Innovation in maintenance - Accenture

Let’s Talk Operations
“Innovation in maintenance”
20 March 2014

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Most industries are embracing Digital as core component of their
growth strategies
Copyright © 2014 Accenture All rights reserved.

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There is an estimated $14.4 Trillion of value at stake between now
and 2022 for ALL companies to realize through Digital Businesses
Value at stake as a result of disruption
$14.4
Trillion
2013 2022
This is the combination of
increased revenues and lower
costs that is created or will
migrate among companies and
industries from 2013 to 2022,
due to Digital Technologies.
Customer experience (addition of
more customers)
Asset utilization (reduced costs)
Employee productivity (greater labor
efficiencies)
Supply chain and logistics (eliminating
waste)
Innovation (reduced time to market)
$3.7
$2.5
$2.5
$2.7
$3.0
Industries will be disrupted to
the amount of:
Source: Cisco; Accenture Analysis

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Digital Plant Vision
36% of the advantage of
the best in class
refineries is due to
effective maintenance
(Solomon)
Best in class have 40%
less operating cost (non
maintenance) than
industry average
(Solomon)
5% of annual production is
lost for unplanned asset
downtime and 80% of the
losses are preventable and
can be avoided as result
there is a 4% production
increase potential. (ARC)
1% increase in asset
reliability reduce 10% of
maintenance costs
(Solomon)
The next generation of Intelligent Plant solutions will integrate real time information to
deliver insight and foresight in operations performance and enables optimization of
plant operation, availability, costs and safety

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Key technology trends
Cloud
Social media/
Collaboration
Analytics/
Big Data
Data Velocity
“Connected
Everything”
Mobile
Infrastructure, platforms and applications as a service enable new levels
of scalability, flexibility and responsiveness.
Social media and collaboration technologies drive new ways of interaction,
personalization and relationship building within and beyond organizations.
Technologies such as in-memory computing enable real-time decision
making based on analytics.
Analytics and Big Data allow for use of rapidly increasing amount of data
from multiple sources to generate new insights and decision making.
Connected devices and cheap sensors enables new ways of automated
and personal interaction.
Mobile devices impact all areas of business and personal live by
transforming how people interact, consume information and services,
collaborate, and work.

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The Digital Plant is integrating processes and solutions to build,
operate and maintain the plant more efficient and safe
For all the above boxes the market will provide a make or buy alternative offering end to end
services through traditional and new players
Ability to integrate data, applications and processes which have been historically
managed by horizontal silos becomes a key capability for each business willing to take
advantage of the digital revolution in operations

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Accenture Digital Plant solutions for Asset Management helps
companies address asset and operational performance challenges
Services
Capital Projects
Improves portfolio and projects “time to value” and
capital efficiency
Operations Optimization
Optimizes plant and supply chain operations to
increase margins and production performance
Asset Optimization
Optimizes asset performance, balancing cost and risk
and enabling operational efficiency
Commercial Optimization
Optimizes entire value chain for asset-backed
commodity traders
• Operating Model Consulting
• Capital Projects Services Office
• Engineering, Project and Data Services
• Asset Data Management Services
• Operational Excellence Consulting
• Application Services and Digital Solutions
– Operations Management
– Production Supply Chain Optimization
• Remote Operations Managed Services
• Asset Performance Optimization Consulting
– Asset Performance Monitoring and Analytics
– Maintenance Execution
• Remote Maintenance Managed Services
• Trading, Investment and Commercial Optimization
Consulting
• Commodity Trading Managed Services
Area

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Digital Plant Apps

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The Digital Plant will be enabled by technology solutions that are
connected, capable, collaborative and contextual
The “Digital Plant” of the future is:
Connected
Ubiquitous wireless infrastructure supports digital
connectivity of equipment. Sites will be connected to
each other and to remote optimization centers
User Solutions will be:
Collaborative
Connecting people and teams across the plant and
enterprise, bringing together skills to solve problems
and optimise operations
Capable
The plant will be developed with in built digital
predictive capability for process and asset
optimisation.
Contextual
Integrating information at the point of interaction to
bring context and insight to operators and engineers.

