Challenge
Shift from calendar-based to condition-based maintenance
In the manufacturing industry, the traditional calendar-based maintenance approach has limitations. Technicians manually inspect machines and collect data like temperature changes, air pressure, and oil quality at scheduled intervals. However, this method has drawbacks:
- Machines may operate suboptimally until the next scheduled maintenance, leading to inefficiencies.
- Technicians spend time inspecting machines that are already in good working order due to the fixed calendar schedule.
- Machines can experience breakdowns between inspections without real-time monitoring.
Servi Group, Norway's largest supplier of hydraulic equipment, aimed to streamline machine monitoring by leveraging their domain expertise, smart sensors, and cloud technology. Their objective was to help manufacturers reduce downtime, optimize maintenance work, and minimize energy consumption.
To achieve their goals, Servi needed a robust industrial data platform that could extract and integrate industrial data from various sources and present actionable insights.
Solution
Servi leveraged Cognite Data Fusion®, the AI-powered Industrial DataOps Platform, to develop their solution. Here's how it empowered Servi:
- Real-time and historical machine data access: Users could monitor machine performance, observe trends, and make informed decisions.
- Condition monitoring and alerts: Cognite Data Fusion enabled Servi’s solution to automatically monitor machine conditions and send out notifications via email or text message when a predefined thresholds were exceeded.
- Automated reporting and tailored recommendations: Reports were generated automatically, accompanied by personalized recommendations for performance improvement.
In addition to machine data, Cognite Data Fusion’s open extractor ecosystem enabled Servi to connect external data sources such as electricity prices, weather forecasts, traffic, documents, or nonphysical measurements.
One example is energy use. The solution Servi built on top of Cognite Data Fusion could calculate energy consumption per equipment over a specific time period, and leverage Cognite Data Fusion’s hybrid AI model to generate optimization recommendations that balanced energy efficiency with production requirements.
Cognite Data Fusion provided instant access to trustworthy and contextualized data, making it easy for Servi to develop, operationalize, and scale their solution.
Impact
By digitizing and automating repetitive tasks, Servi's solution empowered equipment manufacturers and asset owners to optimize production and reduce waste. With real-time visibility into machine performance, asset owners could adopt a more efficient maintenance approach based on equipment condition.
By deploying Cognite Data Fusion® as their Industrial DataOps foundation, Servi realized significant value, this included, but not limited to, estimated reductions in downtime by 30-50%, maintenance costs by 10-40%, and energy use and emissions by 10-20%.
"With real-time monitoring and our cutting-edge expertise in hydraulics, electrical systems, and automation, you can bring your machine fleet into Industry 4.0--and be fully equipped for a digital future."
Morten Brøvig Thomassen, CTO, Servi Group
