Ecolibrium Energy provides predictive maintenance system. Predictive maintenance technologies and sensors help in smoother functionality. Visit us for more info on predictive maintenance software.
2. 2
“In our vision to make our factories smarter, SmartSense is a key tool to help us take early
action in managing our power consumption & critical assets such as Motors. In just one plant,
actions from SmartSense predictive insights have led to savings of nearly INR 10 Million”
Snehashish
Plant Manager– Pepsico India
Making Industries Smarter
3. 3
JLL is managing nearly 72 million square feet of real estate in India. In our vision to create the future of
work, we have partnered with Ecolibrium to help generate insights for transitioning from planned
preventive maintenance to data oriented predictive maintenance.
We are helping our clients optimize their maintenance and Energy costs using the powerful insights
provided by SmartSense.
Rajat Malhotra
COO – Integrated Facility Management (West Asia)
Predictive Maintenance for Buildings
4. 4
Empowers Enterprises to Improve their Asset Efficiency with IoT powered
Predictive Analytics
70 %
Reduction in unplanned Downtime
30 %
Reduction in Maintenance Costs
10 %
Improvement in Energy and
Production Efficiency
Eliminate Production losses and increase Life of
Equipment with PowerGenome® Analytics
Eliminate Manual Data collection, and convert Dumb Data (EMS, BMS,
SCADA) into Automated Actionable Insights for Smarter Maintenance and
Energy Optimization
5. 5
SmartSense: A Proven Solution..
700+
Installations Globally over 300+ Organizations
Incubated and Supported by Global Recognitions
Global Climate
Solver AwardMost Innovative Energy Efficiency Product
Energy Management
Best Practices Award– 2016
Lighthouse Activity International
Ashden Award
6. 6
…Across verticals
FMCG
Engineering and Automobiles
Pharmaceutical & Chemical
Government and Utilities
Commercial Buildings and Facilities
Other Manufacturing
Partners
7. 7
PowerGenome® Predictive Analytics
1. Minimal need of sensors reducing
cost and time of implementation by ~
50%
2. Independent of Brand of Equipment
3. Applied to all critical equipment such
as Motors, Compressors, Pumps, Fans,
Chillers, Transformers etc.
Pathbreaking Predictive Maintenance
Algorithms using Energy Signatures for early
detection of faults as compared to other
methods
12000 Sensors
Being Analyzed over 4000
equipment
200 Million
Data Points Analyzed daily over
> 8000 equipment
9. 9
Buildings IndustriesCity
A1: Acquire
Plug n Play Modular and SecureReady Integration
Ready retrofit with > 200 types of sensors and 12 Industry
protocols – Wireless deployment with minimum cabling
Secure Cloud hosted infrastructure with multitenant
capabilities
3rd Party Integration with systems such as SAP,
BMS, IoT Platforms, etc.
10. 10A2: Analyze
Plant Digital Twin
CREATION OF
DIGITAL TWIN
Asset Digital Twin
Create a Digital Twin of
your plant or building to
identify any anomalies
or leakages in Energy or
Production
Customized to sectors
and Processes
Create a Digital Twin of the
critical assets using
proprietary SmartSense
models using its ‘Sensor-
light” approach
Ready Models for Motors,
Chillers, Transformers, Fans,
Boilers, etc.
AI Pipeline:
Convert unstructured data into
contextualized data in real time by
using our unique expert systems and
Machine learning
11. 11
A3: Act
Customize Dashboards for your Industry Needs
Control Assets remotely
Automated Recommendations with Root Cause Analysis
Get automated reporting and custom alerts
Predictive and Anomaly algorithms identify Energy and asset
optimization Opportunities .Alerts in case of impending Asset
failures
Sectoral Dashboards for more than 10 leading verticals with
customized KPIs. Dashboards for CXOs, Plant heads, and Line
manager
Easy customization using ‘widget-maker’ Dashboard
Excel based reporting engine, and Advanced Rules engine alert
builder
Ability to control equipment from dashboard – Also able to
upload production data from App.
