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    Asset Performance Management

May 18, 2021

Four ways asset OEMs, owners & operators can remove roadblocks to delivering intelligence

Four ways asset OEMs, owners and operators can remove roadblocks to delivering intelligence

This and the last year has been eventful for all sectors, but the pandemic has been particularly devastating for the manufacturing sector, which relies on the delicate balancing of supply chains to work effectively. As one of the first industries to adopt robotics, automation, and IoT, the sector has a long history of technological advancement. Manufacturers have access to an enormous amount of data. 

But less than 11% of the data is used to drive business decisions.

IDC  survey found several impediments to companies extracting value from their data. 

The fundamental one is the lack of integration of the technology infrastructure. For instance, although the growth of IoT devices at the edge of manufacturers’ data networks has been rapid, these devices are disconnected from manufacturers’ headquarters system. Data collection points are dispersed and uncoordinated, making it hard to use data to achieve desired business outcomes such as increasing throughput. Furthermore, this still leaves Information and Operations leaders driving siloed decision making.

Deriving intelligence from data is another roadblock. Manufacturing lags behind other sectors in terms of multi-cloud and hybrid cloud adoption, and the sector also has a lower likelihood of having a central data centre. As a result, data is either discarded rather than being backed up for long-term storage or stored in long-term storage but never analyzed. Managing the storage of collected data and deriving intelligence out of it in a timely manner to drive business decision making is the second most significant problem, behind making the data available.

Ageing infrastructure is often the cause of the slowdown. For instance, data management may find it challenging to incorporate the latest sensor varieties on various factory machines. Or, the ageing infrastructure may not be capable of handling the volume of connected assets entering the facility. As a result, plants often use ad-hoc processes to link and manage assets in the absence of an underlying infrastructure that enables comprehensive management.

Additionally, a skills shortage exists. Manufacturers are confronted with an ageing workforce and a shortage of qualified workers willing to work on the shop floor. Due to the scarcity of new talent, manufacturers can only invest in upskilling current employees – which is not a bad thing on the surface but is not a long-term plan on its own. If skilled workers are the future of manufacturing, a dearth of sufficient skills is one of the most difficult obstacles to overcome.

Makoro™ alleviates these barriers to adoption.

  1. Makoro™ has an open architecture and can be deployed in any configuration. It can be on a fully managed Makoro™ Cloud (managed by us) or in your infrastructure in a BYOI (Bring your own Infrastructure) model or in any cloud and edge configuration.
  2. Makoro™ can work with a wide variety of assets and IT and OT systems. If the system has data in any form, Makoro™ can tap into that data to demonstrate value. You do not have to “big-bang” upgrade your current assets and/or infrastructure.
  3. Once deployed and connected to your assets and OT and IT systems, Makoro™ continuously delivers intelligence based on your data, so your data is not just stashed away without analysis.
  4. Natural language recommendations from Makoro™ augment your workforce. It can capture tribal knowledge, rapidly onboard new employees and enable them to be productive from day one.

#MakoroAI applies the power of #RecommendationEconomy to #SmartManufacturing, augmenting decisions related to the management of critical assets, so you can manage assets more efficiently with a lower total cost of ownership.

Ignoring the intelligence that your data could provide means passing up opportunities to expand, innovate, and boost your bottom line. Investing in intelligent operations will always have a transformative return on investment, but you need to start somewhere and start soon enough. 

It is time to start collecting data and deriving intelligence. All in a single thread, and not as separate stages of the project. And then repeat this thread as frequently as you can.

Sign up for our 10-day challenge to see how Makoro™ can benefit your business.

May 17, 2021

Take control of your proprietary data

Take control of your proprietary DATA

The current IoT landscape is highly OEM-centric – it is heavily OEM-data-biased and at first services the interests of the equipment manufacturer. The end customers, the asset operators, plant owners, and process owners, have been sharing their operational data with their OEM equipment suppliers in return for insights into asset conditions and improved maintenance. And depending on the strategies deployed by the OEM, the end customers and operators often have valid concerns about the credibility of these insights delivered by the OEMs. And more often than not, it is impossible to get a true understanding of the approaches that led to the insights. (Take the over-simplified example of auto-manufacturer-recommended oil change every 3,000 miles.)

However, the end customers are increasingly demanding improved equipment and process reliability across their whole asset/equipment estate. This estate includes operational assets from multiple OEM providers across the entire set of manufacturing and medical laboratory processes, across multiple geographies, with multiple technologies and wide variations in equipment age. And every organization needs a systematic and coordinated set of activities and practices which sustainably manages all its assets’ performance, risks and expenditures over their life cycles for the purpose of achieving the organizational strategic plan. 

Given these conditions, reliance on OEM recommendations not only leads to fragmented asset management strategies across the estate, but these recommendations have mostly proven to be the least effective for assets with medium to high criticality.

