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1,191 case studies
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Minimizing downtime by engaging IBM Services – Technology Support
Minimizing downtime by engaging IBM Services – Technology Support
Minimizing downtime by engaging IBM Services – Technology Support
IBM
Simplifying maintenanceHana Financial Group had recently consolidated the infrastructure and resources of 11 of its affiliates at a local IBM data centre. However, the business was left with more than 100 service and maintenance contracts that needed to be reviewed and renewed periodically. These contracts also involved 100 separate bills that Hana Financial Group had to manage. Managing such a large volume of bills was cumbersome and sometimes resulted in late payments. The group wanted to improve efficiency and eliminate the overhead involved with managing these contracts by consolidating its heterogeneous IT systems and data storage systems under more consistent processes.


Industries: Other
Functions: Maintenance
CN Helped Pine Printshop with a Responsive and Top-notch E-commerce Portal
Capital Numbers Infotech Pvt Ltd.
To digitally expand their business, Pine Printshop was looking for a catalog-based site that would help people buy ready-made products (e.g. apparels, board pins, stickers, etc.) and even allow customers to personalize their own t-shirts, caps, and hoodies.


Industries: Other
Functions: Product Development
4G Power Status Monitoring Alarm Used in Chicken Farm
King Pigeon Communication Co.,Limited
养鸡场使用的4G电源状态监视警报基于4G无线网络通信,用于养鸡场以监控电源故障,缺相,温度,湿度并现场驱动频闪警报器。


Gas Pipeline Improves Station Efficiency and Drives Revenue with DataRPM
Gas Pipeline Improves Station Efficiency and Drives Revenue with DataRPM
Gas Pipeline Improves Station Efficiency and Drives Revenue with DataRPM
DataRPM
In the capital-intensive oil and gas industry, businesses rely heavily on expensive assets that are deployed in harsh environmental conditions. From a drilling point in the sea to an intermediate station in the desert, the dynamic environmental conditions at each point along the long line affect the performance of the assets deployed along the line. The systems that are used to support these mission-critical assets must also be highly reliable, responsive and secure.One company that operated a long-distance gas pipeline encountered numerous challenges with the overall efficiency of its pipeline, ranging from sub-optimal usage to wastage of natural resources. Even with the optimal equipment and setup, the wide array of variables in operating conditions combined with the sheer distance covered by the pipeline made running the business difficult.In this case, there were 22 injection stations along the length of the pipeline, operating under very disparate conditions with different efficiencies. This made it difficult to identify the interdependent effectiveness of these injection stations, despite having a large data set on various parameters at each injection substation. Even a single instance of failure could cost the company hundreds of thousands of dollars in lost revenue as well as any additional costs for repairs that had to be made.The company was spending $5 million per mile of pipeline annually in corrective maintenance. Along with this, the loss of revenue due to the undelivered material was estimated at $250 million. With energy prices dropping, the loss in revenue directly reduced the bottom line of the company. With the clock ticking and revenue dipping, building a perfect efficiency improvement model became a top priority.


Industries: Energy
Functions: Maintenance
Large-scale Implementation of Wireless Predictive Maintenance
Large-scale Implementation of Wireless Predictive Maintenance
Large-scale Implementation of Wireless Predictive Maintenance
Petasense
In 2016, Arizona Public Service (APS) decided to enter the California ISO (CAISO) market, which allows them to sell power into the California market. One of their key assets was Sundance, a 420 MW unmanned peaker plant located 50 miles outside Phoenix. The entry into the CA energy market meant that starts tripled and run hours doubled almost immediately at the plant. They started looking for wireless Predictive Maintenance (PdM) system because the running hours were typically when no one was on site, which meant that traditional forms of PdM were not possible. Typically, a specialist would collect vibration and other condition data on equipment, but it had to be taken during operation, and it was difficult to get personnel out to the site.“Reliability was foremost on our minds,” commented Don Lamontagne, Supervisor of Equipment Reliability Engineering. “We faced huge loss of potential revenue, as well as fines if we weren’t able to generate power when it’s needed.”


Industries: Energy
Functions: Maintenance
Automatic monitoring of acoustic emission saves catastrophic failure
Automatic monitoring of acoustic emission saves catastrophic failure
Automatic monitoring of acoustic emission saves catastrophic failure
Nanoprecise Sci Corp
Traditional measurement tools are ineffective when it comes to slowly rotating equipment. There are faults like Bearing Failure, Ring Plugging, Gear Tooth Crack and many more which can lead to the shutdown of machines. 1 minute of downtime cost the company $10. RingPluggingis a very common issue which Pinnacle Pellet was facing very frequently due to diverse feed quality into the machines. Product ring plugging can be detected as sound levels increase in specific roller bearings.


