AI-Enabled Process Intelligence for Plant Maintenance

Struggling with excessive unplanned downtime due to reactive plant maintenance and short-term fixes, our customer sought to learn more about AI-enabled process intelligence as a sustainable, long-term solution. We deployed Ashling‘s Plant Maintenance Solution to continuously monitor plant floor machines and operators to predict and plan machine maintenance.

Results at a Glance

Anyone involved in making or shipping physical products understands the pain of downtime. Whether planned or unplanned, downtime disrupts manufacturing processes, causing significant issues when equipment is not operational. Disruptions can ripple through the entire value chain, leading to increased costs, revenue leakage, and negatively impacting both customer and supplier experiences. Ultimately resulting in higher downtime, elevated expenses, and reduced overall productivity.

According to a study published by the National Institute of Standards and Technology, 15-70% of a manufacturer’s overall cost is associated with maintenance of their plants. Manufacturing-based organizations are sitting on valuable insights with the advancement of machine-level IoT and digital process automation. However, bringing this information together into a command center to allow for proactive scheduling and predictability has long been a challenge. Ashling’s Maintenance Control Center provides a continuous command centre to explore opportunities of improvement and address the top use cases that have challenged manufacturing operations for a long time.

Ashling's Maintenance Control Center, powered by Celonis, provides event and value-based monitoring of plant floor machine operations. It delivers critical alerts and status updates on breakdowns and operator activities while proactively notifying technicians of high-risk scenarios. Ensuring efficient machine operation monitoring, this application also alerts for breakdowns, and timely notifications for technicians about potential high-risk scenarios involving break-fix activities.

Our solution transforms plant operations from reactive issue management to proactive, data-driven solutions.

1. Enhanced predictability in maintenance planning allows for more efficient capacity management.
2. Utilize plant floor data to quickly address malfunctioning machines and train operators, resulting in a superior product
3. Proactive machine and operator management leads to higher productivity rates per unit.
4. Enhanced capacity and quality lead to higher production output with fewer defects and reduced backlog.
   
   

The Maintenance Activation Control Center provides a platform and application layer to provide insights across machines, operators, and break fix activities. Built on Celonis, the platform consists of databases, connectors, and dashboards to streamline your manufacturing operations. Easy to manage by a business leader and build on enteprise-grade technology that satisfies your IT team, this solution provides a foundation for AI and predictive modeling.

Technology Used