Senseye and its Engineering team have developed a customer success project framework called Senseye ID.
This framework is based on best practices to achieve digital transformation success with Senseye PdM to:
- Decrease maintenance costs by 40%
- Reduce manual inspections
- Optimize spares inventory purchases
- Deploy a successful maintenance plan
What is an Initial Deployment and why is it important?
A small-scale version of a larger project, an initial deployment (ID) is, effectively, an operational trial run. Typically lasting for a fixed period of 12 months, an ID enables an organisation to run a contained predictive maintenance project to assess results, learn from the experience, and take the learning forward to expand the project’s scope across more machines and/or sites.
An ID is a significant step toward realising a longer-term goal - helping to get the wider organisation on board, identifying potential problems to prevent them from escalating, and accomplishing smaller goals before full implementation.
The importance of an ID shouldn’t be underestimated. With the right preparation, commitment, and mindset, this “trial run” is a critical success factor in the journey to wide-scale predictive maintenance.
How do you measure success of PdM projects?
- Reduction in on-boarding effort from ID to wider adoption - for example:
- In engineering hours effort per asset
- In duration to on-board per asset
Senseye ROI is a free online calculator, designed to show how Senseye PdM can help organizations increase their efficiency.
Built for industrial companies who want a bespoke analysis of their unique production environments, it shows the steps they should take to transform their maintenance operations using Industry 4.0 best practices, and the financial returns they can expect by doing so.
Senseye Index is an in-house methodology based on our experience, industry, and technical knowledge to measure where on the predictive maintenance journey industrial companies are.
Why does an index matter?
Overall PdM readiness is a combination of two dimensions - data capture and PdM culture.
Smart automated solutions and cloud delivery make condition monitoring easier to implement than ever before. But users still need to have certain things in place before they can start to produce results, the most important of which is the ability to feed the right data in to their PdM solution.
Without the right data, the PdM solution is being asked to work blind. Assets therefore need to be equipped with the right hardware to capture relevant data, and there must also be systems in place to feed that data into a PdM solution. There also needs to be a way to link that machine data with maintenance records so the solution can learn when certain behavior indicates that maintenance has been carried out.
Senseye has devised a scale for each dimension - data capture and PdM culture - to gauge how far along the path to PdM an organization is. Together, they form the Senseye Index.
At the lowest end of the scale - level one - a site will have little instrumentation and/or poor access to control systems; whole maintenance records will also be poor or non-existent. At the other end - level five - a site will have comprehensive sensor coverage delivering streams of data to a cloud-accessible data store. Maintenance data would be recorded and available automatically from a CMMS system. Most companies will find they are somewhere in the middle.
The other major measure of an organization’s PdM maturity is how ready it is to turn captured data into useful condition monitoring information. At level one, a company may schedule periodic route-based condition monitoring checks, where a technician regularly walks the floor and records the results of a standard set of checks. At level five, however, robust, automated condition monitoring combines with the right PdM solution to give accurate predictions of the time-to-failure and mode of failure of each asset.
Applying the Index
Some parts of an organization are often better prepared for PdM than others. The Senseye Index for an automotive manufacturer’s body shop might be at level three, for example, while the rest of the factory is at level two. In this case, the flexibility of scalable, cloud-based systems can make it possible to focus on progressing PdM in the easiest areas first.
By enabling such a step-by-step approach, Senseye Index reduces risk by minimizing upfront investment, and provides an important demonstration of how PdM capabilities can rapidly deliver significant benefits. This makes it easier to justify a bigger investment in bringing other areas of the business to a level of preparedness that allows them to enjoy similar benefits.