Planning (APS)

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Prognostics Plan To Beat Unplanned Outages

08-Feb-2016
Prognostics Plan To Beat Unplanned Outages
Unplanned equipment outage drains time and resource at every company – now one solution provider is suggesting that one reason for such an outage can be a maintenance schedule not best adapted to the equipment. Swiss-based Cassantec say that maintenance is often carried out either too early, too late or after a malfunction has already occurred. Consequently, an outage of individual components often causes a standstill of the entire production. Spare parts may need to be ordered. It can take days before the equipment can be returned to full working order, sometimes resulting in substantial economic damage to the company. “The enormous costs which can be the result of such a standstill can be avoided“, says Moritz von Plate, CEO of the Cassantec AG.

In order to avoid such equipment outages the company offers condition-based prognoses. Cassantec Prognostics forecasts time windows in which equipment malfunctions can occur. The company compiles an individual report for the respective piece of equipment in order to determine when and with what probability a particular type of malfunction is to be expected. This enables the operator to identify the time frame for necessary maintenance. In cooperation with the customer Cassantec determines what the most critical potential malfunctions are. The Zurich-based outfit say there is no need for a malfunction history as their system can also forecast malfunctions that have not yet occurred in the equipment at hand.

To compile the report the company uses a unique combination of mathematics. This way future condition trends, risk profiles of malfunctions and the remaining useful life (RUL) of equipment is determined. The prognosis is updated in periodical intervals by using historical and current condition data as well as process data such as temperature, vibration and lubricant analyses. The results of the analysis are presented in a decision orientated format such that the schedule for necessary maintenance interventions can be optimised. Cassantec offers the prognostic report on a subscription basis (Software as a Service – SaaS) and in certain cases it is possible to acquire a software licence.

The asset operator profits from such a prognostic solution in a number of areas. By changing from reactive, or as the case may be, preventive maintenance cycles, to condition based maintenance, costs can be cut.