Maintworld 4 - 2017

4/2017 www.maintworld.
com
maintenance & asset management
Enabling
Bigger
Thinking p 36
CLOUD INTEGRATED MOBILITY P 16 PREDICT THE UNPREDICTABLE P 28 OPEN INNOVATION MODELS P 48

While we’re known for our world-class motion control products, Moog’s ability to
maximize your machine uptime doesn’t stop there. Moog Industrial Services provides
products, services and total support that match your specific O&M needs and
machinery challenges.
Download “Lessons Learned” by a Moog maintenance

expert at info.moog.com/mw.
REPLACEMENT PRODUCTS/SPARES
Ensure like-new performance
with new, authentic Moog
replacement products that meet
today’s technical specifications.
FACTORY REPAIRS
Rely on high-quality servo repair
for less unplanned downtime. LOCAL SUPPORT
Work with responsive, locally-
based Moog teams who speak your
language and know your industry
and equipment.
WHAT MOVES YOUR WORLD

FLEXIBLE PROGRAMS
Tailor a program for total confidence
that maintenance is always available.
ON-SITE TECHNICAL EXPERTS

Stay productive with quick and
convenient on-site commissioning,
set-up and diagnostics for total
peace of mind.
HANDS-ON TRAINING
Gain motion control expertise
and effectively manage installation
and troubleshooting.
©2016 Moog Inc. All rights reserved.
moogglobalsupport.com
A New Dimension
in HMI/SCADA
Introducing the world’s first 3D Holographic
Machine Interface. ICONICS has redefined “HMI”
in this era of the Industrial Internet of Things by
integrating its automation software with Microsoft’s
HoloLens. This groundbreaking technology allows
users to superimpose real-time information over a
real world production environment or facility, reducing
downtime and increasing operational efficiency.
Experience it for yourself at SPS IPC Drives

Visit ICONICS in Hall 7, Stand 394
Celebrating 30 Years of Automation Software
www.iconics.com
Servitization –
Game Changer of
the Manufacturing
Industry
TRADITIONAL BUSINESS MODELS are under pressure across all industries: A
study from PA Consulting shows that 70% of manufacturing companies that
were on the Fortune 1000 list ten years ago have disappeared. Survivors in-
clude market leaders such as IBM, Boeing, General Motors, John Deere, Rolls
Royce and Philips – i.e. companies that have continuously renewed their of-
ferings and redesigned their organisations.
Historically, the manufacturing industry has focused on products, not
taking into account the value they could add for their customers. This is no
longer the case. Companies including Rolls Royce are now harnessing the
benefits of servitisation. Instead of just selling jet engines, they have devel-
oped their service portfolio and business model to rely primarily on selling
lifecycle services using sensors and Internet of Things. Philips Healthcare,
on the other hand, has moved
from selling MRI scanners
to selling scans and are close
to selling diagnoses based on
those scans.
As digital disruption moves
Manufacturing companies
are searching for new ways
fast forward, even larger
to gain revenue. As digital companies must rely on a
disruption moves fast for-
ward, even larger companies
combination of agility and
must rely on a combination of
agility and versatility to sur-
versatility to survive.
vive. Forming partnerships
with startup businesses is one way to go forward. According to Finland-based
Futurice, startups offer traditional manufacturing businesses visibility far
beyond their own domain. They also function as a platform for brave experi-
ments.
In this year’s final issue of Maintworld-magazine you may learn how major
industrial companies are teaming up innovative and agile startups in a bid to
develop new business models. You will also find the results from a recently
published market study carried out by Mainnovation and PwC on how pre-
dictive maintenance 4.0 is expected to drastically change the maintenance
32
market in the future. Though the technologies
Wishing you a successful rest of the year and hope you find our newest edi- have changed, many of
tion of Maintworld-magazine interesting and inspirational. the challenges remain
the same: will technicians
Nina Garlo-Melkas and practitioners accept
the change and alter their
Editor-in-Chief of Maintworld-magazine behaviour?
6 maintworld 4/2017
IN THIS ISSUE 4/2017
36
New technologies such
as AI may seem exciting,
but without consistent
standardisation,
problems will arise.
48 The global startup scene

is buzzing and CEOs in all
industries all over the world
are waking up to the need to
renew their business.
8 Global Service Becomes Part of

Maintenance Plan
24 Reliable Flexible Couplings 44 Maintenance Debt Dictates Your
Maintenance Cost
28 Predict the Unpredictable with
12 Connecting Reliability
Improvement to the Business
Predictive Maintenance 4.0
48 Open Innovation Models Help
Companies Disrupt Their Own
Goals
32 The Latest Technology Trend in
Condition Monitoring
Business
16 Predictive Maintenance + Cloud-

Integrated Mobility
36 Enabling Bigger Thinking
20 Customized Shock Absorbers
in Turnstile Applications:
40 Effective
Part 2
Backlog Management -
Maintaining Safety and Security

around the World
Issued by Promaint (Finnish Maintenance Society), Messuaukio 1, 00520 Helsinki, Finland tel. +358 29 007 4570 Publisher
Omnipress Oy, Mäkelänkatu 56, 00510 Helsinki, tel. +358 20 6100, toimitus@omnipress.fi, www.omnipress.fi Editor-in-chief
Nina Garlo-Melkas tel. +358 50 36 46 491, nina.garlo@omnipress.fi, Advertisements Kai Portman, Sales Director, tel. +358 358
44 763 2573, ads@maintworld.com Subscriptions and Change of Address members toimisto@kunnossapito.fi, non-members
tilaajapalvelu@media.fi Printed by Painotalo Plus Digital Oy, www.ppd.fi Frequency 4 issues per year, ISSN L 1798-7024, ISSN
1798-7024 (print), ISSN 1799-8670 (online).
4/2017 maintworld 7
ASSET MANAGEMENT
About the Author

David Stocking is director of Aftermarket Ser-
DAVID STOCKING, vices for Moog. Stocking has more than 35
Director of Aftermarket years of experience as a product/project engi-
Services for Moog, neering manager and operations manager for
dstocking@moog.com. industrial, space and defence applications. He
received his bachelor’s degree in mechanical
engineering from Clarkson University.
Global Service
Becomes Part of
Maintenance Plan
8 maintworld 4/2017
ASSET MANAGEMENT
THE MOTION control systems that make high-performance motion control sys-
up a full-flight simulator replicate the tems for flight simulation, wind energy,
conditions and forces that pilots rou- manufacturing and power generation,
tinely encounter in flight. The motion understands that its flight simulation
control system includes a motion base customers must have parts globally
with actuators as well as control loading available for quick and easy access in
and associated software that work seam- response to planned and unplanned
lessly with the instrumentation, seats repairs.
and sophisticated visuals in the cabin.
The motion base, which includes eve- The logistics behind making
rything below the simulator’s cockpit, repairs
can typically support payloads of up to Moog’s response was to keep a strategic
16,000 kg. inventory of emergency parts in regional
Keeping these full-flight simulators hubs located in Asia, Europe, and the
running requires engineering know-how, United States, so parts can easily and
logistics expertise and creative solutions rapidly reach our customers where their
for maintenance and repair. Full-flight simulators operate. For the last year
KEEPING FULL-FLIGHT SIMULATORS RUNNING REQUIRES

ENGINEERING KNOW-HOW, LOGISTICS EXPERTISE AND
CREATIVE SOLUTIONS FOR MAINTENANCE AND REPAIR.
simulators commonly strive to achieve and a half, we have had a partnership in
99.5 percent availability or uptime. The place with UPS Supply Chain Solutions
continued growth in the number of (UPS-SCS) for warehousing and logistics
commercial airframes, and the growing support. Our partnership has been about
shortage of pilots, drives most commer- much more than shipping freight. For
cial flight centres to operate civil flight instance, UPS-SCS consultants exam-
simulators up to 20 hours per day. One ined our parts-fulfilment network and
A training facility houses aircraft flight simulator manufacturer – which shipping lanes, resulting in a recommen-
simulator cockpits underpinned by
our company, Moog, works with – oper- dation for optimizing the location of our
Moog motion control systems that
prepare flight crews for a wide array of ates a large customer service area with regional stock locations. Once we estab-
flying conditions. wall-size monitors tracking the status of lished the global warehouses, we trained
simulators. Any simulators that are out our 24/7 support team to use UPS-SCS’s
of operation are highlighted, identify- customer-facing software, thereby re-
ing details for the maintenance crews sponding to customer requests for rapid
working on the simulators. When a dispatch of critical spares anywhere in
Flying a plane requires simulator is not available for training the world. Our support team can now
a special feel. Helping and requires maintenance, it can cost be- handle queries whenever a customer
pilots learn this feel is tween US$600 and US$1,500 per hour in logs a maintenance issue from anywhere
lost revenue for the simulator operator. in the world. Moog engineers not only
the mission of the flight Compounding this impact is the logisti- have the ability to quickly analyze the
simulation industry. cal nightmare that results from flight root cause of a simulator’s failure, but
crews arriving for periodic flight certifi- also can dispatch parts around the clock.
According to Aviation cation, only to find there is no simulator Part of the analysis process that we
Safety magazine, perhaps on which to train. went through to set up our response
“the most significant No maintenance professional wants to maintenance issues involved giving
to see his or her simulator unavailable UPS-SCS data on the simulator loca-
factor” in helping pilots fly for training because they can’t quickly tions, which established maintenance
safely “is the high-quality access a spare part to bring their system trends (e.g., type and quantity of parts,
back online. And although this article geographic locations requesting the
simulator training airline highlights flight simulation, the pressure most parts, etc.) for our simulator busi-
pilots receive from their to keep equipment of all kinds running ness. With this, UPS-SCS and Moog were
first flight and continuing to meet customer demand is similarly able to identify where the best places
critical whether it is a wind turbine, were for warehousing spare parts. For
regularly throughout their paper mill or power plant. A company, example, one location was in The Neth-
career.” which has a long history of developing erlands, another was in the Midwest
4/2017 maintworld 9
ASSET MANAGEMENT
Moog technicians seated in front of a

