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Closing the gaps


Keeping your physical and digital assets in sync

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Closing the gaps


Keeping your physical and digital assets in sync

ARE THERE REALLY GAPS?

When it comes to asset information, there are many components that make up the whole picture, and depending on your role in relation to those components the gaps could be non-existent or massive on the same piece of equipment.

If you are in engineering you are dealing with the required function of the equipment - the functional physical object - and the information to support that is typically well controlled. It doesn't change frequently, and when it does its off the back of an engineering change that is again typically well controlled.

But if you are in purchasing, construction, or operations & maintenance you are dealing with a specific piece of equipment from a manufacturer that has been selected to fulfil the required function - the materialized physical object. There are a wide range of circumstances that could result in a different make, model, serial number of equipment being installed at any point in time - logistics, schedule, replacement, etc. And this information could, and generally does, change quite frequently.

Most organizations struggle to initially capture the materialized physical object and then keep it in sync with the changes going on in the physical plant. It is common for more than 50% of asset databases to be without materialized asset information. But once you capture the information, changes in the physical plant lead to data corrosion which can typically be in the 1%-2% per month range.

WHY DOES IT MATTER?

If you just knew you had a car, but you didn't know the make & model of that car, how would you go about planning a maintenance regime that was compliant with manufacturer's specifications. And how would you go about purchasing critical spare parts to ensure that maintenance is not going to be delayed waiting for parts?

And if at one time you knew you had a Nissan X-Trail and planned accordingly, only to find when you go to perform the next service that it had been swapped for a Toyota Camry all of your spares purchases and maintenance planning would be worthless.

But that is exactly the situation being faced by clients who are struggling with closing the gaps in their asset information. Without a strategy to keep your materialized physical object information in sync with the changes in the physical plant your supply chain and maintenance strategies are not delivering the value to the organization that they should be.

ORDITAL Helps You Close the Gaps

Name plates attached to equipment are the most trusted source of materialized asset information. So organizations routinely send people out to physically verify that information. However, traditional inspections are notoriously inaccurate and very expensive to conduct, however up till now it was the only option available to organizations.

ORDITAL is changing the landscape with solutions to allow organizations to quickly and reliably capture classified photographs of equipment and turn this into information with measurable quality that closes the asset information gaps and allows organizations to realize the potential of their Enterprise Asset Management solutions.

Dramatic Efficiency IMPROVEMENTS

In a traditional field audit you would have people out in the field writing down data, or keying it into a handheld device. Aside from the significant inaccuracies in this approach, it is very inefficient. The most expensive part of any audit is getting people to stand in front of the asset. These people have often been through training and inductions required to work in hazardous environments and are generally not cheap labour. By having these people stop and write down or key in data - aside from the inherent inaccuracies - typically results in between 75 to 100 assets being audited per day. This gives a very high cost per asset just to stand in front of the asset. By way of example, if we have a fully loaded man hour cost of $150/hour then 75 assets per day is a cost of $16 per asset just to have someone standing in front of it.

Now lets contrast that with the ORDITAL experience where often see in excess of 300 assets per day being audited. This immediately drops the cost to visit each asset to just $4 - a whopping 75% saving in the most expensive part of the audit. It's simple and makes sense - if someone simply needs to take a few photographs then move on to the next asset they can do that a lot quicker than standing there keying in data in the field. Then by utilizing ORDITAL's On-Demand services you can turn this large high resolution photo archive (big data) into quality information with measurable quality.

 

ASSET NAME PLATES

Contains information that was accurate at the time it was attached to the equipment and is the most trusted source of information in an organization.

SUPPLY CHAIN

Critical spare parts and tools are required to be available to support safe and continuous operation of the facility. Strategies to minimize cost and holdings are critical to an organization.

MAINTENANCE

Maintenance plans are developed to ensure that the facility continues to operate safely and reliably at the minimum possible cost to the organization.

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Asset Owners


Allowing your Enterprise Asset Management systems to deliver on their potential savings

Asset Owners


Allowing your Enterprise Asset Management systems to deliver on their potential savings

SAVINGS FROM EAM SYSTEMS

Asset owner / operators spend significant amounts of money implementing Enterprise Asset Management (EAM) systems in order to achieve saving in some or all of these areas:

  • Reduction in maintenance overtime, labor, and contractor costs
  • Reduction in maintenance material costs
  • Reduction in production downtime
  • Reduction in energy costs
  • Reduction in new equipment costs
  • Reduction in purchasing process costs
  • Increase in fleet availability
  • Increase in warranty cost recovery

MANAGING OBSOLESCENCE

Companies that manufacture products change constantly. They might be acquired, cease trading, or acquire other companies themselves. All of this can lead to obsolescence events such as product lines being merged or discontinued, or spare part number changing with new ERP implementations at the merged company.

