fluke connect condition based maintenance

FLUKE CONNECT CONDITION BASED MAINTENANCEAccelerating issue detection, analysis and resolution

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VALUE OF CONDITION-BASED MAINTENANCEMaintenance managers need to maximize facility productivity, make the best use of their workforce, and optimize the lifespan of expensive equipment.

Condition Based Maintenance (CBM) is how they do it.

Standard returns on CBM

Return on investment 10xReduction in maintenance costs 25 % to 30 %Elimination of breakdowns 70 % to 75 %Reduction in downtime 35 % to 45 %Increase in production 20 % to 25 %

Maintenance allocation, US industry*

At Fluke, our goal is to make it possible for any team to collect the predictive data they need to implement condition-based maintenance.

Perc

enta

ge

60

50

40

30

20

10

0

Reactive Predictive Preventive

1991 2008 2015 Recommended allocation

*Source: Reliability and Maintainability Center, UTK, 2015

By collecting key-indicator data on critical equipment, maintenance managers can build a real-time picture of an asset’s condition and order repairs as-needed. With the right data, managers can prevent failure and decrease the frequency of preventive rounds.

Source: US DOE Operations & Maintenance Best Practices guide, 2010.

“Maximum returns come when 60 % of effort is spent addressing problems identified by predictive inspections and data. 75 % of manufacturers never achieve that.”

However, most facilities aren’t seeing the returns. What would it take to close the gap?

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WHY ARE FACILITIES LEAVING MONEY ON THE TABLE?The desire is there. Reliability is second only to safety in importance to plant managers, and the reliability engineer is one of the fastest growing job titles in manufacturing maintenance.*

Top five obstacles to implementing CBM 1. No time to do things differently and cultural resistance to change 2. Not enough people trained in predictive inspection and analysis 3. IT and retrofit challenges limit automated monitoring solutions 4. Don’t have the metrics to demonstrate the business value 5. Silo’d teams and data

If it was easy, plants would have implemented CBM data collection a long time ago. The reality is that the various software platforms, sensors, controls and assets underpin-ning older plants are difficult to upgrade. They were never designed to be integrated, they’re vulnerable to security issues and the embedded intelligence at the device level is limited.

Old habits die hard Paper is still the most widely used tool to collect and manage data.** Why is that a problem?• Trust. Handwritten data is so prone to errors that it’s hard to draw conclusions from it.• Decision making. Paper log files can’t be accessed remotely or collectively and the data

points are hard to aggregate.

Paper and Excel can’t deliver the scale and efficiency required by modern enterprise. Within three years, 60 % of plants expect automatic data capture to have changed the way their staff operates.**

Common barriers to integrated CBM

65 %

64 %

53 %

38 %

24 %

19 %

15 %

Lack of interoperability Difficult, costly SW integration

Security concerns Hackable sensors on production assets

Value unclear Uncertain ROI from sensor installation

Legacy equipment No connectivity or embedded sensors

Technology immaturity Big data analytics don’t exist

Privacy concerns competitive intelligence

Data analysis Lack of skilled workers

Source: World Economic Forum Industrial Internet Survey, 2014

**ARC Advisory Group survey of plant maintenance, engineering and management professionals.

**Source: Plant Services Peredictive Maintenance Survey 2015

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THE ANSWER: A PRACTICAL CBM SOLUTION WITH QUICK ROITo get past these hurdles, Fluke has paired its trusted hardware with state of the art software to create an easy-to-use, secure CBM system. No IT hurdles, no retro-fits and no specialized labor required: No barriers.

The Fluke system is highly modular, allowing managers to adopt inspection and monitor-ing technologies according to highest need and at whatever scale makes sense. Our Fluke Connect SaaS software platform is the lynch pin, collecting both single-point and stream-ing data.

See the difference connected tools and data can make.Watch now ››

Handheld tools

Portable sensors

Power monitoring

Software

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FLUKE’S CONDITION-BASED MAINTENANCE SYSTEMFluke Connect streamlines data-entry workflows for technicians, provides asset analysis and increases relevance of data for managerial decision workflows

SaaS software aggregates the data streams, pooling electronically-collected inspection data with live-stream monitoring and historical records. When alerts or analysis identify an issue, the asset management and work order features keep all actions and measure-ments looped into the same records and communication flow and reports can be filed instantly from the field.