motion system address field-service
requests for flight simulators.
United States, and a third was in Singa- a fault indicator. Moog has integrated An evolving partnership
pore from where we could rapidly reach schematics, the physical location of Even with all the work and processes
Asian customers. components, along with troubleshooting we have put in place with UPS-SCS,
With a logistics partner thinking about directions based on detected faults, and maintenance is never a static busi-
our maintenance solution, we were also supplied this on a disk located on the mo- ness. As our customers’ needs and
able to strategize about different ap- tion control cabinet door. Maintenance locations change; it is critical to stay
proaches to shipping, such as choosing technicians can load this disk onto their flexible within whatever construct we
warehousing locations in duty-free zones, computer as needed. Motion base users build for ourselves. Here is an exam-
thereby minimizing taxes our custom- receive a new disk if there are modifica- ple of that kind of thinking from our
ers would incur. Additional cash-flow tions to the cabinet after installation by wind energy business: Moog supplies
benefits for our global maintenance Moog personnel. Moog monitors the sup- its wind turbine customers a battery
programme have resulted from UPS-SCS ply chain to determine when to notify in- back-up system to power the pitch sys-
providing fiscal representation in Europe dustry that an item will cease production tems that adjust the angle and inclina-
allowing VAT to be deferred. due to the lack of critical components. tion of a turbine’s blades. These are
Moog has always been the best source And we offer recommendations for avail- critical components that maximize
of repair for the technology we manu- able replacement components. the efficiency of a turbine’s output and
facture, but helping our customers keep With regard to dispatching parts, UPS- protect a multi-million dollar turbine
their simulators running has become as SCS looked at how best to set up central from possible wind damage. A battery
much about the speed of repair as the stock locations and forward stock loca- back-up system‘s charge will degrade
quality of the workmanship. And by ana- tions for us. In China, for instance, there while sitting on a warehouse shelf for
lyzing the parts of our process that were are a plethora of customs requirements, extended periods. To be responsive to
slowing down our delivery, we have been which can take a shipper up to a week or our wind turbine customers’ need for
able to expedite help for our customers more to clear documentation. With a for- a critical part at a moment’s notice, we
facing a critical maintenance issue. Our ward stocking location in Shanghai and are weighing the merits of supplying
approach is twofold. Part one is putting in a third-party customs clearinghouse, we warehouses with battery trays and in-
place technologies that help Moog and its have been able to pre-clear goods to make structing UPS-SCS on how to charge
customers get much better at diagnosing delivery that much faster for our simula- the items prior to shipment.
problems. And the second piece is quickly tor customers in China. While it is not Whether a customer wants to keep
and safely dispatching parts where they necessary for every equipment manufac- a spare part on his or her own shelf
are needed. turer to have a forward stock location, we or rely on Moog to stock the part at
As for the technology, deterministic di- have found being pre-cleared for customs a regional stock location, getting our
agnostics is employed. This gives mainte- speeds up the process of getting a critical customer’s machines up and running
nance technicians and simulator owners part to a customer whose simulator is quickly and safely is our parts-and-
a much clearer picture of what is behind down. service goal.
10 maintworld 4/2017
APM Solutions to
Keep You on Target
nexusglobal.com/apm
RELIABILITY
CONNECTING RELIABILITY
improvement to the business
goals - don’t just focus on risk
Most maintenance and reliability professionals understand the benefits of improved
reliability. Reducing downtime, avoiding costly failure, improving safety and other
benefits would immediately come to mind. But the question is, do they truly under-
stand the impact of reliability measures on reaching set business goals?
they establish asset strategies that focus mitigating risk. They consider most as-
on achieving the business goals? Can sets “critical” and do their utmost to en-
JASON TRANTER, they (and do they) make it clear to sen- sure that they do not fail unexpectedly.
CMRP, Mobius Institute, ior management how their programme That may result in the following:
jason@mobiusinstitute.com helps the management team achieve • Performing “preventive mainte-
their goals? nance” whether those tasks add
It could be argued that if the answer value or not
to those questions is “no” then there is a • Performing extended “planned
THE QUESTION IS, do maintenance and problem with the programme, and seri- maintenance” outages regardless
reliability professionals truly under- ous questions about the sustainability of of whether the maintenance work
stand why the organization invests in a the programme should be asked. performed is necessary or not
reliability improvement programme? In the author’s experience, most • Requiring equipment to be shut
Do they measure the success of the reli- maintenance and reliability people, down for maintenance whether
ability improvement programme via including condition monitoring techni- that is actually the best strategy or
KPIs that reflect the business goals? Do cians and analysts, have laser focus on not
RELIABILITY
• Holding spares whether it be cost them how you are delivering on that in- can result in safety incidents, harm to
effective or not vestment and how you are helping them the environment, extended periods of
• Performing condition monitoring achieve their goals. downtime, expensive repairs, and harm
tests on machines whether it can be The same questions need to be asked to our customers. We have to consider
justified or not of senior management of public utilities, these risks and prioritize our asset strat-
• Measuring success based on sched- senior military officials, and so on. You egy according to the severity and conse-
ule compliance, percentage of need to know what they hope to achieve quences of these risks.
condition-based versus reactive and make it crystal clear how improving And forth, we have to consider how
maintenance tasks, reduction in reliability helps them achieve their goals. improved reliability presents an oppor-
unplanned downtime, and other tunity for us to achieve those targets,
metrics that relate more to the ex- Isn’t it all about risk? something that is rarely done in the
ecution of the programme rather Reliability improvement programmes, author’s experience. If the goal of the
than the goals of the business and the design of asset strategies, typi- business is to produce high quality prod-
A person who did not know any better cally focus on the need to understand uct at a defined production volume, then
might consider that the asset strat- and mitigate risk. An asset criticality we need to turn our minds to how our
egy was purely designed to cover their ranking will be developed so that priority asset strategy will enable those goals to
backsides. Failure cannot occur on their can be given to the assets that pose the be met. Rather than just thinking about
watch. Therefore failure must be avoided greatest risk. And there is no doubt that how we can stop the “bad things” from
at all cost. Yes, failure will harm the busi- risk management is important. However, happening, we have to think about how
ness, and must be avoided. But in the in the author’s opinion, too much focus we can make the “good things” happen.
process of reducing those risks we may is given to avoiding the “bad things” and You may be thinking that the oppor-
also increase our maintenance costs and too little focus is on achieving the “good tunities are just the opposite of the risks.
reduce our capacity. We must balance the things”. They are and they aren’t.
cost of avoiding failure with the cost to the
business.
What would you do if you MOST MAINTENANCE AND RELIABILITY PEOPLE

were CEO? HAVE LASER FOCUS ON MITIGATING RISK.
If you were to put yourself in the shoes of
a CEO of a manufacturing business, what
do you think your priorities would be? “Good things” and When we focus on the risks associat-
1. The CEO will have performance “bad things”? ed with downtime for example, we will
targets. Whether they are in place If we step back for a moment, still wear- consider the types of failure that will
to meet the objectives of the private ing the shoes of the CEO, we could result in extended downtime. We should
owners of the business, or public in- perhaps consider four points of pres- consider proactive tasks that reduce the
vestors and shareholders, they must sure – four aspects that affect the busi- likelihood of developing the fault con-
achieve those targets. Their future, ness. Let’s call it the “business process ditions, and we will monitor the equip-
(and the value of their bonuses), review”. ment so that we are forewarned. But now
depends on it. First, we have the performance tar- we need to turn our minds to everything
2. The CEO must protect the brand gets that drive the business: achieving that can be done so that the equipment
of the organization. That includes shareholder value, delivering a return to delivers peak performance; the highest
keeping key customers happy and the business owners, etc. It is essential quality, highest throughput, most effi-
staying out of the news because of that you understand what those targets cient start-up, minimal interruption at
some form of disaster. are. The true measure of success of your shift changeover or product changeover,
3. The CEO must appease the regula- reliability improvement programme is and yes, the least number of breakdowns.
tors and insurers. whether the business can achieve these Imagine sitting in a room with op-
When asked, a ‘C’ level manager said targets. erators, maintenance people, and engi-
the goal of their mining company was to Second, we have to consider the con- neering, and focusing your attention on
“turn as much rock into as much money straints on the business; what stops what makes the plant achieve its best
as possible”. Maintenance and reliabili- the business from being able to achieve performance. In a separate meeting you
ty-improvement activities can help the those targets. Those constraints may in- can discuss how you can avoid failure. In
company achieve that goal, but only with clude the availability of capital, cash flow, this meeting the focus will be achieving
the right asset strategy. availability of raw materials, etc. We have the targets. You are wearing a different
Any proposal to the CEO (or other to keep those constraints in mind. When hat now. It is an important perspective,
senior level management) will be mea- we choose our asset strategies we may and it is a perspective that enables the
sured against these goals. What will it need to consider which have the lowest business to maximize its opportunities.
cost, what is the likelihood of success, costs, which conserve cash, which results
and what are the benefits? To win their in the lowest waste, etc. What can we do with this
support you have to show how improved Third, now we can consider risk. information?
reliability is a good, safe investment. And What are all the “bad things” that can The bottom line is that we need an asset
at least annually, you need to remind harm the business? Equipment failure strategy that considers these four areas.
4/2017 maintworld 13
RELIABILITY
those benefits, and you can articulate
YOU CAN’T IMPROVE RELIABILITY UNLESS EVERYONE IN those benefits to senior management,
then you will gain their support. With
THE ORGANIZATION IS INVOLVED. that support you will have the essential
ingredient to developing the culture
of reliability (because without that the
programme cannot achieve its full po-
That strategy will need to change with management is not fully on board with tential).
time (as the constraints on the business the concept of reliability improvement, Now you must maintain that focus so
change). And that asset strategy will you will never achieve that goal. And that your asset strategy, and every deci-
definitely be different in different areas senior management will only be fully sion you make (and dollar you spend),
of the business, and different areas of the on board if they see how a reliable plant adds value to the business.
plant. For example, there will be areas of helps them achieve their goals. If you continuously communicate the
the production process that can tolerate value you are delivering, you will main-
small amounts of downtime, whereas in Conclusion tain the senior management support,
the final assembly for example, produc- If you understand how reliability im- you will continue to improve the culture,
tion lost due to downtime, slowdowns provement enables the business to and the reliability improvement initia-
and minor stoppages can never be recov- achieve its goals, and you can quantify tive will be sustained for many years.
ered.
Why is all this important?

It is important for two reasons. First, you
need the support of senior management
because ultimately, they control funding.
While a lot of good reliability improve-
ment tasks can be performed “under the
radar” with budgets managed at a much
lower level, the true benefits cannot be
gained in this “stealth” mode.
Second, and much more importantly,
is that you can’t improve reliability unless
everyone in the organization is involved.
You must have a “culture of reliability”.
Everyone involved in design, procure-
ment, engineering, spares management,
work management, and especially opera-
tions/production must understand what
they can do to improve reliability so that An asset criticality ranking will be developed so that priority can be given to the assets
the business achieves its goals. If senior that pose the greatest risk.
in
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www.InfraTec.eu MEASUREMENT DIVISION
INDUSTRIAL INTERNET
Predictive Maintenance +
Cloud-Integrated Mobility
Recent technological developments in automation soft-
MELISSA TOPP,
Senior Director of
ware have led to some pretty interesting possibilities
Global Marketing, in maintenance for organizations around the world.
ICONICS,
melissa@iconics.com Multiple breakthroughs have combined in order to en-
hance the productivity and efficiency involved with
equipment checkups and repair.
INDUSTRIAL INTERNET
put down your toolbox.

