When any condition measurement goes into alarm, Smart Reliability IIoT Condition Monitoring serves up the problem, the cause, and the remedy in real time through the PTC ThingWorx platform. An Allied Reliability Subject Matter Expert can follow up to prescribe preventive solutions.

Smart Reliability gives your maintenance and engineering team the maximum opportunity to take actions that prevent costly downtime. 

Smart Reliability IIoT Condition Monitoring delivers three major benefits at a lower total cost than previous approaches to condition monitoring for high value equipment assets:

a) Increased equipment uptime through improved machinery reliability
b) Reduced maintenance and operating costs
c) Increased overall operational productivity

Condition monitoring services, such as vibration analysis, are a key part of implementing predictive or proactive maintenance. For companies embarking on an "Industry 4.0" or Smart Factory initiative, IIoT Condition Monitoring offers one of the largest returns on investment (ROI) of any aspect of digital transformation. Allied Reliability offers the industry-leading IIoT Condition Monitoring solution, Smart Reliability, through the PTC ThingWorx platform.

HOW DOES SMART RELIABILITY IIOT CONDITION MONITORING WORK?

Smart Reliability uses Allied's Failure Modes Catalog  to enable a data-driven, failure mode approach to reliability and condition monitoring. This library provides a vast database of machinery component failure modes. Built on over 4,000 man-years of condition monitoring experience, our knowledge base of failure modes is unequalled in the industry. When combined with low-cost wireless sensors that detect defects, this database provides the foundation for Smart Reliability. By combining Allied's failure mode library with the ThingWorx platform, Smart Reliability users can quickly build a predictive and prescriptive maintenance application within an established industrial IIoT platform. This platform approach enables faster ROI, building on the fact that predictive and prescriptive maintenance applications are the leading category of ROI for digital transformation efforts.

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Smart Reliability I-P-F Curve

Smart Reliability IIoT Condition Monitoring and Reliability Engineering solutions are built on the PTC ThingWorx platform. ThingWorx, Smart Reliability, and the ThingWorx Analytics platform provide the analysis needed to drive displays for operations, maintenance and reliability engineering personnel. The open ThingWorx platform adds connectivity to the Computerized Maintenance Management System (CMMS), where additional maintenance data is stored. The CMMS includes time and cost to repair as well as operator rounds data (QPM) and is the manager of work requests and work orders.

When guided by Allied's domain expertise in the form of implementation services, digital reliability projects can yield benefits in a matter of weeks.

ADVANTAGES OF HAVING SMART RELIABILITY BUILT ON THE THINGWORX PLATFORM

In addition to the benefits and uniqueness of the Smart Reliability application, having it built on the ThingWorx platform is also unique compared to Allied's competitors. The ThingWorx application provides connectivity to process data, to enterprise data, and to the CMMS. The ThingWorx application offers augmented reality to improve workers' "first time fix" rate, to improve quality of maintenance, and to reduce time to repair. Allied can leverage this augmented reality, working with our clients to implement digital work procedures that incorporate smart safety glasses and similar heads up displays. Lastly, the ThingWorx platform includes a machine learning engine to help our clients and Allied's condition monitoring personnel find new relationships in the process and condition monitoring data. For example, Allied is already working to release a "virtual" sensor that predicts future oil sample analysis measures. The virtual sensor is based on Allied's historical data of oil analysis and the ThingWorx machine learning engine.

WHAT MAKES UP SMART RELIABILITY IIOT CONDITION MONITORING?

Smart Reliability consists of:
  • A failure mode tree to identify machine components, parts, failure modes, and failure reasons.
  • Sensors or human inspections that can be performed to catch a defect that leads to failure.
  • Statistics on failure mode coverage and sensor coverage for the machine.
  • A confidence factor indicating how well the chosen sensors cover the failure modes they are assigned to cover (not all vibration, oil, motor current, temperature and other sensors are created equal).
  • The trajectory a defect takes toward causing failure, and identification of where the applied sensors can detect the defects.
  • The possible failure modes that are in play with the equipment.
  • Trend charts for the measured parameters associated with the equipment/machine.

Smart Reliability Component Tree

WHAT DOES IT TAKE TO GET STARTED WITH SMART RELIABILITY?

Two key advantages of Smart Reliability on the ThingWorx platform are fast deployment and rapid time-to-value. Using our Smart Start pilot program, you will have immediate access to the database of failure modes analysis. All system webpages are prebuilt, along with the mapping of sensors to failure modes and the alert values. Because it leverages ThingWorx, Smart Reliability is ready to go effectively out of the box.

KEY BENEFITS OF USING SMART RELIABILITY:

Smart Reliability is an IIoT condition-based predictive or proactive maintenance solution. Condition-based predictive maintenance has proven less expensive and more effective than preventive maintenance programs, with the following financial impacts:
  1. Increased machine output
  2. Increased uptime yielding higher capacity for the plant
  3. Lower maintenance and operational costs due to the longer planning horizon that drives down cost of maintenance
  4. Fewer visits to the machines for personnel due to more online monitoring, allowing for fewer safety issues
Allied has a 20+ year track record of success using our domain expertise to help clients in their reliability journey, capturing financial impact along the way. Our reliability improvement work covers virtually every aspect of the people, processes, and technologies used in manufacturing and process plant environments. IIoT-enabled technologies, including Smart Reliability, replace traditional technologies and data collection methods with faster, lower cost, and more efficient processes. Smart Reliability is just one way that Allied Reliability helps our clients detect defects early enough to improve uptime and productivity while lowering their maintenance and operational costs. IIoT Condition Monitoring helps manufacturers achieve their productivity and financial goals faster, given they have the people and processes in place to manage the proactive maintenance Smart Reliability will prescribe.

SMART START

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Rapid Deployment Trial of Smart Reliability IIoT Condition Monitoring

Smart Start offers fast, low-risk introduction to Smart Reliability IIoT Condition Monitoring. The Smart Start process includes a planning workshop followed by rapid deployment of a plug-and-play package of 20 sensors and 2 gateways with cellular cards.

Why Smart Start?

For many manufacturing companies, IIoT Condition Monitoring is the starting point of their digital transformation to the "Smart Factory."  Smart Start is the ideal way to begin the journey:

  • No upfront cost
  • No internal IT infrastructure requirements
  • Less than 2 weeks to operational status 

Within a matter of days, Smart Reliability sensors are feeding our proprietary machine learning rules and algorithms with high-quality triaxial vibration and temperature data.  Visualizations are presented in a high-quality mashup leveraging the "best-of-breed" ThingModels.

Smart Reliability Image View

Smart Reliability Sensor Options

When any measurement goes into alarm mode, the system will show the problem, the cause, and the remedy from the Smart Reliability enabled ThingModel.  An Allied Subject Matter Expert will follow-up with you to discuss prescriptive action.

Two-step Smart Start Program

We begin with the Smart Start Workshop. In this workshop we will:

  • Establish leadership alignment
  • Develop a project charter 
  • Define the business case 
  • Select the targeted assets for Smart Start 

Deployment and Startup: Following the workshop, we will immediately walkdown, provision and commission 20 Smart Reliability sensors and 2 gateways with cellular cards. 

Upon successful implementation of Smart Start, expansion packs of 10 sensors with 1 gateway are available to scale up the pilot program.  Smart Start is fully upgradeable to the Smart Reliability IIoT Condition Monitoring Platform at any time – in the cloud, on the edge, or on premise.

Request a Smart Start consultation

Smart Reliability White Paper Overview