METTLER TOLEDO: Condition Based Maintenance - “Indispensable” Sensor Technology
At the corporation’s Mizushima plant near Okayama, pH measurement during the neutralization of strong acids is closely monitored. For this important measurement Tsutomu Ishikawa and Naoto Ogura, engineers at the plant’s Instrumentation and Engineering Department were not satisfied with the performance of the pH sensors they were using.For this reason, sensors were regularly exchanged at the plant to minimize the chance of failure in the process. But the operation cost was high and Mr. Ishikawa and Mr. Ogura needed a better solution. Specifically, they required to know in advance when a pH sensor would need to be cleaned, calibrated or replaced: “We wanted to grasp how deposits forming on the pH sensors would affect the timing of sensor maintenance and exchange.”
IBM: Improving “people flow” in 1.1 million elevators globally
KONE already provided traditional maintenance services for its more than 400,000 building owner and facilities management customers, but it sought cloud-based analytics technology to capture and use the vast amount of data generated by its elevator and escalator equipment worldwide to transform its service offerings. “We knew that digitalization was changing the industry, and we wanted to become a forerunner, not a follower in this development,” says Markus Huuskonen, the Director of Maintenance Processes and Connected Services at KONE.
SparkCognition: Identifying Vane Failure From Combustion Turbine Data
In late 2015, a deployed combustion turbine experienced a row two vane failure, which caused massive secondary damage to the compressor, resulting in nearly two months of downtime and up to $30M in repairs costs and lost opportunity. This failure, though rare, is representative of typical catastrophic events that are very difficult to catch. Though the onsite plant operations team had been monitoring the asset, this specific failure mode was previously unknown and very nuanced, and existing alarms did not have enough information for SMEs to properly diagnose it in time.The OEM decided to evaluate SparkCognition’s predictive analytics solution, SparkPredict®, with the following objectives:1. Demonstrate the ability to detect and distinguish operational and anomalous online steady-state conditions based on blind data provided from the turbine.2. Provide additional insights about the key contributing factors to the underlying anomalies.3. Provide a UI that interfaces to live streaming data from the asset.
Endian: Moving Quickly into the Digital Age
J.A. Becker & Söhne is a medium-sized German company, that always prioritizes quality and safety. In their old model, a technician travels regularly to the customer’s location to service the compressors. For the international customers, trained service partners assume this regular maintenance role. In case of an issue between the service visits, there is a service hotline at the customers disposal, that is able to solve most of the failures. In cases where the hotline cannot solve the problem remotely, a service technician is sent to the customer. With customers all over the world (including China), this support option is quite time-consuming and very expensive. 
ArtiMinds Robotics GmbH: Robot-supported ultrasonic defect testing and quality control
Ultrasonic testing is a widely used non-destructive test method to check cast parts for invisible defects such as blowholes, pores or cracks. Since the acoustic properties of the material change if those casting defects are present, the ultrasonic sound pulse is reflected and sent back to the test head.Especially if components have complex geometries, ultrasonic testing is often carried out manually. By automating the process with the help of robots, test costs and test time can be reduced and measurements made reproducible.
: Aircraft component manufacturer introduces predictive maintenance
A major European aircraft component supplier encountered this challenge first-hand. A mission-critical, programmable milling machine failed, halting the organization’s production process. Despite the customer team’s expertise, the problem proved challenging to diagnose. At first, it appeared the downtime resulted from a damaged spindle, the most complicated part of the milling machine. However, a costly and time-consuming spindle replacement did not correct the situation. The team was forced to perform an extensive system evaluation to identify the culprit.
IBM: Saving millions with a predictive asset monitoring and alert system
The challenge was to harvest and sift through this data, recognize the patterns that indicate a high likelihood of asset failure, identify the most urgent issues, and get the right information to its engineers with enough lead time for them to take effective action.“Before, we only used between 10 and 12 percent of the operational data we collected, which is the industry average,” comments Benn. “By the time we had searched for, collated and forwarded the right information to the right people, we might respond too late to avoid impact to operations, or have to make last-minute changes to our maintenance schedule, which reduces efficiency. Our challenge was to provide right-time, actionable, effective information proactively, rather than in a reactive or look-back assessment.”“What we wanted was a way to identify patterns in that sensor data that would give us an early warning of asset failure. We saw an opportunity to use analytics technology to extract greater value from the systems and data we already possessed, which would help us to, for example, avoid preventable failures and potentially save millions of dollars.