“Piece of cake,” you think as you quickly resolve the prob-
lem. Just as you finish up, you receive an additional message on
your heads-up display: “While you’re there…”.
The combination of technologies at work in such a scenario
involve Fault Detection and Diagnostics (FDD), cloud comput-
ing, and a groundbreaking new HMI/SCADA user experience
with wearable devices. Each of these separate pieces provide
the necessary features to free up maintenance personnel to be
more proactive with time and resources, rather than continu-
ously chasing break-fix instances or putting out fires.
Fault Detection and Diagnostics

Fault Detection and Diagnostics software analyzes all available
information to detect and predict faults. It utilizes algorithms
that weigh probabilities of faults and advises management,
operators and maintenance personnel of actions to prevent
equipment failures or excessive energy use. When failures
occur, current and historical information are analyzed, along
with symptom/cause relationships that the system has been
taught.
• Information received from such software can be used to:
• Predict, reduce and eliminate equipment downtime
• Automate fault detection and deliver real-time notifications
(anywhere, any time and via any platform) to maintenance
personnel and management
• Reduce maintenance time and determine probable causes
• Improve reliability and control
IMAGINE THIS SCENARIO. You are a maintenance technician

for Company X, an international manufacturer with loca-
tions scattered across the world. Your responsibilities include
maintaining the machinery involved in producing the com-
pany’s popular products. On a typical day, you receive a work
order that might include a brief summary of a single piece of
malfunctioning equipment, in a certain location, about which
you’ve hopefully received enough training and background in
order to return it to normal operation. All in all, a pretty regu-
lar maintenance job, right?
Let’s update the scenario a bit. Once onsite, you put on your
mobile holographic computer, such as a Microsoft HoloLens
holographic computing device or an HMT-1 head mounted tab-
let class industrial wearable from RealWear. You approach the
equipment in question and immediately see a pop-up 2D or 3D
representation of the equipment’s internal pieces. You already
see possible symptoms and causes listed by likelihood, along
with accessible links to more in-depth schematics and step-by-
step repair videos. All this has happened, in an augmented real-
ity field of vision right in front of you, onsite, before you even
INDUSTRIAL INTERNET
Suite. Recently, RealWear, out of Milpitas, California, intro-

duced the world’s first industrial head-mounted android tablet,
and announced integration with ICONICS HMI software tech-
nology. This combination of ICONICS software with hardware
like the HMT-1™ from RealWear allows users to visualize real-
time and historical data KPIs with voice driven, hands-free
usage.
Featuring an intuitive, completely hands-free interface,
the RealWear HMT-1 is a fully rugged head-worn solution for
industrial IoT data visualization, remote video collaboration,
technical documentation, assembly and maintenance instruc-
tions and streamlined inspections right to the eyes and ears of
workers in harsh and loud field and manufacturing environ-
ments.
Mobile holographic computing devices provide mainte-
nance personnel with a hands-free way to utilize data-driven
displays for quick problem resolution. Operators can check
real-time status of devices from anywhere across the globe,
with the ability to drill down to individual equipment KPIs for
Cloud Computing immediate analysis and real-time information-based decision-
Many organizations are increasingly considering the benefits making.
of moving the bulk of their data processing and analytics from
on site to the cloud. Advantages of such a move include: While You’re There…
• Increased Scalability – The computing load can now be Let’s return to our scenario, in your job as Company X main-
spread over multiple/newer hardware, and accessed from tenance technician. That initial service ticket certainly was a
anywhere, at any time, from any web-connected device. piece of cake, when you were provided with all the required
• Reduced Hardware Obsolescence – In turn, an organiza- information, including movable 3D internal schematics, a
tion’s on-premises computing hardware will continue to manufacturer’s guide in PDF format, and even a live video chat
get older and less likely to handle increasing required data with a senior technician who has worked on that same type of
speeds and storage capacity. Making the decision to switch equipment before – all in a heads-up display superimposed
to cloud-based alternatives means less time and expense over your live view of the equipment requiring service.
spent on maintaining aging equipment.
• Expanded Connectivity – Using a cloud-based computing
solution comes with multiple integrated communication
protocols (e.g., AMQP, MQTT, HTTPS, REST/JSON). COMBINING MOBILE HOLOGRAPHIC MACHINE
Some organizations may be early in the process of considering
connecting equipment to the Industrial Internet of Things
INTERFACES WITH CLOUD-CONNECTED DATA
and may be able to afford to purchase equipment with such
networking capabilities built in. Others, with older existing
CAN FURTHER THE PROACTIVE ASPECT OF
equipment, may be able to afford retrofits to gain that ability. PREDICTIVE MAINTENANCE.
However, many organizations may consider an alternative in
the utilization of “edge” devices, also known as IoT gateways.
These IoT devices can also come pre-installed with IoT Just as you’re finishing your repair, returning the machine
software, and provide additional utility, such as establishing to normal operation, you get a message through your mobile
a connection from on-premises data through an IoT Hub to device, “While you’re there, how about taking care of a few
a preferred cloud services provider, such as Microsoft Azure things that could have been trouble later on? Here’s the path to
or Amazon Web Services, through to consuming applications the panel I need you to look at.” Just then, you automatically
such as mobile HMI/SCADA visualization, rapid data histo- see an arrow pointing you in the direction you need to follow.
rian storage/retrieval, advanced analytics (including energy (Your heads-up display happens to use software that integrates
management and fault detection/diagnostics), and more. Plus, with GPS, as well as with NFC, OCR, barcodes, and QR codes.)
in addition to Northbound communication protocols, the IoT It takes you through the facility and just as you approach the
software suite can integrate with Southbound protocols as well next piece of equipment in need of repair, you see the same su-
(e.g. OPC Classic, OPC UA, Modbus, SNMP, BACnet). perimposed info to once again help you work quickly.
Combining mobile holographic machine interfaces with
Wearable Device Technology cloud-connected data can certainly further the proactive
In 2015, Microsoft introduced its self-contained holographic aspect of predictive maintenance. In our scenario, the mainte-
computing device: the HoloLens. The head-mounted comput- nance technician had quickly taken care of what necessitated
er provides a three-dimensional augmented reality (AR) view the initial job ticket. The combination of these several technol-
of process data. Soon after, ICONICS introduced the world’s ogies helped save an additional trip to the same location, and
first 3D Holographic Machine Interface as part of version 10.95 the associated expenses, by identifying what additional prob-
of its GENESIS64™ HMI/SCADA and Building Automation lems could be prevented then and there.
Be a LUBExpert ®
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RELIABILITY
The reliability of
pedestrian turnstiles is
critical to public safety.
To keep them running
smoothly, manufacturers
use customised shock
absorbers.
Text: DIETER KLAIBER, Project & Application Manager, ITT Enidine, dieter.klaiber@itt.com
Customised Shock Absorbers

in Turnstile Applications:
Maintaining Safety and Security
around the World
From amusement parks to high-security buildings and public transportation, pedes-
trian turnstiles are used around the world to control traffic flow and keep people
and businesses safe. Turnstile technology can come in many forms, such as full-
height, tripod and sliding gate, all monitoring capacity, while controlling security.
Subjected to harsh, high cycle-rate environments, turnstile reliability is critical to
public safety, and that is why pedestrian turnstile manufacturers utilize customized
shock absorbers to keep equipment running smoothly.
RELIABILITY
IN A TURNSTILE application, one of the The benefits of custom- able shock absorbers offer manufactur-
biggest issues is user safety. With no engineered shock absorption ers the ability to protect equipment and
shock absorber, the turnstile bars can In some applications, shock absorbers extend machine life, while maintaining
bounce back and cause injury, which is do not provide enough resistance to the or expanding output. In amusement park
a large concern when millions of peo- increased mass and force applied during applications for example, the ability to
ple use turnstiles every day for busi- operation, but redesigning the unit for a enter the park and ride waiting areas
ness, travel and recreational purposes. larger type of shock absorber would be smoothly are as critical to the experience
In tripod turnstiles, shock absorb- very costly and time consuming to the as the ride itself. The turnstiles in these
ers provide smooth and consistent manufacturer. A custom-designed shock applications experience increasing and
dampening for the rotational move- absorber can meet these larger mass decreasing rates of use by hour and sea-
ment, preventing the tri-arm bars and drive force requirements, providing son, but remain critical to ensuring cus-
from swinging too quickly or banging significant savings to the customer for tomers are safe. Shock absorbers are key
at the end of the rotation. These units a modest investment. By designing and to serving industries around the world
protect the turnstile and are tuned developing a modified standard shock ab- and providing rate control and energy
specifically to withstand the energy sorber into a specific application, manu- absorption solutions for lasting operation
delivered by the rotational movement facturers save time and cost associated of turnstiles and gates.
of each turnstile application. Once a with redesigning a turnstile unit to fit a When designing a shock absorber for
person enters the turnstile, he or she standard motion control product. a turnstile application, manufacturers
exerts force on the arm until a certain Adjustable shock absorbers are an- should consider the size, force capac-
point in its rotation, and then the arm other type of custom shock-absorber ity and stroke needed for their specific
drops automatically to the next posi- product that should be considered for function. The shock absorber may be
tion. The shock absorbers are mount- industries where the turnstiles will ex- handling children, adults, or even cat-
ed so that they absorb the energy of perience increasing and decreasing flow tle and the turnstile application, from a
the arm when it drops back to the rest demand. By allowing for adjustments to business entrance to a busy sports arena,
position. the rate and energy absorption, adjust- could vary greatly. Think about public
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Maintenance
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question is where maintenance managers should be looking to find these areas of improvement and where they need to start.
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RELIABILITY
SHOCK ABSORBERS PROTECT

