Business Development Expert Manufacturing und … Development Expert Manufacturing und Industry 4.0...

Business Development Expert Manufacturing und Industry 4.0October 27, 2014

Predictive Maintenance and ServiceAn Overview Presentation

© 2014 SAP (Schweiz) AG. All rights reserved. 2

Agenda

3© 2014 SAP (Schweiz) AG. All rights reserved.

Trends


The World is Connected

devices connectedby 2020*

50 billion 40-50%CAGR for M2Mmarket until 2020*

price of sensors,microprocessors &wireless technologiestoday vs. 4 years ago**

1/5

*Source: Gartner – “Top 10 Tech Trends for 2013” – 2012

**Source: Economist Intelligence Unit – ”The Rise of the Machines” – 2012

© 2014 SAP (Schweiz) AG. All rights reserved. 5© 2014 SAP AG or an SAP affiliate company. All rights reserved. 5

Predictive Maintenance and Service – Business

Dealers and Service Providers:Add-on services for asset owners or on behalf ofOEMs.

• Optimize services delivery

• Improve service efficiency

Owners and Operators:Asset owners optimizing asset performance bymonitoring asset health e.g. condition based orpredictive maintenance, predictive quality, etc.

• Increase asset availability

• Reduce unplanned downtimes

• Improve overall quality and safety

OEMs:Manufacturer of digitally empowered equipmentproviding new service business models to assetowners e.g. selling performance, remote service,etc.

• Higher margin service offerings

• Improve product quality

• Reduce warranty costs

• Enabling of new business modelsaround the asset

Players Value


Challenges


Predictive Maintenance and Service – What it is about…

“Predictive maintenancetechniques help determine thecondition of in-service equipment<by also using sensor/telemetrydata and alerts> in order to predictwhen maintenance should beperformed. This approach offerscost savings over routine or time-based preventive maintenance,because tasks are performed onlywhen warranted.

The main value of PredictedMaintenance is to allow convenientscheduling of correctivemaintenance, and to preventunexpected equipment failures.The key is ‘the right information inthe right time’.” (Wikipedia)


Valuable Insight Lost in Disparate Information Flows& Disconnected Databases

Business & ProductData

Technical & OperationalData

Unstructured Data

OEM

Dealer

Customer


Predictive Maintenance and Service

OEM Customer / Owner / OperatorServiceDealer

Sales ServiceR&D Warranty

“How can I improvemy product’sreliability and up-time?”

“Which service leveldo we need toprovide?”

“How can I improvemy customerssatisfaction andloyalty?”

“How can I providethe best service atthe right time?”

Fleet

“How can I reduceservice andoperational cost?”

Driver/Operator

“How can I improvemy driving style, drivesave and reduce fuelconsumption?”

Emerging IssuesPredictive Analytics

What-if Analysis

Liquidity

Product Reliability360° Transparency

Product Improvement Spare Parts

Profitability

Machine Health Prediction

Customer Service

Ad hoc data mining and exploration,analyze warranty claims, determinespare part stocks, optimize design andmanufacturing…

Add-on services for asset owners,optimize services delivery, maximizeuptime, raise service efficiency…

Analyze fleet behavior, minimizeunplanned downtime, manage assetrelated risks, align between operationsand maintenance,…

Information and Analysis Tools

Common Objective for Customer, Dealer & OEMMaximum Equipment Uptime and Minimum of Maintenance Costs


Solution


Predictive Maintenance and ServiceA key building block for improved asset performance

Predict Act

Sensor Data

Business Data

Environmental Data

Patternand Root

CauseAnalysis Pr

edic

tions

Create work order

Change product specs

Alter maintenanceschedule

Propose spare parts

…

Sense


Traditional Service vs. Optimized ServiceOperator

TechnicianOEM

SupportOEM

TechnicianSpare parts

& tools

Remote ServiceEngineer

Real-time condition monitoring


End-to-End Process for Maintenance & Service

Asset HealthPrediction

Increaseeffectiveness

CreateMaintenance

or Service Order

Execute Orderon Mobile

DeviceVisual SupportSAP solution for

maintenance/service

Schedule Order

ConditionMonitoring

Remote Service

Fault PatternRecognition

IT/OTConnectivity

RemoteMaintenanceand Service

Increaseefficiency

Watch: https://www.youtube.com/watch?v=UlpGDrSmg38


Predictive Maintenance and Service – Vision

SAP HANA

Benchmarking

Prioritize maintenanceand service activities

Early warningsto prevent downtimes

Designimprovements

Asset healthmonitoring

Optimized warrantyand spare parts mgmt

Telemetry Data

Business Data

Third party data …

• Sensor measurements• Geospatial data• Diagnostics• Events• Performance metrics• Battery status