Operators of equipment need to be aware of these changes as they happen so that contingency plans can be put in place to ensure the safe and continuous operation of the facility.

ORDITAL provides a comprehensive and live manufacturer database that can advise of manufacturer organizational changes in real time, and provides a social network for collaboration with manufacturers on product level status.

 

DATA DRIVES SAVINGS

The starting point to achieving the potential savings from an EAM system implementation is ensuring that the data about your assets in the EAM system (the digital plant) is synchronized with your assets in the physical plant.

EAM systems allow you to build extensive maintenance strategies that define what spares you will purchase and what maintenance you will carry out. But if you don't know the make, model and serial number of the equipment currently installed in the plant then you are strategies are compromised and can actually increase costs with restocking fees and time wastage.

IF YOU CAN'T MEASURE IT, YOU CAN'T MANAGE IT

ORDITAL solutions allow for the rapid collection of large archives of equipment photographs that are classified and catalogued at the time of capture on standard smart phones.

The photo archive is processed to extract reliable information with measurable quality that is used to close the gaps in EAM systems.

The photos tell you what was accurate at the time the equipment left the factory, and where it is installed today. The ORDITAL manufacturer database tells you what is accurate as of today. 

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Contractors


Increasing value from existing activities for you and your clients

Contractors


Increasing value from existing activities for you and your clients

CONTRACTORS

Contractors are engaged by the owner / operators of facilities from time to time to provide specialist expertise on projects required to meet regulatory requirements, or to improve the performance and cost effectiveness of the facility. In almost all cases, a key part of any of these contractor's activities is understanding precisely what is installed in the facility so that they can provide optimum recommendations to their clients.

As part of their role, contractors are commonly sending people to inspect the equipment and take digital photographs of the equipment. These photographs contain a lot of valuable information, however the cost and time required to catalogue and interrogate these photographs is often prohibitive. The end result is that this information is often lost.

ORDITAL provides solutions that allow contractors to cost effectively capture and catalogue classified equipment photographs that can be used to close asset information gaps and provide a valuable reference from on-going work with the asset. It allows contractor organizations to provide their clients with another tangible continuous improvement whilst saving money themselves in the capture and cataloguing of as-built information.

INSPECTORS

Inspection contractors visit equipment and carry out tests to provide independent certification that the equipment remains safe to operate and is compliant with relevant regulations related to the operation of that type of equipment.

A common example of this type of inspection would be those on pressure vessels by classification societies.

SERVICES

Services contractors provide maintenance services on equipment on behalf of the operator. The services contractor may be related to the manufacturer or vendor that provided the equipment, or they may be general purpose maintenance service providers.

The service contractor is under pressure to provide continuous improvement to demonstrate value and retain the ongoing services contract with the operator.

ENGINEERING

Engineering contractors provide services for projects to improve the performance of the existing asset. This might take the form of a shutdown, revamp or expansion. Maintenance engineering may also take place from time to time to improve maintenance performance of the facility.

Understanding exactly what is installed in the facility is often the first step in these improvement projects.

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Manufacturers


Protecting your installed base and expanding into your competitor's territory

Manufacturers


Protecting your installed base and expanding into your competitor's territory

MAXIMIZING REVENUES FROM YOUR INSTALLED BASE

A company's installed customer base is a sales organization's most valuable asset. And companies that produce products for sales are first and foremost sales organizations. It might be stating the obvious, but companies that produce products for sale survive or fail on their ability to sell those products. Plenty of great products fall by the wayside without an adequate avenue to market.

As the sales organization's most valuable asset, the installed base needs to be protected. For most companies this means that they need to ensure that their products are not replaced with a competitor's products (protecting the base), but then work to have your competitor's products replaced with your products in that customer account (expanding into your customer's territory).

However, in a globally distributed business there are often many transactions between the manufacturer and the ultimate end user of the product which can obscure the true status of the base. Without an accurate picture of the base the sales organization is going to struggle to protect that base and expand it.

With so many links in the information handover chain between manufacturer and operator, the chances of the operator getting accurate information about your product, or your local representative (subsidiary or vendor) knowing they have your product in their territory, are remote. Properly classified photographs of the products however can clarify this situation - photographs taken by either the operator or the local representative - can remove the ambiguity.

ORDITAL solutions allow the operator, manufacturer, and local manufacturer's representative to find each other. Once that connection has been established the integrated social network allows this community to engage and allows manufacturers and their local representatives to educate their clients on value added services and new products they have available. This facilitates a move away from traditional selling to social selling.