TURNSTILE MACHINERY BY
OFFERING PREDICTABLE,
“Shock absorbers protect turnstile RELIABLE AND CONTROLLED
machinery eliminating machinery damage,
reducing downtime and maintenance costs, DECELERATION.
and increasing lifespan and reliability.
transportation. You have people cross- and full-height turnstiles. five years ago, Enidine was required to
ing through turnstiles, from small kids For more than 20 years, Enidine has adjust their shock absorber design to
to adults, which means you have differ- worked closely with Automatic Systems meet new regulations. Automatic Sys-
ent weights and different speeds, which to supply shock absorption solutions for tems received outstanding support from
creates different forces. These varying their tripod turnstile applications. Eni- the Enidine engineers, as they were
weights, speeds and forces that have to dine’s shock absorbers protect turnstile required to perform extensive testing
be absorbed need to be considered when equipment at an extremely high cycle over the course of several months and
choosing an off-the-shelf or designing a rate for robust and reliable performance, several million cycles. As their clients
custom-engineered shock absorber for perfectly suiting them for typical heavy- depend on reliable turnstiles, Automatic
a turnstile. To have the best design for use tripod turnstile sites, such as leisure Systems did not want to take any risks.
these turnstile applications, manufac- centres, stadiums and factories. Ultimately, Enidine provided a modified
turers should look to experienced engi- Installed over 20 years ago and sur- shock absorber design that withstood
neers to design a shock absorber to meet passing 25 million cycles, Automatic the extensive testing and met global
all of those requirements and conditions. Systems’ oldest tripod turnstiles, featur- regulations in a fast turnaround time.
20 years and 25 million cycles: Auto- ing Enidine shock absorbers, are still Automatic Systems was fully satisfied
matic Systems’ tripod turnstiles built to in place and working today. Over the and maintained their longstanding
last with Enidine shock absorption course of the past 20 years, some Auto- relationship with Enidine. Automatic
Automatic Systems is a world leader matic System customers have needed to Systems is extremely pleased with the
in the automation of secure entrance replace the stainless steel casing of the reliable, attentive service provided by
control, with more than 19 million peo- turnstiles due to typical wear-and-tear Enidine engineers.
ple in 25 different countries using their damage after years of use, but the in-
equipment daily. Automatic Systems stalled Enidine shock absorber system is Protect equipment; reduce
designs and manufactures vehicle, pe- still meeting cycle rate and safety stand- cost and downtime; increase
destrian and passenger-access control ards, with no need for replacement. reliability and lifespan
equipment, including public transport, In keeping with their reputation for Shock absorbers protect turnstile ma-
security entrance lanes, tripod turnstiles service and support, approximately chinery by offering predictable, reliable
and controlled deceleration. In addition
to the human safety aspect, harmful side
“In tripod turnstiles,
effects of motion, such as noise, vibra-
shock absorbers provide
smooth and consistent
tion and damaging impacts, are mod-
dampening for the erated or eliminated. This eliminates
rotational movement, machinery damage, reduces downtime
preventing the tri-arm and maintenance costs, and increases
bars from swinging too turnstile lifespan and reliability. Addi-
quickly or banging at tionally, the flexibility provided by some
the end of the rotation.
shock absorbers means turnstiles can
operate at higher cycle rates and, if re-
quired, can be designed to meet specified
safety standards.
The customizable design and devel-
opment of shock absorbers in turnstile
applications is critical to increasing
safety and prolonging machinery lifes-
pan. With so many variations in weight,
speed, energy and environments, turn-
stile manufacturers need highly engi-
neered parts to ensure people around
the world continue to stay safe and
secure.
Successful reliability
programs have one thing
in common…
a strong condition monitoring team.
As a condition monitoring
professional or manager, you may be
faced with starting a condition monitoring
program or tasked to get a program back on
iLearnReliability
track. There is a lot to know; multiple technologies,
monitoring practices, analysis, fault-reporting
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and trending, not to mention proper corrective and

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CONDITION MONITORING
Reliable
Flexible
Couplings
Figure 3 -
SDT270DU:
ultrasound
and vibration
input
Simon is a condition monitoring specialist from a local

oil refinery. He contacted my office for advice about
predicting flexible coupling failures. Currently, they
perform basic vibration analysis on their pumps and
motors using an overall meter. They have some suc-
cess predicting bearing failures but the same cannot
be said for couplings. Several unexpected failures shut
them down this year.
About the Author

Allan Rienstra is the director of business development for SDT International, a Brussels-based
ALLAN RIENSTRA,
manufacturer of ultrasound solutions comprised of hardware, software, training and consulting.
SDT International, ,
allan@sdthearmore.com A 25-year commitment to ultrasound applications has seen Rienstra play a leading role in the
deployment of ultrasound-based solutions in 5 continents. He is the co-author of “Hear More,
A Guide to Using Ultrasound for Leak Detection and Condition Monitoring.” Rienstra lives in
Cobourg, Ontario, Canada with his wife and two sons.
WITHIN THE FACILITY, 58 pump I explained to Simon how several

systems considered “A Critical” were clients already trend couplings using the Figure 1 -
Flexible
identified, meaning if they go down, the Flexible Wand. The SDT270 collects a
Coupling and
plant goes down. I suggested ultrasound STATIC ultrasound measurement that Airborne
as a fast, safe, and affordable solution. gives four indicators of condition. The Ultrasound
Specifically, the SDT270DU offered the first two – Overall RMS and Max RMS – Sensor
best value. Not only could Simon use it indicate the level of friction produced by
to monitor couplings with ultrasound, it the defect. When these indicators rise,
could also take vibration measurements, maintenance may consider corrective
thus eliminating the need for Simon to alignment during a planned shutdown.
carry two data collectors. The second two – Peak and Crest Factor
Flexible couplings cannot be moni- – identify the emergence of impacting.
tored with vibration analysis for two Together, all four indicators establish a
reasons. First, there is no suitable con- lifecycle trend for each coupling.
tact point for an accelerometer. Second, Once impacting appears, the Peak
the primary defect symptoms, friction indicator increases in step with Overall
and impacting, are best measured with
ultrasound. By placing an airborne
sensor near to the coupling Simon can
quickly trend an evolving defect. The ANY ULTRASOUND INSPECTOR WORKING AROUND ROTATING
SDT270DU gives Simon the choice to
either spot check for defects – good – or EQUIPMENT MUST BE REQUIRED TO DEMONSTRATE AN
integrate all 58 couplings into his estab-
lished bearing routes – best.
UNDERSTANDING OF COMPANY SAFETY POLICIES.
RMS. Since Crest Factor (CF) is a ratio be-