Industries: Other
Functions: Maintenance
Predictive Maintenance For Connected Vehicles
Predictive Maintenance For Connected Vehicles
Predictive Maintenance For Connected Vehicles
Luxoft
By 2025, Transport for London will have to meet strict emission-control regulations. This means buying and operating new fleets of hybrid or fully electric, zero-emission buses. As a consequence, many Original Equipment Manufacturers (OEMs) and operators will have to develop new technologies to help them get-to-market fast enough to meet demand.


Industries: Automotive
Functions: Maintenance
Temperature and humidity monitoring solution
King Pigeon Communication Co.,Limited
温湿度监控解决方案血液站属于医疗卫生机构,负责收集和储存血液并将血液提供给临床或血液制品生产单位。因此,血液站中心的血液非常宝贵。温度和湿度环境对于确保血液在血液站中的安全非常重要。


Industries: Chemicals
Functions: Other
Identifying Vane Failure From Combustion Turbine Data
Identifying Vane Failure From Combustion Turbine Data
Identifying Vane Failure From Combustion Turbine Data
SparkCognition
In late 2015, a deployed combustion turbine experienced a row two vane failure, which caused massive secondary damage to the compressor, resulting in nearly two months of downtime and up to $30M in repairs costs and lost opportunity. This failure, though rare, is representative of typical catastrophic events that are very difficult to catch. Though the onsite plant operations team had been monitoring the asset, this specific failure mode was previously unknown and very nuanced, and existing alarms did not have enough information for SMEs to properly diagnose it in time.The OEM decided to evaluate SparkCognition’s predictive analytics solution, SparkPredict®, with the following objectives:1. Demonstrate the ability to detect and distinguish operational and anomalous online steady-state conditions based on blind data provided from the turbine.2. Provide additional insights about the key contributing factors to the underlying anomalies.3. Provide a UI that interfaces to live streaming data from the asset.


Industries: Energy
Functions: Maintenance
Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox
Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox
Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox
Infinite Uptime
The calendar machine run by a motor has a shaft mounted gearbox connected to the roller. This gearbox allows maximum paper load and feeds the paper with reduced speed to the roller. In spite of scheduled preventive maintenance, it was observed that gearbox used to fail frequently. The rise in vibrations leading to the eventual failure of gearbox adversely affected the quality of the paper. Monitoring the gearbox was thus vital and critical.


Industries: Other
Functions: Maintenance
Condition Based Maintenance - “Indispensable” Sensor Technology
Condition Based Maintenance - “Indispensable” Sensor Technology
Condition Based Maintenance - “Indispensable” Sensor Technology
METTLER TOLEDO
At the corporation’s Mizushima plant near Okayama, pH measurement during the neutralization of strong acids is closely monitored. For this important measurement Tsutomu Ishikawa and Naoto Ogura, engineers at the plant’s Instrumentation and Engineering Department were not satisfied with the performance of the pH sensors they were using.For this reason, sensors were regularly exchanged at the plant to minimize the chance of failure in the process. But the operation cost was high and Mr. Ishikawa and Mr. Ogura needed a better solution. Specifically, they required to know in advance when a pH sensor would need to be cleaned, calibrated or replaced: “We wanted to grasp how deposits forming on the pH sensors would affect the timing of sensor maintenance and exchange.”


Industries: Chemicals
Functions: Maintenance
Improving Manufacturing Processes with Essilor
Improving Manufacturing Processes with Essilor
Improving Manufacturing Processes with Essilor
Dataiku
Seeing that one of their goals is to find ways to better answer consumer and business needs, the Global Engineering (GE) team was facing the challenge of improving processes and performance of the surfacing machines to significantly improve their production by using the increasing volume of data."We wanted a data science platform that would allow us to solve our business use cases very quickly. Thanks to Dataiku and its collaborative platform, which is agile and flexible, data science has become the norm and is now used more widely within our organization and around the world," said Cédric Sileo, Data Science Leader at Global Engineering, Essilor.


Industries: Other
Functions: Maintenance
Anaren Microwave Implements their manufacturing CMMS
Anaren Microwave Implements their manufacturing CMMS
Anaren Microwave Implements their manufacturing CMMS
Fiix Software
Like many organizations, Anaren had a homegrown work order application that had basic asset management functionality. “It was menu driven, so quite cumbersome,” explained Bill, “reporting was limited and it still relied heavily on paper transactions and records. We looked at our business needs going forward and decided this was one area that could be modernized.” On launching the Manufacturing CMMS project, Bill, the business analyst of the company identified three major areas for improvement:1. Improve efficiency by eliminating paper.2. Improve the control of preventive maintenance. 3. Improve inventory management.


Industries: Equipment & Machinery
Functions: Discrete ManufacturingMaintenance
Predictive maintenance of medical devices based on years of experience and advan
Predictive maintenance of medical devices based on years of experience and advan
Predictive maintenance of medical devices based on years of experience and advan
Hitachi
Failure prediction by human operators requires advanced skills, and the limited number of experts cannot monitor all MRI systems around the world. "Corrective maintenance" for repairs after breakdowns has also become inevitable.