13. 13
The SmartSense Journey
#FullStack solution with Hardware and Software
o Ready Integration with any 3rd Party Systems
o Plug n Play Wireless Deployment in days
o Scalable Multi-Tenant Solution
#Low cost Software as a Service (SaaS) Solution
o Modular Analytics with no upfront costs
Enterprise
Dashboards
Enterprise
Insights
Productivity
Insights
Condition
Monitoring
Predictive
Insights
Acquire data to get a Real Time custom dashboard with Automated Reports and Alerts
Track Energy Costs and automatically identify
optimization from Bill or energy sourcing from Exchange
or Renewables
Automated Anomaly detection of idle consumption
of network or process health issues
Integrate Energy data with production data
and identify inefficiencies in Specific
energy in shifts or products
Asset Condition Monitoring and predictive
insights to avoid inefficiencies and downtime
14. 14
SmartSense Impact Stories: A Peek
Enterprise Analytics identifies
Billing and consumption (Load
factor and power factor)
optimization ~ Rs. 4 Lakhs per
month. Demand Optimization
leads to avoided Capex
investment of Rs. 5 Crores
Industries
Buildings &
Commercial
Infrastructure
Asset Insights identify Motor
inefficiencies using predictive algorithms
– Identifies saving opportunities of
nearly 20% in energy consumption. Also
monitors drug storage with temperature
alerts to avoid stock wastage.
Enterprise and Asset insights identify
savings of nearly Rs. 5 crores per
year from demand optimization,
trading feasibility, and chiller
inefficiencies improvement. Expands
scope to cover its tenants
Asset Insights of Chiller helps
perform predictive maintenance–
identifies potential breakdown due to
refrigerant leakage costing more than
Rs. 60 lakhs a year
… and 300 more!
15. 15
Join the SmartSense Journey
SmartSense Services:
a. SmartSense secure Hosting, Dashboard, Reports, Alerts,
analytics as per Applicable Package
b. Remote support and Domain Expert Advisory
c. Link+ Gateway with communication (for India only)
• Meters, Sensors & Convertors (If not present or
Retrofit not possible)
• Installation and 3rd Party Integration (SAP, BMS, etc)
charges
One
Time
Cost
Site Survey Questionnaire to
be filled and discussed
Primary Proposal, Scope
Finalization and Order
Processing
SmartSense Commissioning
and ongoing analytics
SmartSense Costs
3 days Depending on Scope
1- 10 Weeks
Yearly
Subscription
18. 18Develop a Customized Enterprise Dashboard
4. Track Asset performance in
Network View: To see
architecture of all assets in the
facility with energy contributions
and trends
1. Track custom KPI trends on My Dashboard
Widgets based Dashboard – For easy customization of
tracking energy, water, gas, Fuel, production, etc.
3. Monitor distributed facilities
GIS Map View For Centralized
monitoring
2. Automate MIS Reports/ Critical Alerts
Customized SMS/ Email alerts on critical situations as per
site and automated reports as per requirements
19. 19Optimize Energy costs with Billing Insights
1. Monitor Real Time
Energy Costs
• Performance
against Target
• Historical
• Current Month
• Anticipated bill
• Time of Day costs
Analysis
• Demand and Power
Factor Charges Tracking
3. Act on cost saving
opportunities (What if Scenario’s)
• Demand
• Power Factor
• TOD
• Renewable sources mix
• SPV Capacity
2. Identify and Avoid
Penalties due to Demand
Overshoot, Low Power Factor,
etc. with alerts
20. 20Optimize Power Purchase costs with Sourcing Insights
Power
Purchase
Grid
Power
Exchange
Rooftop
Solar
Bilateral
Diesel
Genset
Sourcing the Cheapest Power
1. Monitor Real time cost benefits
from Trading
• Dashboard of 15 min slot
consumption to track overtraded and
under traded units
• Automated Net Benefit Analysis
report daily to track benefits and
losses against Utility charges
3. Act to increase Benefits from
Trading by Optimizing Bid
by up to 20% on exchange using analytics
keeping into account sourcing from various
options
2. Identify Potential Losses and get
Automated Alerts and reports
Alerts on overbidding and underbidding
situations.
21. 21Automated anomaly detection using Network Insights
Anomaly Detection Algorithms using AI
• Unusual Energy Consumption
• Power Health
• Sector Specific Parameters: Temperature,
Pressure, Flow, and other KPIs
Enterprise Insights
22. 22
1. Identify Network
Anomalies
Health
• Voltage & current
Variations
• Power factor issues
• Harmonic Issues
Unusual Energy
Consumption
• Non- working hours
• Non-Working days
• Idle running
2. Track Potential Savings
and get customized
Recommendation
Best Practice identification and
savings if issue brought under control
3. Act on Issues and
maintain activity & Impact
log
Track the complete life cycle of issue
and resolution status
Network Insights Dashboard
23. 23Automate Specific Energy Monitoring with Production Insights
Integrate SmartSense with Production data to track productivity on a live dashboard, and track anomalies to
generate actionable insights
Link+
GPRS/ Wi-fi
Assembly Line Production Sensor / Convertor
Limit Switch/ PLC
Option 4.
