The Advantages of Predictive Maintenance

The Advantages of Predictive Maintenance

, August 31, 2020

What options do organizations have if they want to improve their maintenance performance? Traditionally, companies implement a break/fix method, but why not consider a more smart and proactive method? By using the available information from various assets and combining these to create new actionable insights, we can set up a condition-based approach. Using automated processes and intelligence, you can focus on the right-on-time action. This predictive maintenance strategy allows you to make great improvements. Yokogawa can support you in adding significant value in terms of efficiency, integrity, safety, and costs.

A Brand New Integrated Asset Management Service is on its Way!

Predictive Maintenance Dashboard

Don’t blink – Soon we’re launching a brand new integrated asset management service for all your assets including PCs, controllers, cybersecurity, and IIoT, creating extra added value for end-users. Starting small, this new solution will show initial gains with more to be obtained in future rollout and developments. By providing asset performance compliancy and security insights via one single dashboard, this new game-changing platform aims to be vendor-independent, enabling your plant to become even more (cost) efficient by gaining more insights into data and integrity to act upon. Various routine-based maintenance activities are often proved to be unnecessary and can be replaced with more precise condition-based interventions. Everything is about to change. Step up your game in predictive maintenance and improve the overall productivity of your production process and human resources to reduce plant downtime.

Minimize Plant Shutdown Risks

How can you prove that the manual intervention of an engineer or operator on an unhealthy valve, lead to a plant shutdown? When is it necessary to perform a shutdown, due to loss of visuals, or the risk of being vulnerable that might lead to a cyberattack? It is always a combination of several mistakes. Based on statistics, it is proven that the increase in manual interventions leads to a plant shutdown. In a typical plant, 5% of the annual production is lost because of unscheduled shutdowns and start-up delays. That being said, there is room for improvement. While only a few solutions provide a ‘single pane of glass’ to manage your asset, everything is about to change. Yokogawa’s new solution makes maintenance more efficient and offers you the possibility to do integrity checks efficiently, resulting in fewer risks that leads to shutdowns and unsafe situations.

Benefit 1 from practice: 90% Reduction in Annual Valve Overhauls

In a turnaround at a plant, many production valves were detached from the production lines and sent back to the manufacturer/supplier for internal inspection and overhaul. In many cases, the condition of the valves was still good enough to proceed with, at least, for another production season. Based on condition-based maintenance-data, the annual valve overhaul scope can be reduced up to 90%. A leakage analysis based on historical data will be performed upfront. Additionally, a valve signature is created from the valve friction data. This data supports the maintenance organization to decide whether a valve needs internal inspection and overhaul, instead of only taking preventive actions such as replacing the valve, leading to high costs.

Benefit 2 from practice: Integration of Alarm Insights into daily Work Processes

In the case of another plant, alarms from field equipment are followed up when necessary. Two dedicated engineers – with skills in field instrumentation and process control – are responsible for the follow-up of those alerts and assess based on the last 24 hours. This is based on the integrated alert dashboard of the PRM servers. All individual alerts are then further examined depending on their priority to prevent device and production errors. By early detection of device failures, unexpected production failures are regularly prevented. Mitigation measures can be taken in time, before the production unit trips due to a device malfunction. On a critical production asset with high production demands, it can save up to multi-million euros in deferment costs.

Predictive Maintenance View

Curious about our game-changing Predictive Maintenance Solution?

Get ready – a better asset management service awaits for better predictive maintenance. Stay tuned for our upcoming big announcement regarding our new maintenance solution. Interested? Register here to be the first to get informed about our upcoming update. If you have any further questions, please get in touch with us via your sales representative or +31(0)88 464 1000 /


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