement of machine uptime and reduction ofmaintenance costs.
IndustrialMachinery& Construction
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Summary
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Predictive Maintenance and Service - Solution
Internet of ThingsEnablement Platform• Device connectivity• Device management
Remote Monitoring• Sensor data
visualizationand analysis
• Device alerts via flexiblethreshold
• Machine health factsheets
Condition BasedMaintenance and Service
• KPIs definition• Rule based action
triggers• Seamless
integration intomaintenance andservice processes
Predictive Analysis• Fault pattern
recognition viaunstructured data
• Machine healthpredictions
• Root causeanalysis forengineeringimprovements
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Predictive Maintenance (Repeatable Custom Solution)Powered by SAP HANA
Business SituationMaintenance is responsible for keeping equipment running andavoiding unplanned downtime with is costly side effects.Basic maintenance strategies are scheduled maintenancebased on simple metrics, such as time intervals, machine hours,or distances traveled, drive maintenance schedules andactivities.Condition based maintenance reflects the actual conditions ofthe equipment and its components. It requires that respectivedata is collected from built-in sensors and analyzed in orderidentify any kind of problems.Consequent follow up processes such as spare parts supply,technician visit are triggered.
ChallengesDisconnection between equipment and business processesresults in higher costs:
High operation costs due to high failure ratesAutomated gathering of relevant machine data from remotelocationsInability to do root cause analysis and prediction decreaseequipment productivity and innovationPoor precision of spare parts planning, results in high spareparts inventory rateSome parts need to be expedited at high costs
Value DriverReduce Operations & Maintenance Costs: Higher assetproductivity with automated monitoring & notificationprocessesImprove Reliability & Visibility: Increase asset availability withcondition-based maintenance procedures and toolsImprove Cash Flow: Decrease spare parts inventory rateMaximize Asset Uptime: Decrease unplanned outages withpreventive & predictive vs. reactive maintenance
Preview
Benefit SAP HANAPossibility to combine business and product data,unstructured data and technical as well as operationalequipment data in a unified data modelLeverage the statistics and predictive abilities provided byHANA
Process Innovation• Equipment Benchmarking / Control Center: Build a control
center that gives you an overview of your completeequipment in the field. Search and filter for machines via listsor maps.
• Reactive to Predictive Service: Identify problems, understandactual status, send problem notification to customer, sendservice technician and identify required spare parts.
• Energy Analytics: Analyze the energy consumption ofmachines in the field. Find anomalies or potential problems.Offer an automated utilization billing based on consumptiondata.
SolutionAssessment Service with subsequent Custom DevelopmentProgram (CDP)
AudienceR&D EngineerService Coordinator &ManagerFleet Manager
Asset ManagerWarranty Manager
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Predictive MaintenanceAdditional information
MaturityAssessment Service with subsequent Custom Development Program (CDP)
• CDP project• Customer provides HANA system including licenses or HEC• Involvement of SAP CD / SAP Consulting funded by customer• Involvement of SAP Development• Outcome is a project that can be used productively for daily business
• Co-Innovation project• Infrastructure and trial licenses optionally supplied by SAP Development• Involvement of SAP Consultants, Data scientists and Designers with Customers business
users and IT• Outcome is a prototype. The goal is to close a follow-up CDP project to build a solution that
can be used productively.
Impact IT-Infrastructure• High Availability of the systems is required• Possibility of hosting the complete solution in the cloud (HEC)
Invest/ CostSAP HANA, Sybase IQ, SAP Data Services, Sybase ESP, SAP Predictive Analysis, SAPLumiraData Science Services 20 – 40 daysHadoop Resell
Architecture Overview
AssetsLars Bastian (CVS), Bernhard Gonschorek (BTS), Oswald Wieser (Co-InnovationDevelopment)Referenzen: Keaser Kompressoren,
Internal
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Predictive Maintenance and Service – Benefits
For asset manufacturers /service providers:• Improve service profitability
• Lower service costs• New revenue streams
• Higher percentage of calls resolved withouttechnician dispatch
• Higher first-visit-fix rate
• Customer satisfaction and retention
• Higher service contract renewal rates
• Enable innovative business models
For asset owners / operators:• Higher overall equipment effectiveness
(asset availability & performance & quality)
• Improve maintenance efficiency
• Lower maintenance costs
• Faster reaction to alarms and failures
• Higher mean time between failure
• Lower mean time to repair
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ImprovedQuality
BetterVisibility
ReducedCosts
HigherUptime
IncreasedReliability
OptimizedPlanning
CustomerRetention
LowerInventory
Summary
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Thank You!Contact information:
Tony AschwandenBusiness Development Expert Manufacturing und Industry 4.0+41 (0)58 871 61 [email protected]
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