Automated Production
Monitoring
Option 2: Mobile App
Smart sense Production Mobile App
ERP
Option 1: SAP Integration
• Production planning module
• Planned maintenance module
Manual Entry
Manual Entry
Option 3:
Manual Production Monitoring
Upload in Excel sheets
Production Insights
24. 24
Production Insights Dashboard on
Track Energy trends for each
product on a real time basis by
integrating SmartSense Energy and
Production data
Track Specific Energy
consumption of producing each product in
each plant - Integrates PP module with
IoT data
Track OEE performance against
targets
Anomaly Detection of
productivity deterioration - Identify
shifts or areas causing issues
26. 26Asset Insights make Predictive Maintenance possible
SmartSense help identify early signs of Asset deterioration - leading to increased uptime, and savings in
Energy and Maintenance costs!
27. 27Prevent Asset breakdown with SmartSense Insights
Early detection of Asset Fault
Track Consumption increase due to impending faults
Asset Insights
Centralized Asset Issue Dashboard
28. 28Protect Motors with SmartSense Predictive Insights
1. Acquire
3. Act
2. Analyse
Automated Identification of Mechanical or
Electrical Issues
• Rotor or Stator Faults
• Bearing faults
• Power Quality issues (THD, Imbalance)
• Loading ( Underload / Overload)
• Any other Anomalies
SmartSense Motor Insights is done using a patented PowerGenome approach using only Electrical
Data for predictive maintenance – eliminating need for vibration or MCSA tests – thus saving upto
50% on motor maintenance costs
Neural network using FDD
29. 29
SmartSense protected Chillers
1. Real Time Tracking
of KPIs
• Running IkW/TR
• Running COP
Chiller Issues
• Refrigerant Leakage
• Condenser or Chilled water Flow Deviation
• Condenser or Evaporator fouling/Scaling
• Compressor Motor health/Efficiency (Fault detection in motor)
• Pumping unit Efficiency including Pump Motor health/Efficiency
• Cooling Tower system health Issues
• AHU Motors Health/Efficiency
3. Act on Automated recommendations to
save Running costs and prevent downtime
2. Unusual Trends identified using Chiller Analytics
Engine
SmartSense Chiller Insights is done using a patented PowerGenome approach using which does not
require expensive flow meters for predictive maintenance – thus making predictive maintenance
possible with minimal data
30. 30
SmartSense protected Transformers
1. Track Transformer
Health KPI’s
(Loading, power quality, Running
losses/ oil temperature and voltage
levels)
• Loss Increase due to connection or internal faults
• Loading Optimization possibility:
• Under/ overloading
• Harmonics/ Phase balance issues
• Power Factor Issues
• Predictive Maintenance of:
• OLTC Defects
• Oil Quality or quantity issues
3. Automated Alerts for Improvement
Opportunities
2. Track Unhealthy patterns in KPI’s
SmartSense Transformer Insights track mechanical issues such as OLTC problems using a patented
PowerGenome Approach using which does not require extra sensors – thus making predictive
maintenance possible with minimal data and costs
34. 34
Industry 4.0 has arrived..
…and here to stay
Big Data
Energy
Analytics
Predictive
Maintenance
Enhanced
Productivity
Connected
Machines
20 billion + connected devices by 2020.
As per a Mckinsey Survey - 82% of Business and technology decision makers feel adopting IoT analytics improves
business process efficiency, and allows for a stronger position in the marketplace
The Organizations who ‘opt-out’ of this Industrial revolution face an uncertain Future’
35. 35
.. Producing opportunities to optimize Productivity
Production
Capacity
(Hrs)
Actual
Production
(Hrs)
OEE LossCapacity
Utilization
Loss
Lack of
Demand
Unplanned
Downtime
Planned
Downtime
Optimize with
PdM
43%
business and technology decision makers
lack of IoT technology will affect product
quality and customer satisfaction
USD 7mn
Potential savings per company year due to
predictive Intelligence – saves 30min per
technician per day
IoT and Predictive Intelligence can help plug in
the gaps in productivity and dramatically
increase OEE Scores of the Company
36. 36
.. and reduce Energy and Maintenance costs with predictive insights
20x
Cost of sudden repairs as compared to
scheduled maintenance
~ USD 24,000
Per minute wastage in running a large
defective machine
50
36
21
13
50
20
40
60
80
100
120
Year 1 Year 2 Year 3 Year 4 Year 5
Reactive maintenance Preventive maintenance Predictive maintenance
50 %
10 %
15 %
45 %
50% Reduction in Costs Energy and Maintenance costs
contribute to nearly 50% of Running
costs in Enterprises - Transition from
Reactive to predictive Maintenance
can help reduce nearly 50% of OpEx
EnergyandMaintenanceCosts
$$
Year 1 Year 2 Year 4Year 3 Year 5