• Sales contract• Warranty information• Maintenance/ Service history• Customer profile• Dealer events• Cost and risk

• Structured and unstructurede.g. weather forecast


Data ModelsM2M Agent

Business Data

Mobile App

Web App

Equipment Data

Predictive Maintenance and Service on SAP HANA

Sales

Service

Engineering

createactionableinsights

predicthealth

monitorasset

Prediction Notification

FlexibleModeling

Visual RulesDesigner

PredictiveAnalysis

Recordings

Weather

Unstructured Data

Temperature

Voltage

ServiceCoordinator

R&DEngineer

AssetManager

WarrantyManager

UI

TelemetryData Import

Unified DataModel

PredictionEngine

NotificationServer

Analysis &Exploration

UserInterface

Business Data ImportBusiness Process

Integration

Any Text basedData Analysis


SAP Predictive Maintenance and Service, Cloud EditionPlanned Capabilities

3rd Party Device Cloud

Communication Networks (by Telcos)

Devices

Connectivity Platforms (by Telcos)

SAP HANA IoT Edition

MachineMgmt

Rules &Alerting User Mgmt Vibration

Analysis …

Hot Cold

Integrationservices

Dashboards Lists Graphs &Charts …Maps

IoT Connector


Scenarios


Defect Pattern Identification

Identification and prioritization of machine failure pattern for product improvement

Based on claims, damage reports, business and configuration dataCombining in an iterative approach

Visualization (parallel coordinates, multi-dimensional scaling)Mapping of expert knowledge into HANA andStatistical analysis (text clustering, association analysis,decision trees)

Improved product quality at lower costsQuick identification of new defect patternsGuidance for root cause analysisReduction of manual work in quality managementCost reduction & increased customer satisfaction

IndustrialMachinery& Construction


Machine Health Prediction

Sense & predict machine health supporting the solution provider transformation

Using machine dataPredict breakdowns via decision treesCalculate energy consumption pattern profiles with k-means clusteringModel domain expert knowledge in SAP HANA with decision tablesProvide 360° view on machines with real-time calculation of KPIsfrom ERP and telemetry data

Scale and improve service business byBetter transparency of current conditionMachine health prediction from historic dataOptimize field technicians scheduling, includingfailure predictions

Machine A



Vehicle Health Prediction

Improve manufacturing quality, service planning and customer satisfaction

Single point of access to all related business and technical informationIntegration of SAP HANA and for reportingand predictive analyticsAssociation rule mining and regression tree learning tocorrelate production rework and customer satisfaction dataSAP HANA/R data mining and data visualization based onsurvey - and manufacturing data sets

Improved prediction of upcoming warranty cases80% accuracy based on vehicle diagnosis andprevious warranty claims

Automotive


Emerging Issues

Faster product improvement and early failure prediction to reduce downtime

Single SAP HANA based platform that combines sensor and warranty dataAnalysis of equipment's telematics dataDetection of potential issues and relation to equipment's service and warranty data usingtext mining, association analysis and HANA database capabilitiesShorter detection-to-correction cycle

Reduced warranty costsQuick identification of potentially defective behavior of fleetCreation of evidence packages as input to root cause analysisMachine warranty cost reduction & improved up-time



Vibration Analysis

Identification of health finger print based on vibration analysis

Monitoring of machine health using failure patternA 360 degree view of a machine by integrating technical machineand business data in a flexible data model in HANATrend analysis and pattern comparison onvibration and process data

Better machine utilization & reduction of warranty costsDetect emerging dangerous vibrationsChange from manual, reactive vibration analysis processto an automated, proactive processImprovement of machine uptime and reduction ofmaintenance costs.



Summary

34© 2014 SAP AG or an SAP affiliate company. All rights reserved.