Microsoft Azure: A Hybrid Switchgear-Communication Solution Satisfies Shopping Center’s No-Antenn
Based in Bolton, England, Ascribe is a leading provider of business intelligence (BI) and clinically focused IT solutions and services for the healthcare industry. Ascribe estimates that 82 percent of National Health Service (NHS) trusts in the United Kingdom use its products. With access to large volumes of data maintained by the trusts, the company wanted a BI solution that would help healthcare providers detect, predict, and respond more quickly to outbreaks of infectious disease and other health threats. Healthcare analysts typically work from data collected and coded when patients receive treatment in clinics and hospitals. “By the time they get that information it’s usually out-of-date,” says Paul Henderson, Business Intelligence Division Head at Ascribe. “The data has already been coded and stored in a record-keeping system, or it’s been collected from a hospital workflow, and that doesn’t always happen in real time.” In addition, huge volumes of potentially useful data existed in text files from sources such as unscheduled visits to emergency rooms, school attendance logs, and retail drug sales. The Internet offered another trove of untapped information including clickstream analysis and social media such as Twitter. “If you think about each clinician who struggles with getting timely, accurate data, and you compound it on a national scale, then it becomes an immense challenge,” says Henderson. “You have lots of small pieces of data coming in from multiple places, and it can be very difficult to aggregate and interpret.”Ascribe had previously worked on a solution to support the analysis of national emergency care attendance. The system was designed to monitor the daily number of people who visited emergency departments in the UK and raise an alarm when it identified unusual levels of activity such as a potential outbreak of an infectious disease. However, it was difficult to collect data from a rapidly growing number of healthcare providers, including mobile clinicians. In addition, clinicians were unable to use the exploding volume of unstructured data from patient case notes and social media feeds. “The processing power you would need to handle all of that information is beyond the capability of most organizations,” says Henderson. “A hospital can’t just stand up a server farm to process millions of case notes from an emergency care system in addition to other data.” To solve these problems, Ascribe decided to design a proof of concept that would create a standardized approach to working with healthcare data. The company asked Leeds Teaching Hospitals, one of the biggest NHS trusts in the UK, to participate in the project. Leeds can generate up to half a million structured records each year in its Emergency Department system. The hospital also generates approximately 1 million unstructured case files each month.Ascribe wanted to create not just a proof-of-concept BI solution for monitoring infectious disease on the national level, but also a tool that could be used to improve operations for local care providers. “Our goal was to find a way to make data flow more quickly in near-real time,” says Henderson. “We also wanted to augment clinically coded data with data harvested from case notes.” The company wanted to create a national knowledge base that both analysts following disease outbreaks and local clinicians could use to improve healthcare. Ascribe needed a highly scalable, end-to-end solution that could work with multiple data types and sources, as well as provide self-service BI tools for users.
IBM: Automotive manufacturer increases productivity for cylinder-head production by 2
Daimler AG was looking for a way to maximize the number of flawlessly produced cylinder-heads at its Stuttgart factory by making targeted process adjustments. The company also wanted to increase productivity and shorten the ramp-up phase of its complex manufacturing process.
General Electric: Vale Fertilizantes Saves $1.4M in Production Losses with Predix Asset Performanc
Reducing production lossesIn 2013, the company identified a need in the maintenance and operation of its acid nitric plant to reduce production losses and improve annual production. Vale noticed there was a gap in nitric acid production from 2011 to 2012 and discovered that three pieces of equipment were responsible for the main losses, including two weak acid condensers and a compressor discharge air cooler. The condenser’s losses were due to thickness loss, lack of availability of the spare condenser, and shell cracking.With a production loss above 14,000 tons in 15 months, Vale aimed to reduce annual loss by 10,000 tons by August 2015. 
TEKTELIC : IoT Solutions In Medical Clinics
Proper storage plays a vital role in safeguarding the integrity of pharmaceutical products. Many drugs, medicine, and other pharmaceuticals are susceptible to temperature and humidity levels, and as such, have stringent storage requirements.Improper storage can result in medications losing their efficacy or becoming harmful to patients. To avoid deterioration in pharmaceutical product quality, clinic operators must consistently and accurately measure, monitor, and track real-time conditions in pharmaceutical storage cabinets. Controlling these conditions presents a significant challenge for medical facilities, as manually checking temperature and humidity is inefficient and labor-intensive, also carrying the risk of human error in measurement accuracy and reporting. IoT technologies are enabling medical practitioners to automate temperature monitoring of pharmaceutical storage cabinets. As one of the most renowned private medical clinics in Switzerland, the Merian Iselin Clinic sought a reliable and effective method of remotely monitoring and maintaining ideal temperature and humidity conditions within its pharmaceutical storage cabinets.