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Connected: Plant wide connectivity

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Connected: Leading Mobile Devices by Environment
XCIEL
(I-Pad)
Apple
I-Pad
XCIEL
(I-Pad)
Panasonic
(CF19 –
CF29)
Apple
I-Phone
Samsung
Galaxy
Phone
Getac
(B300)
Motororla
(ET1 pad)
Ecom
(Handy 07
IS Phone)
Intermec
(CK32 -IS)
Getac
(V100)
Apple Macbook
Windows 7
laptop
Intec
(ExPC
Terminal)
Xplore
(iX104C4)
Selections based on:
• Features
• Form Factor
• Ecosystem Support
• Portability
Motorola
Smart phone
(Defy+)
Atex Zone 0 Atex Zone1 Atex Zone2 Ruggedized High St
Class 1 Div 1 Class 1 Div 2
Dofero
(Viz-iCARRY iPad)
Dec2012
Rampage6
(Android)
Intermec
(CK32-IS)
Ecom
Iroc.
(CI70-ex
PDA) Bartec
(MC9090ex)
Mobility options are beginning to change with the introduction of Tablet Devices in
the Ruggedized and Atex Zone 2, Class2 Div II environments

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Capable: New Application Architectures
New technologies provide a more intuitive way to consume immense amount of data
Google-like search Links between content
4D+ planning and analysis Simulation for improved planning

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Capable: Better use of analytics
Dashboards Drill down functionality
Advanced Analytics
& Simulation
 Balanced scorecards based on a clearly
defined set of metrics.
 Insurance that definitions are
consistent across the scorecards and
allow to further analyze the shown
data and drill into details
 Break through the time barrier:
Instead of reviewing what happened,
drive to see what will happen
 Allowance to simulate potential
outcomes and select the optimum
 Drill down on bad actors to identify
root causes in a few clicks
 Integration of information across siloes
Real time data access and reporting facilities provide management information.
Advanced Analytics builds models and scenarios to support operational decisions

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Capable: Digital plant workforce
Smart equipment and digital
control with wireless
capabilities
Plant and fleet remote monitoring and
control centers
Electronic work packages and mobile
wireless
3D plant rendering
The digital
workforce
Using digital technologies to drive performance improvements and resource efficiencies

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Collaborative: Video Collaboration – technical support
The Future:
Individuals can use wireless
infrastructure and video camera
to obtain remote support on
the plant floor.
The Benefits:
• Improving repair
decisions in the field and
avoided costs
• Reduced asset downtime
• More optimal use of
scarce deep experts – 1
to many model
• Enhanced supplier
collaboration
Design type required:
Location
For companies with operations spread across the globe, delays in equipment
maintenance issues or production problems can result in significant costs. Often times
the most skilled engineer is located somewhere other than the plant in need, and
standard practice is to board a plane to go and try to solve the problem.

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Contextual: Augmented Reality for O&M Mobility
Application of Wearable Displays for Maintenance
Source: Accenture Research 2014
O&M relevant Areas of application
 Heavy Equipment Operator: assist in the operation of heavy
equipment (cranes, shovels, and trucks) to improve execution,
accuracy and safe working conditions
 Over the Shoulder Coach: just-in-time training or coaching,
connecting remotely with off-site control center to
 Work Discrepancy Resolution: identify current status of equipment
using red, green, yellow traffic light indicators and to drill down into
contextual information
 Emergency Evacuation Support: to alert personnel of an emergency
situation by providing audible and visual indicators
Description
 Computing devices with displays worn on the body for easy access ,
showing contextually relevant information
 Wearable displays have the potential to support, augment, and
optimize the physical workforce
 Wearable displays will affect every industry:
 Innovative companies must be prepared to rethink their processes to
get the most out of wearable displays
 Gartner forecasts that Google Glass and other “smartglasses” will
help make employees more efficient, ultimately adding more than $1
billion per year to company profits by 2017.
• Improve efficiency
• Reduce non-productive time
• Reduce re-work
• Reduce time to decision
• Reduce exposure
• Reduce travel
• Enhance training experience
• Positive identification
• Reduce mechanical failures
BenefitsWearable Displays Augmented Reality

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Contextual: Update drawings in the field
One of the hardest things to finalize after a project is complete is updating as built
plant infrastructure and equipment drawings (e.g., P&IDs); however this is very
important for compliance management.
Unit Plot Plan
PI&D
The Future:
Update drawings real time in the
field when standing/ inspecting
the assets
The Benefits:
• Close out Management of
Change (MOC) required
documentation more
efficiently
• Reduced compliance issues
• Increased data management
integrity for maintenance
Design type required:
Coverage

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Contextual: Virtual Operations Environment
Characteristics
• Virtual plant environment that enables training and supports work execution -
complementing high-resolution simulators
• Enable early visualization & walk-through prior to construction or MOC
• Validate safety procedures in virtual environments before rolling out the
training
• Train & evaluate response to emergency situations
• Enable distance learning with multiple users accessing the same environment
at the same time
• Promote virtual collaboration
Requires
• 3D CAD designs to import as models
Benefits
• Ability to reinforce Operations procedures and Emergency Response training
in a low cost manner
• Ability to evaluate and improve TA planning
• Ability to assess maintainability before finalizing designs
Virtual environment to simulate complex processes and train people

Innovation in maintenance - Accenture

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