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Asset Performance & Reliability
Integrated Solutions

Asset Performance & Reliability

Keep critical assets running - identify issues early, act confidently, and turn reactive fixes into planned work.

When uptime matters, you need a straightforward way to monitor assets conditions, detect patterns before failures occur, and seamlessly move from detection to work and parts. Start with 2-3 high-impact assets, validate the process within weeks, then scale at your teams pace.

What you’ll get on this page

  • A staged approach you can run with existing systems
  • Clear KPIs
  • Short Use Cases with links to OpreX™ Integrated Solutions pages
Keep critical assets running - identify issues early, act confidently, and turn reactive fixes into planned work.

 

Why Yokogawa

  • One connected flow from sensing conditions to diagnosis and maintenance execution
  • Hybrid diagnostics that combine rule-based and model-based insights under process constraints
  • Stepwise rollout that raises reliability indicators and reduces unplanned downtime

 

Overview

  • Challenge
    Fragmented data and after-the-fact maintenance obscure early warning signs, turning small anomalies into unplanned downtime and quality loss.
  • Approach
    Create a single, connected experience:continuous condition visibility -> hybrid diagnostics (rules + models) -> seamless work and parts flow through to completion.
  • Outcomes
    Improved MTBF, fewer and shorter stoppages, more consistent maintenance effort, healthier spare parts inventory.
  • Primary KPIs
    MTBF (Mean Time Between Failures), MTTR (Mean Time to Repair), planned maintenance ratio, unplanned downtime, first-time-fix rate, spare parts stock-out rate.

We describe methods and typical goals. Actual outcomes vary by site conditions, data quality, and operating constraints.

Details

Challenges

 

Do any of these sound familiar in your operations?

 

Foundational asset protection & lifecycle management

Foundational asset protection & lifecycle management

Limited visibility into renewal plans and asset status hinders confident investment decisions.

Real-time equipment monitoring & failure diagnosis

Real-time equipment monitoring & failure diagnosis

Dependence on time-based maintenance, isolated systems, and subjective diagnostics.

Managing equipment parts & inventory

Managing equipment parts & inventory

Without clear visibility into stock locations and conditions, executing real-time replenishment is challenging.

 

How Yokogawa helps

 

Practical ways to address these challenges with your team

 

Prioritize & govern the asset base
 

Prioritize & govern the asset base

  • Establish asset-protection standards
  • Introduce lifecycle management practices
  • Make renewal/ROI planning transparent
Monitor what matters—then diagnose consistently

Monitor what matters—then diagnose consistently

  • Implement real-time monitoring and integrated analysis
  • Start with rules and thresholds, add predictive methods after actions are defined
  • Digitize maintenance workflows
Connect event → work → parts
 

Connect event → work → parts

  • Improve visibility with real-time parts tracking
  • Forecast critical spares
  • Integrate supply-side links

 

Use Case

 

[Case 1] Unified asset operations to prioritize and govern the asset base

When alerts, work, and compliance data are fragmented, small signals turn into downtime. Bring them into one timely view, set clear ownership, and prioritize by operational risk so teams act earlier and sustain compliance.

Team achieves
  • A single, relevant view of asset health
  • Earlier, context-rich triage and actions
  • Work prioritized by risk and readiness
[Case1] Unified asset operations to prioritize and govern the asset base

 

[Case 2] Continuous monitoring: rules first, predictive second

Predictive methods miss when actions are undefined. Start with rules/thresholds that trigger clear work, then add predictive layers to widen the early-warning window and shorten alert-to-work time.

Team achieves
  • Fewer false alarms and clearer next steps
  • Shorter lead time from alert to work order
  • Improved reliability indicators (e.g., MTBF directionally)
[Case2] Continuous monitoring: rules first, predictive second

 

[Case 3] Robotics for inspection and fast degradation diagnosis

Manual rounds vary and stretch resources; early signs go unseen. Standardize routine observation with robotics, log anomalies with context, and route targeted checks to raise first-time-fix while reducing exposure.

Team achieves
  • Consistent observation quality across routes
  • Earlier detection of subtle degradations
  • Lower field time in risky areas
[Case3] Robotics for inspection and fast degradation diagnosis

 

[Case 4] Drone inspection for linear & rotating assets

Height, heat, and distance create blind spots and hazards. Remote inspection surfaces defects earlier and turns ad-hoc fixes into planned interventions.

Team achieves
  • Earlier defect detection on hard-to-reach assets
  • More planned maintenance windows
  • IDocumented evidence for better decisions
[Case4] Drone inspection for linear & rotating assets

 

Solution Pick Up

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