Microsoft Azure: Ground-breaking Service for Millions Uses Cloud for Online Psychotherapy
According to the World Health Organization (WHO), there are approximately 1.7 billion people in the world suffering from a range of mental health conditions. This might be anything from acute anxiety and clinical depression to obsessive-compulsive disorders. The WHO believes there are 23 million people suffering from these and similar conditions in Egypt alone. However, one of the factors preventing people from receiving treatments are cultural values and social stigma: they say that either these conditions do not exist, or that if people are indeed suffering, they just need the willpower to overcome their afflictions rather than seeking specialized treatment.With an estimated 10,000 website hits per month, Shezlong needed a hosting platform that could not only provide a foundation for the service but also accommodate its open source architecture.
Endian: Università degli Studi di Udine
University of Udine is a college committed to the highest education standards, research, interaction with surrounding territories. The collaboration with Endian brought its technological vocation beyond the academic field to translate into a project aimed to protect and safely manage accesses to electrical and thermal control systems, access control and video surveillance.
Fiix Software: How a major player in the oil & gas industry decreased downtime
Sean Simon is the SVP of Operations at CIG Logistics, where sand is transloaded and stored for third parties in the oil and gas industry. Before looking into CMMS solutions, his team spent three years trying to manage their maintenance operations with a paper-based system, leaving them with the major issue of not being able to gather or access data. “There’s no way to mine paper. There was no daily summary, no way of tying together comments or keywords.” As a result, trying to track and schedule preventive maintenance was nearly impossible. “It was like owning a car in the 1950s. You had to try to remember the last time you did something and guess at the maintenance that needed to be done in the future”.
Faststream Technologies: Wireless Control Smart Switch for Electrical Appliances
The client requirement was to develop an IoT-based device, which can control the on-off of any electrical device at home by using wireless technologies. The device is connected to the internet via Wi-Fi, and access through the smartphone application.
Plex Systems: Argent International Takes On-Time Delivery To A New Level With PLEX
Argent used to track its operations in an ERP system from QAD. But the company’s end users found the system cumbersome—and its decision-makers grew concerned about the costs associated with the system. “Because we had installed QAD in-house, we had to purchase and maintain our own servers,” said Randy Garreston, System Administrator for Argent International. “We also found the upgrade process to be disruptive. Just when we’d get used to one version, they’d change it and we’d have to learn how to navigate a reconfigured interface.”
Fiix Software: Anaren Microwave Implements their manufacturing CMMS
Like many organizations, Anaren had a homegrown work order application that had basic asset management functionality. “It was menu driven, so quite cumbersome,” explained Bill, “reporting was limited and it still relied heavily on paper transactions and records. We looked at our business needs going forward and decided this was one area that could be modernized.” On launching the Manufacturing CMMS project, Bill, the business analyst of the company identified three major areas for improvement:1. Improve efficiency by eliminating paper.2. Improve the control of preventive maintenance. 3. Improve inventory management.
Petasense: Wireless Predictive Maintenance to Fix a Dated Walk-Around Program
C&W Services was using a manual condition monitoring program at one of its leading life sciences’ client up until last year. At best, data was collected manually every 30 days, even on the most critical machines, using a handheld data logger. After the data collection, all of the data analysis had to be outsourced to a third party for analysis. This approach has several limitations:1. Unplanned Downtime2. Shortage of Manpower3. Safety and Access to Machines4. Inconsistent Readings Collected by Manual Processes
Infinite Uptime: Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox
The calendar machine run by a motor has a shaft mounted gearbox connected to the roller. This gearbox allows maximum paper load and feeds the paper with reduced speed to the roller. In spite of scheduled preventive maintenance, it was observed that gearbox used to fail frequently. The rise in vibrations leading to the eventual failure of gearbox adversely affected the quality of the paper. Monitoring the gearbox was thus vital and critical.
Faststream Technologies: Digital Alcohol Breath Analyzer
Mobile App based on non-invasive for estimating blood alcohol content (BAC) from a blood sample.Portable DeviceLess ExpensiveAccurate as compared to the standard Breath Analyzer.BAC test result varies between individuals consuming identical amounts of alcohol due to race, gender, weight, genetic predisposition, metabolic rate.
Capital Numbers Infotech Pvt Ltd.: CN Helped Pine Printshop with a Responsive and Top-notch E-commerce Portal
To digitally expand their business, Pine Printshop was looking for a catalog-based site that would help people buy ready-made products (e.g. apparels, board pins, stickers, etc.) and even allow customers to personalize their own t-shirts, caps, and hoodies.
IBM: Minimizing downtime by engaging IBM Services – Technology Support
Simplifying maintenanceHana Financial Group had recently consolidated the infrastructure and resources of 11 of its affiliates at a local IBM data centre. However, the business was left with more than 100 service and maintenance contracts that needed to be reviewed and renewed periodically. These contracts also involved 100 separate bills that Hana Financial Group had to manage. Managing such a large volume of bills was cumbersome and sometimes resulted in late payments. The group wanted to improve efficiency and eliminate the overhead involved with managing these contracts by consolidating its heterogeneous IT systems and data storage systems under more consistent processes.