FLUKE CONNECT® CLOUD

GATEWAY

VOLTAGE SENSOR

CURRENT SENSOR

TEMPERATURE SENSOR

ASSET MANAGEMENTWORK ORDER MANAGEMENTANALYTICS

AND REPORTS

FLUKE CONNECT® WIRELESS TEST TOOLS FLUKE CONDITION MONITORING 3-PHASE POWER MONITOR

MANAGER WORKFLOWCMMS

TECHNICIAN WORKFLOWCONDITION BASED MAINTENANCETHIS SOLUTION FROM FLUKE AUTOMATES DATA-ENTRY AND PROVIDES RELEVANT DATA FOR ASSET ANALYSIS AND MANAGERIAL DECISION MAKING.The system utilizes Bluetooth Low Energy (BLE) and point to point wireless to transfer data, using type 2 encryption from the gateway to the cloud and from the cloud to cli-ents, as well as AWS security at the cloud itself.

“Keep it simple, practical and realistic–any [CBM] technology solution has to make sense to technicians as well as management. It has to be something that can become a daily habit and part of culture”

-Klaus M. Blache, Ph.D., MBA, CPE, RMIC. Director, Reliability & Maintainability Center, UTK

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WHAT’S DIFFERENT ABOUT THE FLUKE APPROACHEasier, safer, faster and better maintenance

#1 One system start to finish From baseline to inspect or monitor, analyze, correct, and track completion

#2 Easy to start Get started with 1 tool, 1 sensor and 1 license

#3 Easy to use Straight forward data entry for technicians; logical dashboard for managers

#4 Scalable Add tools, sensors and licenses as needed

#5 Easy to analyze Vibration and infrared data, side by side

#6 No IT Out of the box self-guiding setup, no retrofit or custom programming

#7 Safety Using wireless tools increases the distance between technicians and dangerous equipment

Install here Monitor here

Immediate success “We have more than 100,000 pieces of equipment and the reliability team can only assess so many.

We’ve never been able to have maintenance techs collect data for us, until now. It had to be easy and quick.”

-Supervisor, Reliability Centered Maintenance, North American auto manufacturer

See the difference that Fluke condition monitoring can make.Watch now ››

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INCREASING OPERATIONAL EFFECTIVENESSAsset failures and workflow inefficiencies add up. Start tracking and the value of prevention becomes clear.

“Products [like Fluke Connect] that are quick and easy to install and provide simple-to-determine ROI metrics should appeal to manufacturers.”

-Christian Renaud, Research Directorof 451 Research’s Internet of Things practice. 451 Research is focused on the business of enterprise IT innovation within emerging technology segments and provides timely insight to end user, service provider, vendor and investor organizations worldwide.

Avoidable costs per plant

7-8 un-monitored critical assets per plant

x

$20-100K replacement cost

+

Avg 1 hour/day spent tracing cause of failures between

un-networked assets

$2,000

$1,500

$1,000

$500

$0Operations

optimizationPredictive

maintenance

Potential 10-40% cost savings

Cost benefit

$500

$400

$300

$200

$100

$0Operations

optimizationImproved equipment

maintenance

3-5 % productivity gain; 5-10 % of equipment costs and maintenance

Productivity benefit

Maintenance stakeholders care about:• Downtime • Throughput• Total cost of ownership

Delivering quick wins that matter to your organization is the best way to build support from all sides for continuous improvement.

Potential benefit to factories($ billion annually)

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Start building your system todayconnect.fluke.com844-427-2269

SUMMARYFluke Connect Condition Based Maintenance pairs trusted hardware with a robust, secure SaaS platform with no IT hurdles: the quick and easy recipe for maximizing uptime and maintenance productivity.

Five reasons to adopt Fluke Connect Condition Based Maintenance1. Start from where you are2. Demonstrate the ROI of CBM with accurate electronic data3. Build toward future productivity requirements4. Optimize labor and lifetime equipment performance 5. Machine-agnostic solution crosses all equipment, network and facility types.

©2016 Fluke Corporation. Specifications subject to change without notice. 10/2016 600508a-en

Modification of this document is not permitted without written permission from Fluke Corporation.

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