tween RMS and Peak, a rising CF indicates
that the window for simple maintenance
has narrowed. At this stage inspectors
collect a DYNAMIC measurement. The
DYNAMIC measurement gives a visual
representation of friction and impacting
severity using the time view. For both
STATIC and DYNAMIC measurements it
is important to define the signal acquisi-
Figure 4 - Measuring ultrasound without user defined tion time.
acquisition time results in missed data points User defined signal acquisition time,
available exclusively on SDT instru-
ments, is a luxury that lends ultrasound
technicians the highest level of precision.
Without the ability to set the sample time,
inspectors must guess when to pull the
measurement trigger, and question the
validity of their data. Simon explained
that all 58 pumps turn at speeds above
1800 RPM. Accordingly, he should set
his SDT270’s signal acquisition time to
between one and three seconds. One to
three seconds at 1800 RPM samples the
Figure 5 - User defined acquisition time samples coupling for 30-90 revolutions.
the complete signal resulting in more reliable,
meaningful data Shaft couplings are guarded
for safety
Any ultrasound inspector working around
rotating equipment must be required to
demonstrate an understanding of com-
pany safety policies. Safety considerations
are engineered into SDT sensors. The
Flexible Wand’s 10mm diameter sensor
is designed to access the coupling with
the safety guard in place (see figure 2).
The 21” long sensor sports a comfortable,
ergonomic grip that allows an inspector to
collect danger-free data.
Figure 2 - Simon seemed convinced, but wanted
A Flexible to hear more. Since this solution was
Wand from SDT already working well at a nearby paper
detects friction
mill, I introduced Simon to the plant
and impacting
from a flexible
manager, Sunil, and invited them both
coupling to lunch. Sunil and Simon connected on
so many common reliability issues that
afternoon. He confirmed the affordability
of this solution was based on coupling
failures alone but went on to explain how
their mill was rolling out ultrasound for
acoustic lubrication, steam trap moni-
toring, electrical inspection, and air leak
management. Simon and Sunil continued
their conversation well into the afternoon.
They agreed that ultrasound, with its 8
primary applications for reliability, repre-
sented a fast, safe, and affordable technol-
ogy with the potential to revolutionize re-
liability culture. I sat back, happily watch-
ing two impassioned specialists strategize
about reliability culture. I love my job.
Road Map to Operational
Readiness and Asset
Performance
Ensure a Safe, Reliable, and Compliant Operation
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and enabling a sustainable business strategy for operational excellence and safety.
© 2017 Bentley Systems, Incorporated. Bentley, the “B” Bentley logo, and AssetWise are either registered or unregistered trademarks or service marks of Bentley
Systems, Incorporated or one of its direct or indirect wholly owned subsidiaries. Other brands and product names are trademarks of their respective owners.
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• Risk assessment and work prioritization
• ISO 55000 implementation
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• Operational analytics
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ASSET MANAGEMENT
Text: NINA GARLO-MELKAS, Maintworld-magazine
Predict the
Unpredictable with
PREDICTIVE
MAINTENANCE 4.0
Predictive maintenance 4.0 is expected to drastically change the maintenance mar-
ket. Besides the traditional reliability engineer we will begin to see new roles in the
maintenance & asset management department: the data scientist.
PDM 4.0 is seen increasing the predict- October 2016 and June 2017 was con- The availability of data was mentioned
ability of the assets and the processes. ducted in three countries: Belgium, Ger- most often as a critical success factor, fol-
Companies that apply PdM 4.0 will have many and the Netherlands. A total of 280 lowed by technology, budget and culture.
a strategic advantage to their peers that respondents submitted their answers. – At this early stage in the PdM 4.0
steer away from PdM 4.0, a market study – We have seen that many companies lifecycle, companies still see consider-
carried out by Mainnovation and PwC are ambitious when it comes to PdM able technical obstacles to its implemen-
reveals. 4.0; half of the companies we surveyed tation. However, they recognize that
– The potential benefits of PmD 4.0 have plans to implement PdM 4.0, one in PdM 4.0 implementation is not a purely
are very high. If maintenance has the three wants to do so within the next five technical challenge. Companies should
ability to predict “unpredictable fail- years. We have also seen that companies’ also pay attention to organisational
ures” we can take a big step in competi- current predictive maintenance capa- dimensions, and ensure the project man-
tiveness. On the other hand, there are bilities are not yet at the level needed for agement and change management skills
some major challenges: PdM 4.0 requires PdM 4.0. We can conclude that signifi- needed for a successful PdM 4.0 imple-
a huge change. A lot of companies fo- cant efforts and resources will be needed mentation.
cus on the technical and technological to implement PdM 4.0, Decaigny says.
change, but underestimate the organiza- According to Decaigny, uptime im- Building data analytics
tional implementation, says Partner at provement is the main reason why re- capabilities
Mainnovation Peter Decaigny. spondents have plans for PdM 4.0. Other Success with PdM 4.0 will ultimately de-
PdM 4.0 requires a complete culture important reasons relate to other tradi- pend on skills and knowledge. The report
change: PdM 4.0 tools will have another tional value drivers in maintenance and shows that lack of skills or competencies
position in the decision process. The asset management such as cost reduc- in the company’s workforce is the big-
tools will suggest the moment to stop an tions, lifetime extension for ageing assets gest challenge respondents see when it
installation or to change process param- and the reduction of safety, health, envi- comes to using data analytics.
eters. This has to be embedded in the ronment and quality risks. Respondents – We found that only 27% of our sur-
daily operations. also identified a number of critical suc- vey respondents currently employ reli-
The study that was executed between cess factors for PdM 4.0 implementation. ability engineers in predictive mainte-
ASSET MANAGEMENT
nance, and even fewer (8%) employ data tors, process technologists, data scien- to 11% overall. This confirms our percep-
scientists. Companies’ biggest obstacle, tists and IT specialists who together tion of the rail sector as being innovative
thus, may be their ability to recruit the develop new ways of working and com- and sophisticated in the field of mainte-
people needed to put PdM 4.0 in place. municating. All such aspects of a PdM nance.
Companies generally understand that 4.0 implementation require a robust a Comparing the three countries tar-
it is critical to have in-house data analyt- digital culture. geted in the survey, PdM 4.0 is more
ics capabilities in order to successfully – PdM 4.0 cannot be implemented in popular in Belgium (23%) than in the
drive Industry 4.0 applications. Building complete isolation within the mainte- Netherlands (6%) and Germany (2%).
these capabilities takes, however, far nance organisation. It should be embed- Belgium is also considered a front-run-
more than hiring new talent with PhD’s ded into an overall digital manufacturing ner in real-time condition monitoring.
in statistics, data science or AI. strategy that is owned and fully sup-
– No matter how much talent compa- ported by top management. CASE: Growing Pressure on
nies bring on board, these talents will not Infrabel’s Maintenance
be as effective as they could be without Who are the front-runners Infrabel is the state-owned company re-
the right organisation and governance in PdM? sponsible for Belgian rail infrastructure.
in place. Perhaps the most important Companies with similar assets are fur- Infrabel spends around a billion euros
aim of designing a PdM 4.0 governance ther ahead in terms of predictive main- each year on the management, main-
structure is to create an environment tenance than companies with unique tenance and development of rail infra-
in which data scientists and reliability assets. This can be attributed to the fact structure, which contains over 3,600 kil-
engineers can interact and complement that a base of similar assets provides a ometres of railway lines, 86 signal boxes,
each other. richer data set for advanced analytics. 10,249 main signals and almost 12,000
A good first step for companies con- Looking across business sectors, the civil infrastructure works like crossings,
sidering how to best arrange their data rail sector seems to be a front-runner in bridges and tunnels. Over 4,200 trains
analytics could be crossfunctional expert applying PdM 4.0: 42% of respondents run on the Belgian railways each day, and
teams with reliability engineers, opera- in the rail sector are at level 4, compared the number of daily passengers has in-
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ASSET MANAGEMENT
creased by 50% since 2000, to 800,000. improve safety is accompanied by central Data Cell has been created where
Pressure to improve the safety and additional susceptibility to failures increasing volumes of data generated by
reliability of rail infrastructure has also compared to the old dumb assets, and these tools are collected and analysed.
increased for a number of reasons: hence necessitates additional main- A wide range of home-made IT applica-
• Safety is of paramount importance. tenance. tions for maintenance is being replaced
To improve safety for its employees, by a single tool where data from various
for example, Infrabel wants to reduce Making dumb hardware smart systems is integrated and standardized.
the number of visual inspections by In response to these challenges, Infrabel A number of pilot projects to test predic-
maintenance crews walking along the has invested heavily in automating a tive analytics in maintenance have been
tracks. number of maintenance processes. It has started, and Infrabel is currently recruit-
• The railway network is becoming become exceptionally strong in developing data scientists to take its mainte-
increasingly strained. Not only due ing innovative condition monitoring nance operations to the next level.
to an increase in passengers and tools such as sophisticated measurement
freight trains, but also because new trains for inspecting tracks, railway ties On the eve of a new era in
high-performance trains exert greater and overhead lines; cameras mounted on maintenance
stress on the tracks. A busier schedule overpasses to monitor the panthographs By making these preparations, Infrabel
also means smaller windows of op- of passing trains; sensors for detecting has put itself in an excellent position for
portunity for maintenance. Planned overheating in shaft sleeves on passing the large-scale application of data analyt-
downtime must be communicated to trains; semi-automatic vehicles to check ics in maintenance. Even though this im-
railway operators a couple of years in whether sign-post visibility meets the plementation could face a few regulatory
advance. regulatory requirements; and meters hurdles - stemming from strict safety re-
• The general public and governments to detect drifts in power consumption, quirements and current regulations that
are demanding safety and accuracy. which usually occur prior to mechanical prescribe a minimum number of visual
Every incident is negative publicity failures in switches. inspections per year, Infrabel is still ex-
for Infrabel and further increases pected to make progress in this area.
pressure to prevent future incidents. Building organisational That would be a major step along
• In the coming years, Infrabel will be foundations the way of what Infrabel, describes as
confronted by a wave of retirements A number of organisational changes will “a complete transformation of Infrabel
and will have to find ways to replace be encountered when deploying smart into a digital enterprise in which ‘basic’
the knowledge and experience it will condition monitoring tools. The once assets are replaced by smart assets that
be losing. very fragmented maintenance organisa- are integrated in an Internet of Things.
• There is a trade-off between safety tion has been fused into larger units in This transformation enables Infrabel to
and reliability. The installed base of order to reap synergy-related benefits. become increasingly data-driven in its
smart assets needed to monitor and At Infrabel headquarters in Brussels, a decision-making.”
The 4Cast from UE Systems is

the latest innovation in assets’
remote monitoring using
ultrasound
The Latest Technology Trend in

The ability to monitor the condition of assets 24/7, from any location, is becoming
the new trend in maintenance practices. Ultrasound, being a key technology in con-
dition monitoring, will play a key role in this trend.
clude Internet of Things, cloud no longer simply a leak detector – it is a

computing, big data, tablets, vir- valuable technology that allows main-
ADRIAN MESSER , tual and augmented reality, wear- tenance teams to identify mechanical
CMRP, able devices and so on. faults earlier in the P-F Curve and even
adrianm@uesystems.com
Though the technologies have changed, develop a more effective lubrication
many of the challenges remain the same: practice.
will technicians and practitioners ac- Coupling remote monitoring with
cept the change and alter their behav- ultrasound could prove to be one of
JUST AS TECHNOLOGY has been rap- iour? Can IT departments keep newly those paradigm-shifting developments.
idly developing in fields like telecom, online assets safe from cybercrime? Is Ultrasound works best when you have
data analytics, smart devices and infra- the infrastructure available for massive as much sound information to work
structure, the same can be said of asset amounts of data? Do we have the skilled with as possible – that makes it easier
condition monitoring. Just how far has workers necessary to champion these to identify patterns, establish baselines
technology come in asset maintenance, tools and then pass their knowledge and pinpoint inconsistencies. Moreover,
and what does that mean going forward? along to others? And finally – what do we as much as today’s maintenance techni-
What current technology is the equiva- even do with all this data? cians want to avoid reactive mainte-
lent of cutting-edge developments in
those other fields – playing the role of
RFID or Internet of Things? For asset
maintenance, it is remote monitoring – AS TECHNOLOGIES LIKE REMOTE MONITORING EMERGE,
the ability for technicians to utilize
modern tools to collect and parse
THEY HAVE A POSITIVE NET EFFECT ON INDUSTRY.
through continuous data sets from a
given asset without the need for 24/7 Finally, to add a bit of perspective, nance, there are certain assets that take
in-person attention. consider this: today’s college graduates priority over others. Anything that is
It is important to recognize that new were born after Amazon opened, eBay closer to failure will earn more attention,
technology often calls into question old came online and Yahoo registered its meaning other assets could fly under the
methodologies or habits. Each time some domain name. They have largely grown radar if they are assumed to be newer
development emerges, the industry in- up with technology – that’s a good thing. and in better shape. Remote monitoring
volved must adapt to make best use from Those who go into engineering and can give technicians a way to keep an
it. That can be particularly difficult in maintenance will be comfortable using eye – or ear – on assets that aren’t being
the industrial setting, often driven by the modern tools and techniques – and or- monitored. That is true for ultrasound
mantra, “If it’s not broken, don’t fix it.” ganizations must be prepared for a monitoring on both mechanical and
But plant maintenance technicians generation of labourers who expect the electrical assets.
have increasingly recognized the ben- most up-to-date tools to be available. There are few limitations on the ap-
efits of predictive maintenance in terms plication for ultrasound remote moni-
of keeping equipment online, preventing Ultrasound remote monitoring toring. Any instance where maintenance
unplanned shutdowns, increasing plant Ultrasound technology has emerged as professionals are collecting manual data
efficiency and saving money for the or- an essential tool in its own right. It is through handheld devices might be an
ganization.
The paradigm shifts of asset

condition monitoring
The book “Asset Condition Monitor-
ing Management” by Jack Nicholas, Jr.,
outlines four ways asset condition moni-
toring has changed over the decades,
including nowadays:
1. In the 1980s, microprocessors
made way for more portable data
collection devices.
2. In the 1990s, laptops emerged
while software packages gave all
computers better memory stor-
age.
3. In the 2000s, wireless data trans-
fer arrived as the methods for re- Ultrasonic Remote Access
porting and analysing data grew Sensors are permanently
more sophisticated. installed to continuously
capture ultrasonic emissions
4. In this decade, the condition
from bearings
monitoring paradigm shifts in-
Technological advancements make it now

possible to check bearings’ sound recordings
24/7, from any location
opportunity to monitor remotely. In tracking and arcing, ultrasound usage ultrasound emissions and send them to
other cases, equipment that is difficult is driven by safety, insurance agree- the 4Cast, which then sends that infor-
to access – dangerous, remote, isolated, ments, standards and improved tech- mation to data management software
or submerged – can receive the type of nology and software. Keep in mind in the form of decibel readings. The tool
regular monitoring that extends useful here, that it is a good idea to use more collects these readings from the sensors
life. Additionally, slow speed assets are than one technology to avoid missing on a regular basis, but allows the user to
great candidates for remote monitoring potential problems, especially corona. specify how often to send information to
because it would otherwise require the • Condition monitoring: Bearings, the software. It will also send a sound file
maintenance technician to take a longer rotating equipment, and condition- to the Spectralyzer (software for deep
time to gather enough information based lubrication are all good candi- sound analysis) when necessary.
manually. dates for regular remote ultrasound With an available Ethernet connec-
Beyond the advantages of larger data inspection. The best practice here is to tion, the 4Cast sends all its readings
sets and remote collection, remote mon- establish a route, find baseline read- and recordings using the plant’s net-
itoring comes with an easy installation ings, determine trends and identify work, which brings obvious advantages:
and the potential for a wireless setup. alarm levels. Ultrasound is particular- maintenance personnel will be able to
Compared to other systems, ultrasound ly helpful with slow speed bearings. access these readings and sound files
remote monitoring is a cost-effective
choice.
Ultrasound use cases ULTRASOUND TECHNOLOGY HAS EMERGED AS

