Software AG Solution Series: Manufacturing

IoT Predictive Maintenance Capitalize on a new revenue stream while ensuring higher service quality

Your Problem:As a manufacturer, you’re charged with retain-ing customers, improving profit margins and growing revenue. Traditionally, you’ve relied upon attracting new customers, selling more products and adopting lean practices to meet these objectives. However, as the sophistication of equip-ment increases and ability to monitor equipment improves, you now have an opportunity to capitalize on a new revenue stream: maintenance services.

Maintenance services have always been important. But As equipment becomes more complex and automated, the resources and skills required to maintain equipment become scarce and expensive. Equipment owners, or lessees, are seeking alternatives to manage and maintain their precious assets.

Preventative (as opposed to predictive) main-tenance pre-plans a maintenance schedule to ensure high uptime and optimized use of service technicians. Preventative maintenance can be expensive and run the risk of machine failure, urgent remediation activities and unplanned downtime. From the servicer’s perspective, this carries the threat of Service Level Agreement (SLA) penalties, reputational damage and loss of business.

The right set of predictive maintenance capabili-ties can assure you deploy only maintenance teams and equipment parts when maintenance is really needed, thereby ensuring uptime and product quality at reduced cost. That’s where Software AG comes in.

Software AG Solution:Software AG brings together the Internet of Things (IoT), streaming analytics and process analytics into an integrated predictive mainte-nance solution for manufacturers.

By tapping into the power of the IoT, manu-facturers access usage and status data directly from sensors and actuators embedded in equipment. Streaming analytics continuously analyze this data for real-time alerting as well as enrich it with historical intelligence to predict equipment failures and drive maintenance services when they’re needed. Furthermore, streaming analytics goes beyond analytics on inbound data streams to take automated intelligent action, such as kicking off a business process to dispatch a part or sched-uling a technician. And by combining process analytics, the IoT and GPS sensors the solution enables you to monitor and understand field-service technicians’ tasks and performance in real-time—to balance your ability to combine a static route with dynamic scheduling opportuni-ties. The end result: reduced technician costs and improved service levels—enabling you to deliver more competitive service contracts at lower costs than your competitors.

Solution DetailsSeamless IoT and machine sensor data integration is critical as well as a low-latency messaging backbone for scalable, fast and reliable transport. Delivering potentially large quantities of data at sub-second speeds is key to downstream activities. webMethods Integra-tion, featuring Universal Messaging, addresses this need with an enterprise-grade service bus for connectivity, messaging, transformation and security of machine data for advanced real-time analytics.

Why Software AG?Staying ahead of customers’ main-tenance needs requires agility and insight. At the heart of our solu-tion is a suite of award-winning platforms that provide:• Combined historical maintenance profiles

and real-time sensor data

• Higher levels of equipment availability at a lower cost point through real-time, condition monitoring to drive prediction

• Accurate prediction of run-time failures and preventative measures

• Identification of maintenance requests that cannot be completed during planned downtime

• Identification of specific production process points prone to maintenance sensitivity and their impact on product quality and uptime

• Monitoring and understanding field service technician tasks and performance in real-time

• Dynamically connecting with field techni-cians to obtain service information and job completion assurance

SOLUTION BRIEF

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Software AG Solution Series: Manufacturing | IoT Predictive Maintenance

Software AG’s SolutionOnly Software AG offers a comprehensive, custom-tailored suite that delivers:Connectivity, speed and scale: webMethods Integration Plat-form & Terracotta• Handle huge volumes of data for

improved system performance

• Access, analyze and deliver data to any device in real time

• Turn big data into the opportunity to generate more revenue, improve customer service and differentiate product offerings

Flexibility: webMethods Business Process Management • Interact with service providers in

real-time

• Get real-time event and process data at your fingertips

• Increase business productivity and deliver process-driven situational and case management applications that enable you to quickly respond to changing business and customer needs

Combined streaming and process analytics: Apama and web-Methods Optimize• Monitor sensor data to determine

equipment condition• Analyze and act on high-volume

business operations and customer interactions in real- time

• Correlate, aggregate and detect patterns across large volumes of fast-moving data from multiple sources to take the right action at the right time and leverage data in advanced prediction engines

A scalable, flexible platform for streaming analytics is also essential to correlate data from multiple sources and support fast, effective de-cision-making. The platform must enrich stream-ing data with a deep understanding of historical and predicted equipment availability and effec-tiveness to pinpoint when it’s time to repair or replace. Apama, Software AG’s market-leading platform for big data streaming analytics, does this by monitoring and correlating sensor data in real-time. With the ability to manage 35 million events per second, Apama identifies unplanned equipment degradation, performance and usage for large fleets of deployed equipment as well as automatically sends data to a prediction engine. Apama alerts operators to maintenance requirements via real-time dashboards and can even instantiate maintenance calls automati-cally if needed. Apama stands alone as the only platform that can automatically manage alerts based upon criteria, such as time, so it can re-prioritize alerts as they become more or less critical to exception managers.

And of course, monitoring the effectiveness of business process is key to monitoring service levels. webMethods Optimize is the real-time process analytics engine to measure and alert on KPIs, such as volume of events and response times, those typical for service providers to manage. The response to identified exceptions and maintenance opportunities is critical to unlocking the value of predictive maintenance. That’s why intelligent business process man-agement is needed for a wide range of activi-ties, such as dispatching technician, re-routing a shipment and placing an emergency order for consumables. Through webMethods Business Process Management, the solution can dynami-cally manage exceptions, interact with service providers in real-time and deliver contextual content to everyone in the service chain.

webMethods is fully integrated with Apama to combine streaming data, such as weather, equipment usage and traffic data, with process data, such as process step activity and inventory availability. webMethods binds the solution to the rest of the enterprise so other enterprise maintenance resources can mobilize at unprec-edented speed.

Key BenefitsSoftware AG’s solution brings equipment manu-facturers closer than ever to their customers and turns a costly operational expense into a source of competitive advantage. Benefits include:

• More stringent SLAs and customized maintenance services than competitors

• Improved operating margins due to decreased technician and maintenance costs

• Increased real-time visibility into field service technician tasks and performance

• Improved remedial planning when maintenance requests cannot be completed during planned downtime periods

• Insights into preventative measures—for ex-ample, using predictive maintenance as the basis for continuous improvement in preventative maintenance

Critical Aspects of an IoT Predictive Maintenance Solution • Obtaining diverse data types from multiple

sources at speed to drive real-time analysis

• Flexible use of operating data in the context of process capacities and customer require-ments

• Combined streaming and process analytics to understand changes in capacity, usage trends for both customers and service providers

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ABOUT SOFTWARE AGSoftware AG helps organizations achieve their business objectives faster. The company’s big data, integration and business process technologies enable customers to drive operational efficiency, modernize their systems and optimize processes for smarter decisions and better service. Building on over 40 years of customer-centric innovation, the company is ranked as a “leader” in 14 market categories, fueled by core product families Adabas-Natural, Alfabet, Apama, ARIS, Terracotta and webMethods. Learn more at www.SoftwareAG.com.

© 2014 Software AG. All rights reserved. Software AG and all Software AG products are either trademarks or registered trademarks of Software AG. Other product and company names mentioned herein may be the trademarks of their respective owners.

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