Predictive Maintenance and Service - Solution

Internet of ThingsEnablement Platform• Device connectivity• Device management

Remote Monitoring• Sensor data

visualizationand analysis

• Device alerts via flexiblethreshold

• Machine health factsheets

Condition BasedMaintenance and Service

• KPIs definition• Rule based action

triggers• Seamless

integration intomaintenance andservice processes

Predictive Analysis• Fault pattern

recognition viaunstructured data

• Machine healthpredictions

• Root causeanalysis forengineeringimprovements


Predictive Maintenance (Repeatable Custom Solution)Powered by SAP HANA

Business SituationMaintenance is responsible for keeping equipment running andavoiding unplanned downtime with is costly side effects.Basic maintenance strategies are scheduled maintenancebased on simple metrics, such as time intervals, machine hours,or distances traveled, drive maintenance schedules andactivities.Condition based maintenance reflects the actual conditions ofthe equipment and its components. It requires that respectivedata is collected from built-in sensors and analyzed in orderidentify any kind of problems.Consequent follow up processes such as spare parts supply,technician visit are triggered.

ChallengesDisconnection between equipment and business processesresults in higher costs:

High operation costs due to high failure ratesAutomated gathering of relevant machine data from remotelocationsInability to do root cause analysis and prediction decreaseequipment productivity and innovationPoor precision of spare parts planning, results in high spareparts inventory rateSome parts need to be expedited at high costs

Value DriverReduce Operations & Maintenance Costs: Higher assetproductivity with automated monitoring & notificationprocessesImprove Reliability & Visibility: Increase asset availability withcondition-based maintenance procedures and toolsImprove Cash Flow: Decrease spare parts inventory rateMaximize Asset Uptime: Decrease unplanned outages withpreventive & predictive vs. reactive maintenance

Preview

Benefit SAP HANAPossibility to combine business and product data,unstructured data and technical as well as operationalequipment data in a unified data modelLeverage the statistics and predictive abilities provided byHANA

Process Innovation• Equipment Benchmarking / Control Center: Build a control

center that gives you an overview of your completeequipment in the field. Search and filter for machines via listsor maps.

• Reactive to Predictive Service: Identify problems, understandactual status, send problem notification to customer, sendservice technician and identify required spare parts.

• Energy Analytics: Analyze the energy consumption ofmachines in the field. Find anomalies or potential problems.Offer an automated utilization billing based on consumptiondata.

SolutionAssessment Service with subsequent Custom DevelopmentProgram (CDP)

AudienceR&D EngineerService Coordinator &ManagerFleet Manager

Asset ManagerWarranty Manager


Predictive MaintenanceAdditional information

MaturityAssessment Service with subsequent Custom Development Program (CDP)

• CDP project• Customer provides HANA system including licenses or HEC• Involvement of SAP CD / SAP Consulting funded by customer• Involvement of SAP Development• Outcome is a project that can be used productively for daily business

• Co-Innovation project• Infrastructure and trial licenses optionally supplied by SAP Development• Involvement of SAP Consultants, Data scientists and Designers with Customers business

users and IT• Outcome is a prototype. The goal is to close a follow-up CDP project to build a solution that

can be used productively.

Impact IT-Infrastructure• High Availability of the systems is required• Possibility of hosting the complete solution in the cloud (HEC)

Invest/ CostSAP HANA, Sybase IQ, SAP Data Services, Sybase ESP, SAP Predictive Analysis, SAPLumiraData Science Services 20 – 40 daysHadoop Resell

Architecture Overview

AssetsLars Bastian (CVS), Bernhard Gonschorek (BTS), Oswald Wieser (Co-InnovationDevelopment)Referenzen: Keaser Kompressoren,

Internal


Predictive Maintenance and Service – Benefits

For asset manufacturers /service providers:• Improve service profitability

• Lower service costs• New revenue streams

• Higher percentage of calls resolved withouttechnician dispatch

• Higher first-visit-fix rate

• Customer satisfaction and retention

• Higher service contract renewal rates

• Enable innovative business models

For asset owners / operators:• Higher overall equipment effectiveness

(asset availability & performance & quality)

• Improve maintenance efficiency

• Lower maintenance costs

• Faster reaction to alarms and failures

• Higher mean time between failure

• Lower mean time to repair


ImprovedQuality

BetterVisibility

ReducedCosts

HigherUptime

IncreasedReliability

OptimizedPlanning

CustomerRetention

LowerInventory

Summary


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