Let’s break down a few of the most com-
mon ways plant technicians utilize
AN ESSENTIAL TOOL IN ITS OWN RIGHT.
ultrasound maintenance to improve
reliability: The 4Cast and Remote even outside of the plant’s network
• Leak detection: Huge energy-saving Access Sensors – thus allowing for true 24/7 remote
(and therefore, money-saving) poten- UE Systems’ remote monitoring tool, monitoring.
tial in compressed air and gas leaks, 4Cast, interfaces with a bearing asset to Today’s facilities should capitalize on
steam trap testing and valve testing. continuously collect data and send an the latest trend in reliable maintenance
This is the most common application alert to the technician’s route-planning to ensure they get the most out of their
and it gives back the quickest return software if any alarm levels are sur- assets. As technologies like remote mon-
on investment. Some ultrasound tools passed. It works together with ultrasonic itoring emerge, they have a positive net
can even be coupled with a free leak- Remote Access Sensors (which can be effect on industry. Remote monitoring is
reporting app in iTunes and Google very useful by themselves to inspect the latest important plant maintenance
Play, like UE Systems’ Leak Survey enclosed or hard-to-reach bearings) technology, enhancing an already valu-
app. – the sensors, which are permanently able tool and allowing plants to build a
• Electrical inspection: For corona, mounted on the bearings, pick up the predictive maintenance culture.
When things
just work,
work gets done.
Kepware’s industrial connectivity software provides

secure and reliable data from the shop floor to the top
floor, so you can focus on productivity.
Learn more at kepware.com/MW

INDUSTRIAL INTERNET
Enabling
STEFAN HOPPE, Global
Vice President of OPC
Foundation
stefan.hoppe@
opcfoundation.org
Bigger IF YOU ARE a regular reader of Maintworld, you

will no doubt be familiar with many of the new
technologies that are permeating the enterprise
business world today.
These technologies may seem somewhat glam-
Thinking
orous, and can be used to help re-imagine the way
we work, make decisions and collaborate. But in
the same way you cannot build a house without
solid foundations, it is important not to overlook
the basic requirements for success.
OPC Foundation is the organisation behind
OPC Unified Architecture (OPC UA) – the stand-
ard for industrial interoperability between dif-
ferent vendors, different devices and different
New technologies such as artificial intelligence vertical markets today. OPC UA scales from the
embedded world up to the cloud world, and Mi-
may seem exciting, but without consistent crosoft has not only deeply integrated this stand-
standardisation, problems will arise. ard into the Azure cloud platform but also Mi-
The Industrial Interoperability Standard www.opcfoundation.org
OPC UA: Set for Industrie 4.0

OPC UA is a framework for Industrial Interoperability
➞ Modeling of data and interfaces for devices and services
➞ Integrated security by design with configurable access rights for data and services –
validated by German BSI security experts
➞ Extendable transport protocols: Client/Server and Publisher/Subscriber and roadmap for TSN
➞ Scalable from sensor to IT Enterprise & Cloud
➞ Independent from vendor, operating system, implementation language and vertical markets
Information models of different branches are mapped onto OPC UA to make them interoper-
able with integrated security. The OPC Foundation closely cooperates with organizations and
associations from various branches:
TM
German and english version OPC UA is secure VDMA-Guideline OPC UA OPC UA ist requirement
under opcfoundation.org/ Proved by experts ISBN 978-3-8163-0709-9 in product-criteria catalogue
resources/brochures/ opcfoundation.org/security No Industrie 4.0 without OPC UA
UPDATE
1
NEW
Industrie 4.0 Communication Guideline

Based on OPC UA
OPC Unified Architecture

Interoperability for Industrie 4.0 and the Internet of Things
Industrie 4.0:
Product criteria for
OPC UA Security Analysis Industrie 4.0 technologies
Which properties does a product need in order to be Industrie 4.0 compatible? The Reference
Architecture Model Industrie 4.0 and the Industrie 4.0 component provide a basic method and
24/01/2017 orientation. Nonetheless, answering this question has been difficult until now. Currently there
are an immense number of terms and labels that appear to confirm the Industrie 4.0 or IoT
capabilities of products.
Therefore, based on the Reference Architecture Model The Industrie 4.0 product criteria
Industrie 4.0 (RAMI 4.0) and the Industrie 4.0 compo- The criteria are based on RAMI 4.0 and in particular
IoT
nent, ZVEI is developing manufacturer-independent on the properties of the Industrie 4.0 component (see
product criteria that will provide buyers with informa- figure 1). They are divided into three categories that
tion regarding the Industrie 4.0 capabilities of prod- build on one another: Industrie 4.0 Basic, Industrie
ucts in the future. The product criteria are designed 4.0 Ready and Industrie 4.0 Full. To be placed in one
4.0
so that they not only provide an orientation aid for of these three categories, a product must fulfil all
Industrie
buyers, but will also become guidelines for manufac- the properties of the category in question. The dis-
turers when developing future Industrie 4.0 product tinguishing features of the properties are the cross-
generations. They also highlight the need for research manufacturer approach and service orientation.
and standards.
M2M Figure 1: Product criteria are based on RAMI 4.0 and the Industrie 4.0 component
Industrie 4.0 component RAMI 4.0 Criteria for Industrie 4.0

Industrie 4.0 communication Architecture levels Standard functions
Contact: Basic functions that are the same
regardless of device
Gunther Koschnick
Managing Director Business Industrie 4.0 semantics
Administration Shell
Automation Division A shared language
Phone: +49 69 6302-318 Functional (vocabulary and sentence structure)
Digital world
Virtual description
E-mail: koschnick@zvei.org Industrie 4.0 services
Version: April 2016 Information
Asset,
Author: Industrie 4.0 communication
e.g. machine Communication That can map new services
Martin Hankel,
Bosch Rexroth
Integration Identification
Unique labeling of
Real
physical things and data

Assets
in cooperation with
Source: ZVEI
Security
INDUSTRIAL INTERNET
crosoft is the world largest open source different machines worked, we had to specific standard that meets the require-
contributor to the OPC Foundation. know everything the big handbook told ments of Industry 4.0.
One of the most exciting technologies us about them. We needed to under- But that is exactly what OPC UA offers
to emerge in recent times is artificial stand different IT protocols, and then right now. It is the mandatory required
intelligence (AI). AI requires data, and understand how the robots work and the communication standard for Industry
involves working with this data to gain commands they would have to follow. 4.0. The VDAM, the largest European as-
insight. OPC UA acts as the interface to All these descriptions were different for sociation of machine builders, including
the data sources. each vendor, providing a complicated the biggest robotic associations, under-
In this scenario, OPC UA is the ena- challenge. stood the need of standardised, fully-
bler. Think of a USB stick. The USB part In today’s world however, robots have secured access to certain technologies,
is just the enabler, but the functionality interfaces that can be easily understood if artificial intelligence is to truly take
of the device is beyond the USB part it- by human beings. Everybody should be off. Everybody then has the same under-
self. The same stands for OPC UA: OPC able to easily understand these inter- standing of the parameters at play.
UA is the enabler to move data left and faces and interact with the robots thanks Do companies in the artificial intel-
right, but the true functionality of this to standardisation. ligence space fully understand this need?
That is debateable. I remember being
quite shocked when I was sat in a room
IT IS IMPORTANT NOT TO OVERLOOK THE BASIC with 18 leaders in the robotics space at
a recent event in Germany. They were
REQUIREMENTS FOR SUCCESS. talking about the parameters within
which they operate, but there seemed
to be different meanings in different
data is the real value. USB is a physical Let us look a little further afield. Tech- companies. This complicates matters,
connection between two devices – OPC nologies like voice recognition, speech and certainly does not make things easy
UA is the ethernet connection between machines and Microsoft HoloLens are for end users. This is why there are high
ethernet-connected devices. OPC UA helping companies re-imagine their engineering costs in plants to integrate
delivers on top the meaning and descrip- processes today. But getting true insight these robots. The good news is that they
tion of data – the semantics, which is the from these technologies, or predict- are standardizing semantic now, agree-
real value to make use of the data. ing when they may fail, is another step. ing on the same interfaces for data and
Artificial intelligence requires easy, Intelligent services can offer support services based on OPC UA! The results
fully standardised access to data sources here, but without the right levels and will be available mid next year at the Au-
– be it from robots or other machines – standards of connectivity, they cannot be tomatica conference. Is your robotic sup-
to let users take advantage of all that the utilised. plier supporting this initiative? Ask them
technology has to offer. It is obvious then that having stand- if it allows the connection of your robot,
In the days of artificial intelligence, ards in this area makes sense. ther is a within 20 minutes, to general IT Enter-
for human beings to understand how push and pull in the market to agree on a prise and Azure cloud solutions.
R
Prepare for the New Era of Automation

22º C
At the heart of this new era of automation is a flexible and
adaptable data transfer mechanism for field-to-enterprise
connectivity—the OPC Unified Architecture (UA) standard.
OPC UA is a data exchange standard for safe, dependable, 480 amperese
manufacturer and platform-independent industrial

communications. Indeed, it is a key ingredient of the ongoing
industrial revolution.
50 psi
1900 Nm
OPC UA Products You Can Use Today in Your IIoT

Industrie 4.0 Strategy
UA Modbus Gateway
R
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easy to deploy – the Modbus UA UA-enabled client applications to
[For Software Developers] the first Gateway facilitates access to PLCs, communicate with OPC Classic
high-performance developer toolkit that RTUs, and other MODBUS based Servers and Clients, as well as
quickly and easily enables any application, devices via OPC UA. OPC UA Servers and vice versa.
regardless of size, with OPC UA.
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To learn more about Matrikon, visit www.MatrikonOPC.com
Legacy
OPC
3
Embedded OPC
1 Classic OPC UA Server
Server EMEA: Asia-Pacific:
R
Americas:
Proprietary
3rd Party Device