Industries: Other
Functions: Maintenance
Wireless Predictive Maintenance to Fix a Dated Walk-Around Program
Wireless Predictive Maintenance to Fix a Dated Walk-Around Program
Wireless Predictive Maintenance to Fix a Dated Walk-Around Program
Petasense
C&W Services was using a manual condition monitoring program at one of its leading life sciences’ client up until last year. At best, data was collected manually every 30 days, even on the most critical machines, using a handheld data logger. After the data collection, all of the data analysis had to be outsourced to a third party for analysis. This approach has several limitations:1. Unplanned Downtime2. Shortage of Manpower3. Safety and Access to Machines4. Inconsistent Readings Collected by Manual Processes


Industries: Other
Functions: Maintenance
Detecting Cavitation And High Vane Pass Frequency For Pumps
Detecting Cavitation And High Vane Pass Frequency For Pumps
Detecting Cavitation And High Vane Pass Frequency For Pumps
Nanoprecise Sci Corp
The Condensate Cooling Water (CCW) pump, one of the critical pumps in maintaining steadystate operations, is a horizontal vane pump operating at up to 1650 m3/hr with a discharge pressure of 9 MPa (62 psi) at 986 rpm. Each day this pump is offline costs the plant $250,000 in lost revenue and each failure costs tens of thousands of dollars to execute an unplanned repair. Thus, Larsen & Toubro (L&T) really needed a predictive maintenance solution to detect faults at an early stage and provide a reliable prediction of Remaining Useful Life (RUL)


Industries: Energy
Functions: Maintenance
Sentilo Terrassa (Smart City Open Data)
Sentilo Terrassa (Smart City Open Data)
Sentilo Terrassa (Smart City Open Data)
Opentrends Inc.
Terrassa City was in need to ameliorate their information and communication flow between municipal managers, in order to generate new services to its citizens. The City Council was missing an internal management platform of the municipal services, and wanted to initiate a Smart City strategy to solve this issue, along with bringing value to all parties involved (municipality, businesses, citizens and other local entities). 


Industries: Other
Functions: Other
Mondi Implements Statistics-Based Health Monitoring and Predictive Maintenance
Mondi Implements Statistics-Based Health Monitoring and Predictive Maintenance
Mondi Implements Statistics-Based Health Monitoring and Predictive Maintenance
MathWorks
The extrusion and other machines at Mondi’s plant are large and complex, measuring up to 50 meters long and 15 meters high. Each machine is controlled by up to five programmable logic controllers (PLCs), which log temperature, pressure, velocity, and other performance parameters from the machine’s sensors. Each machine records 300–400 parameter values every minute, generating 7 gigabytes of data daily.Mondi faced several challenges in using this data for predictive maintenance. First, the plant personnel had limited experience with statistical analysis and machine learning. They needed to evaluate a variety of machine learning approaches to identify which produced the most accurate results for their data. They also needed to develop an application that presented the results clearly and immediately to machine operators. Lastly, they needed to package this application for continuous use in a production environment.


Industries: Other
Functions: Discrete Manufacturing
Smart Ccondition Monitoring Saves USD 30 Thousand In A Forging Unit
Smart Ccondition Monitoring Saves USD 30 Thousand In A Forging Unit
Smart Ccondition Monitoring Saves USD 30 Thousand In A Forging Unit
Infinite Uptime
The 1000 Ton main forging press had a 75 HP motor and fed a trimming machine. The motor pulley combination was situated on top of the Press at a height of about 15 feet thereby reducing its access for routine maintenance. The company found difficulty ensuring constant uptime of the Press.


Industries: Other
Functions: Maintenance
Saving millions by avoiding expensive downtime for hydraulic fracturing equipmen
Saving millions by avoiding expensive downtime for hydraulic fracturing equipmen
Saving millions by avoiding expensive downtime for hydraulic fracturing equipmen
Luxoft
To extract shale oil and gas, specialized equipment is used to fracture rock via a process called hydraulic fracturing (or “fracking”). To do this efficiently, users must know when their equipment needs maintenance. If the equipment stops working while in the well, millions of dollars are lost due to downtime and logistics. Additionally, our client, a major oilfield equipment company, needed a way to make their product stand out. They wanted to accomplish this by providing oil and gas software solutions but had no idea on how to develop and deliver software in the cloud.


Industries: Energy
Functions: Maintenance
USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life
USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life
USD 1.2 Million Saved On A Forging Press Line By Predicting Cutter Life
Infinite Uptime
The major press line in the company has a circular saw machine which cuts metal rods with precision in predefined lengths for further heating in the furnace. The cut pieces are then fed to the forging line to make automotive components. The length and perpendicularity of the cut pieces are crucial to obtain a good quality forging.It was observed that circular saw failed to maintain the precise length and perpendicularity while cutting the metal rods leading to heavy rejections. This was a serious concern and routine preventive maintenance was unable to overcome it.


Industries: Other
Functions: Maintenance