: Temperature and humidity monitoring solution
TEKTELIC : Optimizing the tourism travel experience in Switzerland
Arcade Solutions AG is an IT and IoT company based in Lucerne Switzerland that has been revolutionizing the travel tourism industry. Arcade is the proud creator of an application called the iParkiere Bus smart travel tourism and parking application which is now the primary navigation application for all coach drivers in Switzerland.
Luxoft: Saving millions by avoiding expensive downtime for hydraulic fracturing equipmen
To extract shale oil and gas, specialized equipment is used to fracture rock via a process called hydraulic fracturing (or “fracking”). To do this efficiently, users must know when their equipment needs maintenance. If the equipment stops working while in the well, millions of dollars are lost due to downtime and logistics. Additionally, our client, a major oilfield equipment company, needed a way to make their product stand out. They wanted to accomplish this by providing oil and gas software solutions but had no idea on how to develop and deliver software in the cloud.
: Gas Pipeline Improves Station Efficiency and Drives Revenue with DataRPM
In the capital-intensive oil and gas industry, businesses rely heavily on expensive assets that are deployed in harsh environmental conditions. From a drilling point in the sea to an intermediate station in the desert, the dynamic environmental conditions at each point along the long line affect the performance of the assets deployed along the line. The systems that are used to support these mission-critical assets must also be highly reliable, responsive and secure.One company that operated a long-distance gas pipeline encountered numerous challenges with the overall efficiency of its pipeline, ranging from sub-optimal usage to wastage of natural resources. Even with the optimal equipment and setup, the wide array of variables in operating conditions combined with the sheer distance covered by the pipeline made running the business difficult.In this case, there were 22 injection stations along the length of the pipeline, operating under very disparate conditions with different efficiencies. This made it difficult to identify the interdependent effectiveness of these injection stations, despite having a large data set on various parameters at each injection substation. Even a single instance of failure could cost the company hundreds of thousands of dollars in lost revenue as well as any additional costs for repairs that had to be made.The company was spending $5 million per mile of pipeline annually in corrective maintenance. Along with this, the loss of revenue due to the undelivered material was estimated at $250 million. With energy prices dropping, the loss in revenue directly reduced the bottom line of the company. With the clock ticking and revenue dipping, building a perfect efficiency improvement model became a top priority.
Infinite Uptime: Smart Ccondition Monitoring Saves USD 30 Thousand In A Forging Unit
The 1000 Ton main forging press had a 75 HP motor and fed a trimming machine. The motor pulley combination was situated on top of the Press at a height of about 15 feet thereby reducing its access for routine maintenance. The company found difficulty ensuring constant uptime of the Press.
: 4G Power Status Monitoring Alarm Used in Chicken Farm
Infinite Uptime: USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life
The major press line in the company has a circular saw machine which cuts metal rods with precision in predefined lengths for further heating in the furnace. The cut pieces are then fed to the forging line to make automotive components. The length and perpendicularity of the cut pieces are crucial to obtain a good quality forging.It was observed that circular saw failed to maintain the precise length and perpendicularity while cutting the metal rods leading to heavy rejections. This was a serious concern and routine preventive maintenance was unable to overcome it.
Endian: Endian Technology Helps to Support Hera Group to Provide Utilities & Services
Hera is now among the nation’s largest multi-utilities, born in 2002 out of the aggregation of 11 municipal companies operating in Emilia-Romagna, Italy. The first corporation of its kind nationwide, Hera worsks mainly in the environment (waste management), water (aquaduct, sewage and purification) and energy (electricity, gas distribution and sales, energy services) sectors. Other services offered include public lighting and telecommunications. Its range of activities undergoes continuous and constant development, and meet the needs of 4.4 million citizens in over 350 municipalities in Emilia-Romagna, Friuli-Venezia Giulia, Marche, Tuscany and Veneto. Right at the technological heart of HERA is HERAtech, the company that manages the work requested by customers for all network services managed by the Hera Group and also handles the design and construction of plants and networks in addition to highly specialised technical activities, such as plant remote control, the technical call centre that manages Emergency Services and the Analysis Laboratories for drinking water, wastewater and waste.The project by Endian for Hera is developed in cooperation with the Fluids Remote Control Division and its main goals are to fully manage the suppliers’ access to plants and devices, and to punctually monitor the network distributed over the regions covered by the service. Control activity takes action in multiple data centers, the places where all critical infrastructure is housed, and it’s all about authorizing access to suppliers and scanning all connections to detect any possible unauthorized devices or intrusions. 
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