Phone: 1-780-448-1010 Phone: +49 221 969 7710 Phone: +61 (2) 4960-1000
Fax: 1-780-448-9191 Fax: +49 221 969 7722 Fax: +61 (2) 4960-1212
houstonopc@MatrikonOPC.com europe@MatrikonOPC.com asiapacific@MatrikonOPC.com
OPC UA data connectivity & migration
ASSET MANAGEMENT
Effective
Backlog
Management –
Part 2
Backlog management has a number of different but interdependent focuses: Back-
log Work Order Quality, Age of Backlog and Backlog Size Management. This article
will focus on Age of Backlog, while the next edition of Maintworld-magazine will
cover Backlog Size Management in more detail.
gressing, he should address the reason. of work orders moving through the
There should also be a more formal backlog grows. Improvement across
STEVE GILES,
review (monthly) to identify and re- a number of measures of the mainte-
Marshall Institute,
sgiles@ solve any slow or overdue work orders. nance programs will clearly be visible.
marshallinstitute.com This review needs to be attended by The credibility of the work manage-
the main stakeholders – Maintenance ment process and the planning and
supervision and Operations supervi- scheduling process specifically will be
sion with the ability to make decisions growing.
THE MAINTENANCE BACKLOG can have
needed to resolve any issues. This management process consists
many different stages. A generic view I have experienced many different of reviewing only those work orders
includes four main stages or queues: backlog management processes:most that are overdue or in danger of going
• Awaiting Planning – newly converted
were ineffective in actually managing overdue. Overdue status is determined
work requests awaiting the planning the backlog. The factors that create by the target date for executing the
process these different approaches lie in man- work order. A work order system that
• In Planning – work orders the plan- agement’s view of the purpose of the uses work order targets by execution
ner is actively planning backlog. Some management teams week provides a much cleaner means
• Awaiting Materials or Services –
hold a negative view of the work order to determine if a work order is overdue.
planned and estimated work orders backlog. This is many times the result Work order systems that use a window
awaiting delivery of special ordered of a highly reactive maintenance en- of execution based on priority are a lit-
materials or for a specialty contrac- vironment. This approach to backlog tle less clear on when to classify a work
tor to commit to a requested time of management will usually result in order as overdue or in danger of being
execution reviewing the entire backlog sorted by overdue. But in either case, the process
• Ready to Schedule – work orders that
age. If the right personnel are in attend- focuses on that subset of work orders
are fully planned with all materi- ance, some progress can be made, but it that are not progressing through the
als on the site and any contract or will be frustrating, slow, and painful. backlog stages as expected.
services needed to commit to the Systems like this do not understand By only dealing with this subset of
required timing or appreciate the most important pur- work orders, the meeting can be kept to
The timely progress of work orders pose of a maintenance backlog: provid- a reasonable length.
through the different the backlog stages ing time for the planner to actually plan Of course, it is also important that
must be monitored regularly. As he per- the work. the overdue list be distributed prior to
forms his daily actives, the planner will As a business develops a more ef- the meeting, so the attendees can in-
review the work orders in each stage. If fective Work Management Process, vestigate and be in a position to make a
he finds work orders that are not pro- the understanding and appreciation decision during the meeting.
ONE BUS FITS ALL
Sercos = Real-Time + IoT.
That‘s the Sercos® world.
www.sercos.org
ASSET MANAGEMENT
Figure 1.
result in an inefficient meeting, and over
Planning Process time, reduce attendance.
Procurement
Attendees should include Operations
or Production management, Mainte-
Work Orders
Work Orders
Materials or
Unplanned
Ready to
schedule
Awaiting
Planning
Services
Standard:
Daily Work
nance management and any other or-
Standard:
Request Schedule ganization that has a work order being
Review
Meeting considered.
External Services As the overdue list is processed, the
reason for a work order being overdue
Overdue or Soon to be Overdue Work Orders is determined and an action item devel-
oped for the appropriate party to address
Figure 1. illustrates the journey each marked as complete (by oversight) at an agreed upontime.
work order must complete before it can • Work order without a clear business This review should include all work
be placed on the schedule. Again, if the purpose and should be considered that is to be done by site maintenance or
work order is progressing through the invalidate a supplemental or specialty contractor.
backlog stages as expected – leave it • ork orders for the same task, but I have reviewed backlogs with work
alone and let the system work. If condi- with differently worded titles or orders 18 to 48 months old. While there
tions have changed, move it to an urgent problem descriptions may actually may be reasons for a work order staying
or emergency work order that will be be duplicates in backlog that long (requiring a shut-
removed from the backlog and executed • Work order with an incorrect down or turnaround) many aree simple
by the Maintenance supervisor. priority:priority of a work order can tasks that struggled, competing with
The only work orders that should be change over time and require an ad- new work for resources. Any work order
reviewed are those overdue or soon to justment (i.e. A minor leak that has that has been passed over for 12 months
be overdue. If the work order process is increased in size) or longer should really be objectively
performing well, this subset should be • Work order with overdue material reviewed for canceling. If it hasn’t been
~10% of the total backlog. If the work or- needs. Work orders that require spe- seen as important for an extended pe-
der process is still a work in progress, the cially ordered material , when the riod of time, why spend the resources to
percent may be higher, but it will still be expected delivery date is overdue or do it?
a subset of the total backlog. close to being overdue The bottom line for addressing a
Once this subset of the backlog is de- • Work order requiring contract slow progressing work order is to build
termined, each work order is processed resources should be reviewed to en- credibility for the work order system –
through a series of questions, in search sure the contractor is committed to remove the negative stigma of being in
of the underlying reasons for its being the required timing backlog. As credibility grows, use of the
overdue. • Work orderincorrectly flagged origi- process will also grow, and attempts to
nally: a task that must be done dur- beat the system by assigning an incorrect
Backlog Meeting Process Flow ing a shutdown or turnaround priority to tasks will be fewer.
The questions should review these as- It is important that the list of work or- Credibility of the Planning and
pects of the work order: ders to be reviewed is distributed to the Scheduling process is critical to achiev-
• Work orderhas been completed meeting attendees prior to the meeting, ing any degree of success in implement-
either as part of another work order giving the attendees time to adequately ing a Work Management Process.
or on an urgent or emergency basis, investigate the reasons for work order Part 3 of this article will focus on
orng work ordermay not have been tardiness. Failure to take this step will Backlog Size Management.
1.3 Standard: Backlog Management

Before Meetng During Meetng Afer Meetng
Maintenance Planner
/
[1.3.20] Update
Sc hed uler
[1.3.2] Review CMMS

[1.3.1] Run Backlog Backlog and
Report Resource
Requirements
[1.3.19] Publish
Meetng
Results/Minutes
[1.3.10] [1.3.17] Review

Cross Functonal
[1.3.7] Is [1.3.13] [1.3.15] [1.3.18] Follow

[1.3.3] Stll [1.3.5] Stores Item Remaining
Yes No Priority Yes No Requires No Work Order Yes Up on Open
Valid? Duplicate? Availability Man-Hour
Correct? Outage? Planned? Issues
Issues? Requirements
No Yes No Yes No
Yes
[1.3.16] Ensure
[1.3.11] Is [1.3.14] Assign
[1.3.4] Mark [1.3.6] Mark [1.3.8] Correct Work Order is
Expeditng No to Outage
Cancelled Cancelled Priority Assigned to
Appropriate? Planning
Planner
Yes
Store ro o m
Accoicate
[1.3.12]
Expedite
Materials
Pro d u c to n
Team Lead
Man ag e r
/
[1.3.9] Notfy
Requestor of
Changes to
Work Order
The Uptimization Experts.
The Uptimization Experts.
What
What does
does
What does
DOWNTIME
DOWNTIME
DOWNTIME
mean
mean to
to you?
you?
mean to you?
marshallinstitute.com
LEADERSHIP
LEADERSHIP
MAINTENANCE DEBT
Dictates Your
Maintenance Cost
Most maintenance managers feel the pressure of lowering maintenance costs and at
the same time improving reliability. As you know, annual maintenance costs have a
strong correlation as to how well basic work processes such as planning, scheduling,
and preventative maintenance are executed in our mills, mines and factories.
and scheduling and other key work pro- rial. But, for the theory to work in the
cesses. Thanks to this dedication they long term, they also have to implement
TORBJÖRN
IDHAMMAR,, have maximized their resources and efficient work processes to be able to
President of IDCON INC effectively managed their maintenance maintain that level of reliability.
in Raleigh NC, USA, budget; retaining a maintenance debt of If we assume that 30% of Chaotic’s
www.idcon.com
$300,000. Chaotic, on the other hand, maintenance debt ($1.5 M) is material,
has spent the last 10 years working re- and one maintenance hour costs about
actively, leaving them unable to keep up 60 dollars, the total cost to get to Effi-
ANOTHER FACTOR that heavily influ- with repairs. They are falling behind and cient’s reliability will be 58,333 mainte-
ences maintenance costs is your existing need to spend $5 million to make all nec- nance hours + $1.5 million in materials.
“maintenance debt”. IDCON’s definition essary repairs. The annual maintenance Breaking it down further: 31 full-time
of maintenance debt is the total cost of budgets for both plants are identical, and employees working a full year (58,333
repairing all equipment in need of repair. they have the same resources and staff hours and 1,880hrs/worker/year) + ma-
This equation does not include improve- size. The reliability is at 90% for Effi- terial.
ments, only the costs for repair of exist- cient Plant and 75% for Chaotic Plant Alternatively, the repairs can be done
ing equipment problems. It is important and each plant currently has about 100 over a longer period of time since it may
to remember that the maintenance debt craftspeople. be hard to plan and schedule for that
is the sum of all repairs, because a valid A fairly typical reaction for many number of people in one year, there is a
maintenance repair job can never be companies in Chaotic’s situation is to training period, and other factors that
avoided, only delayed. If you think about reduce the maintenance budget in an play a role. One could, for example, add
that statement, and find it to be true, you effort to minimize the expenses and 10 additional people for 3 years. If Cha-
will also arrive to the conclusion that you through this effort show better results otic gets its PM, planning and scheduling
have to pay the maintenance debt, there (theoretically). The problem? The an- implemented in the plant, the additional
is no other alternative. ticipated results will only last for a very people will be a temporary need. A
short time. An industrial organization good idea may be to match the incoming
can never avoid a valid repair work or- “temporary addition” with natural attri-
der. Sooner or later the repairs have to be tion in the work force, in order to keep a
A VALID REPAIR CAN done. On top of this, 99.9% of the time, trained work force in place?
NEVER BE AVOIDED, it is more cost effective to repair sooner
rather than later, often by a ration 1:3 Understanding the Cost of
ONLY DELAYED. -1:9. Maintenance is Crucial
We have an upcoming job with a large
Putting a Price Tag on Chaos corporation, where the maintenance
Imagine two identical organizations: So, what is the price tag for Chaotic to debt plays a key role. Two of their plants
”Efficient Plant” and ”Chaotic Plant”. reach the same reliability as Efficient? It have $45/unit higher maintenance
For the past 10 years, “Efficient” has will cost roughly $4.7million (The differ- cost than the other. IDCON’s task is to
kept up, and continuously improved its ence in maintenance debt between the analyze why. It is an interesting project
preventive maintenance (PM), planning plants) in maintenance hours and mate- and we need to understand how mainte-
nance is run, how finances are reported, can tell it will take 2-2.5 years to man- 12
Two similar plants - Different History
Millions
and the history of these plants. age all the valid repairs needed with an
It is important for the project to un- additional 15-25 people, assuming all 10
derstand what it costs, and how much craftspeople work 1,880 hours per year. 8
time is needed in order to improve the 6
reliability. We inspected a portion of From Analysis to 4

the equipment with knowledgeable in- Implementation Plan
2
house personnel and analyzed the back- After this analysis, we created an im-
log with each maintenance department plementation plan with each plant, and 0
Chaotic Plant Efficient Plant
and came up with an estimated value reached the typical conclusions for reli- Maintenance Debt Annual Maintenance Budget
of the current maintenance debt. It is a ability improvement projects. In order
Table 1: It will cost Chaotic Plant $4.7
rough estimate, based on a few sample to effectively reduce a maintenance
Million including and 31 additional
areas. While an exact sum would be debt, the plants need to validate all work craftspeople for a years and 1.41 Million
great to have, the most important thing requests and prioritize, plan and sched- in materials to catch up with Efficient
is to initially identify whether the debt ule, every validated work order. They Plant’s results. The theory only works if
is small, medium, or large. The project also have to make sure preventive main- Chaotic Plant’s manages to perform as well
approach we used can be summarized tenance and condition monitoring is in as Efficient in the future with regards to
as follows: place in order to minimize and identify planning, scheduling, PM and other basic
work processes.
1. A work process study to deem potential new problems or breakdowns.
whether existing preventative The added benefit of adding an
maintenance, priorities, plan- analysis of the maintenance debt is that
ning, scheduling, and basic you get approximate figures of work
material management work pro- hours and costs needed to improve the
cesses effect the maintenance situation.
cost. The most important piece of the
2. Comparing maintenance costs puzzle is that corporate management
with another successful plant in accepts the identified repairs that have
order to get a feel for bookkeep- to be dealt with before reliability can be
ing practices. Verify that similar expected to improve significantly. They Table 2: Three plants of similar size
items are included in the main- have created a 3-year plan including and maintenance budget have different
tenance cost when we compare an additional expense budget (around maintenance debt. The maintenance debts
plants. 2 million / year/ plant) for the mainte- are causing plant 1 & 2 to over run their
maintenance budget every year.
MAINTENANCE DEBT IS THE SUM OF ALL REPAIRS,

BECAUSE A VALID MAINTENANCE REPAIR JOB CAN
NEVER BE AVOIDED, ONLY DELAYED.
3. Trying to identify the size of the nance debt. Both plant and corporate
”maintenance debt.” leadership understand that the biggest
4. Collectively documenting a plan, risk factor for success is to get person- Table 3: An estimate of the number of
work hours that is needed to eliminate the
in order to improve the situa- nel in the plant implementing the
maintenance debt in each plant.
tion. basic work processes. But, with strong
5. Implementation. leadership and some patience, I am
6. Follow up. convinced they will succeed with this
At our initial audit for our client, we sensible approach.
estimated the maintenance debt to be This corporation’s situation with
$3.5 million, which includes 40,833 struggling plants, could describe most of
work hours in one plant, and $4.2 mil- the clients IDCON works with. The only
lion and 49,000 work hours in the other. difference is the size of the maintenance
At a third plant, which has much better debt. The size of the maintenance debt
reliability and lower maintenance cost is oftentimes directly related to how
than the other two, the maintenance well PM and planning and scheduling Figure 4: Plant Chaotic needs 31 effort
debt was only $1/4 million with 4,700 has been carried out in past years. I years to reduce the maintenance debt.
They decided to use 10 additional people
work hours. hope these thoughts and examples can
over 3 years. An idea is to add 15 people
All three plants are about the same help you get a grip on maintenance debt, to the regular workforce and let attrition
size, with around 110 maintenance em- to improve reliability in your mine, reduce the workforce back to 100 over 3
ployees. In the two problem-plants, we plant or mill. years.
INNOVATION
Open Innovation
Models Help Companies
Disrupt Their Own Business
Even in traditional industrial companies,
the pressure to renew their business is growing as
software moves into the very core of the business in every industry. To shield
themselves from disruption, more and more companies are looking at open in-
novation models – in other words, they strive to create partnerships with outside
players via hackathons, startup investments or other avenues.
LEADERSHIP
to disrupt their own business models. 1. A company needs a culture that

ANNI HARJU, The global startup scene is buzzing supports innovation, which, in
Principal, Futurice and CEOs in all industries all over the turn, requires measuring the right
&startups world are waking up to the need to renew things and operating at a higher
anni.harju their business. Now is the right time to clock speed than is customary for
@futurice.com invest in it, too. Statistically, startups are your average industrial company.
far less likely to succeed (0,002%) com- Innovations are not born in the
Photos: Gökçen Keskin, Jussi Heltttunen pared to projects by companies build- boardroom or the corner office.
ing new business on their established The whole organization has to be
AS SOFTWARE BECOMES more integral strengths (12,5%). ** lean enough to create the com-
to all business, digital disruption has a Which begs the question: What is pany’s next success story.
significant impact on even the most tra- keeping large corporations from devel- 2. Traditional governance and deci-
ditional industries. There are plenty of oping new business models? sion-making processes do not sup-
good and bad examples of how to try and It is not a question of will. According port the development of disruptive
secure the future of your business. Rolls the to the aforementioned survey by KP- business where the added value ex-
Royce is a good one - instead of just sell- MG, the three central strategic priorities perienced by the customer may be
ing jet engines, they have developed their for companies are developing innovation a better indicator of potential busi-
service portfolio and business model to activities (21%), improving customer- ness value than revenue streams.
rely primarily on selling lifecycle services centeredness (19%) and implementing 3. Business renewal is overly conserva-
using sensors and the Internet of Things. disruptive (18%). tive, especially early on – invest-
According to an international sur- ments are insufficient and failures
vey produced by KPMG*, 65 percent of How to Facilitate Innovation frowned upon, which tends to
CEOs are afraid that newcomers will Based on our experience, innovation dampen the desire to experiment
disrupt their company’s business model. activities often meet one of the following and innovate. Typically, companies
Over half feel that they don’t do enough obstacles: also look too close to home for
MARCH 13 –16 2018

SWEDISH EXHIBITION
& CONGRESS CENTRE, GOTHENBURG
EUROPE’S NO.1 MAINTENANCE TRADE FAIR AND CONFERENCE
SMART MAINTENANCE MEANS

KNOWING WHAT HAPPENS NEXT
Alrik Danielson
THERE’S ONLY ONE SURE WAY TO FIND OUT. President and
Chief Executive, SKF
UNDERHÅLL 13 –16th of March 2018
Europe’s No.1 maintenance trade fair and conference.
FOCUS AREAS Dr. Ashkan

Fardost
Scientist,
Advisor & Global Speaker
Productivity Digitisation and IoT Sustainable Maintenance Industrial Safety
www.underhall.se #underhållsmässan
INNOVATION
ADVERTORIAL
their benchmarks. In a digitaliza- This requires a larger and more clearly far removed from the company’s core
tion survey Futurice carried out defined budget, but because business competence. They offer visibility far be-
on large Finnish corporations, development takes place outside of or- yond one’s own domain and function as
almost all respondents mentioned ganisational boundaries, the pressure to a platform for brave experiments.
only other Finnish companies as change the company’s decision-making The way Futurice’s new initiative, Fu-
their competitors. *** or budgeting processes is weaker. As turce &startups works is predicated on
Open innovation processes that utilize approaches go, this is still fairly light, the idea that the most effective business
players from outside the organization but it also means that some of the im- innovations of the future are created by
are one way to sidestep these issues. material capital of an industry leader, combining organisational interfaces. In
When an outside stakeholder becomes such as customer networks and domain our case, our partners bring to the table
a part of a company’s business devel- expertise, remains partially or even fully their deep domain expertise, and we
opment activities, the organisation unexploited. bring our 17 years’ worth of experience
is forced to let go of their old thought in software development, digital busi-
models and change is accelerated. Find Suitable Partners and Create Your ness models and service design. Becom-
Open innovation models can be Own Ecosystem ing an equal partner, instead of a vendor,
utilised in renewing business on three The best thing to do is to build an open in selected projects is a big change for
levels: innovation model that efficiently ex- Futurice and a major opportunity for
ploits fresh thinking and expertise our clients.
Try Out Openness by Running found outside the company and com- Fortum is a company that has been
a Hackathon bines it with the company’s ability to actively looking for new value chains
Organising hackathons with outside utilise industry networks and other and business models in the field of en-
partners are frequently the first step immaterial capital gained over the ergy. In a world where more and more
companies take towards using open years. This way an outside party can use people can make the change from pro-
innovation models. A hackathon is an their expertise to fill needs like building ducing and consuming clean energy,
intensive, typically two-day event dur- digital or data-based business models. energy companies need to find new
ing which a group of people get together Furthermore, in a larger company the revenue models and new markets. In
to solve problems. Often they involve outside partner can drive projects in a India, Fortum and Futurice &startups
designing and maybe even building way that prevents the development of are looking at new ways of delivering so-
software or apps. Hackathons are a good nascent business from being left in the lar energy in areas without dependable
way to introduce an organisation to the shadow of the established ways of doing grids – or grids, period – using digital
concept of venturing outside to look things. technology. Instead of selling energy,
for ideas, but if the organisation has not the new business model being devel-
changed enough to exploit the nascent The Future Belongs to oped offers local producers a platform
business models created during the Ecosystems they can use to sell their solar energy.
event, the impact hackathons can have In the future, even larger companies will There’s a potentially huge demand for
will be very limited. The question to ask have to rely on a combination of agility platforms like this in the developing
when organising a hackathon is: What and versatility to survive. Ecosystems world, where lack of access to energy
do we want to happen in the one to six are a better way of ensuring access to a has been a hindrance to development
months following the hackathon? What variety of expertise and resources than and established ways of producing en-
about on the next working day? What large investments in areas that are too ergy can be very polluting.
will be different?
Guard Your Back by Investing Source 1*: https://home.kpmg.com/xx/en/home/media/press-releases/2016/06/2016-

in a Startup ceo-outlook-next-3-years-more-critical-than-previous-50.html
Another way to protect your company Source 2**: https://hbr.org/2016/12/when-large-companies-are-better-at-
from a potential disruption is to invest entrepreneurship-than-startups
in startups – directly or through funds. Source 3***: Futurice digitalisation survey 2015
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