End customers and asset operators require clear and accurate recommendations on process optimization. Unfortunately, many consider this information to be their proprietary data, their playbook, their operational cookbook, and this is confidential to their ecosystem. In addition, many manufacturing or process operations are competitive and thus deferential to their product offering and cost. 

There is a trend in which end-customer business models move to a lower-cost model, with the lower deployed operational resource. However, employed process technology generally is increasing in complexity. 

Makoro™, therefore, recommends and delivers continuous improvement in quality and asset/equipment total through-life cost while maintaining high process availability (OEE) and delivering a reduction in downtime based on the end customers proprietary data from their whole ecosystem while still sharing nominated data with selected OEM providers. 

Makoro™ is a technology for the end-user, the asset operator.

Makoro™, by design, works with multiple and simultaneous data sources, protocols and connected and non-connected devices, legacy operational, and maintenance data. You do not have to have IoT fully deployed with every edge device reporting to get immediate value. 

We sell directly to the asset operators, through process consultants and also to OEMs that recognize any IoT platform must support all the process stakeholders while protecting the intellectual proprietary of the end customer process. 

We also licence our technology via API to extend the capability offering of already deployed  Enterprise Asset Management (EAM), Field Service Management (FSM), Asset Performance Management (APM), Computerized Maintenance Management (CMMS) and Enterprise Resource Planning (ERP) systems. 

Too many people tell you where the problem is, but shy away from recommending solutions. This is where Makoro™shines – we not only pinpoint the problem but also recommend solutions.

Makoro™ lets you take control of the proprietary data you collect from your line and your manufacturing process devices. You decide what you wish to share with the OEMs providing your equipment maintenance.

Sign up for a 10-Day Outcome Challenge to learn more about what Makoro™can do for your business.

 

May 12, 2021

Industry 4.0 – The Data analytics revolution

Industry 4.0 - The Data analytics revolution

Manufacturing is embarking on a data-driven revolution, but as with all transformations, realizing its full potential will take the right actions, both individually and collaboratively. Within a few years, manufacturers will collaborate in hyperconnected value networks where data and analytics technologies will drive competitiveness, new consumer experiences, and societal and environmental impact.

Indeed, data and analytics are critical to realizing the “Factory of the Future” because they allow transparency, prediction, and augmented and autonomous systems.

Already today, leading manufacturers are leveraging data and analytics to meet their performance, sustainability, and resilience goals. The imperative to increase efficiency and productivity is motivated by extreme cost pressures as well as liquidity concerns resulting from market disruptions caused by the COVID-19 pandemic. Many businesses prioritize sustainable operations – 79% have set a net-zero target, according to a recent Boston Consulting Group (BCG) survey of over 1,700 manufacturing executives. Simultaneously, businesses are attempting to create more robust and connected supply chains in order to predict and react more quickly to disruptions.

The majority of businesses are aware that data and analytics are transforming the way they produce products. 81% of survey respondents report having introduced at least one data and analytics use case, and 72 percent report that the value of data and analytics has risen over the last three years.

Despite their lofty goals and compelling value propositions, businesses have yet to realize the full potential from their analytics initiatives. Currently, only 16% of manufacturing executives report that their business has derived value from data and analytics. While the majority of companies have deployed at least some use cases, only 37% have scaled applications outside particular areas of a factory.

One factor is the focus on data. That may sound like an oxymoron, and it is. The holistic purpose of what your business needs is lost when you focus too much on the data and how it should be made available.

Instead, Makoro™ focuses on the value that your data can deliver to your business. Specifically in terms of predictions, insights and recommendations, thereby providing companies with the agility and capacity to foresee. It helps in planning for changes in process efficiency, employee engagement, and asset performance.

This results in a rapid increase in decision-making continuity and transparency.

Leaders who adopt Makoro™ report an increase in operational agility between 21% and 35%.

May 11, 2021

Pandemic & Global Manufacturing Industry

Pandemic & Global Manufacturing Industry

Industry 4.0 is characterized by a connected world. But Covid was a rude awakening – when manufacturers and asset owners/operators discovered the truth about their not-so-nimble operations and not-so-connected supply networks,

Covid intensified market developments that were already underway, although hesitantly.

Globally, we are now seeing a more intense focus on “connected” supply chains. Manufacturers have expanded on the idea of just-in-time production and are now more flexible in their adoption of “agility” in order to respond to market fluctuations, trade policy adjustments, and natural disasters.

Covid has forced manufacturers to reconsider their rigid operations. How do I strengthen the resilience of my supply chain? How will I manage a changing workforce? How do I make the transition from a workforce in which 80 to 90% of employees report to work daily to one that allows for remote work? These are the hard questions manufacturers are challenged with.

Additionally, there is a demographic change in ageing employees and the arrival of a new generation of workers, and manufacturers are attempting to retain the tribal knowledge before it is too late.

Moreover, they are attempting to attract and retain talent by transitioning from analog to digital manufacturing.

What function do artificial intelligence and advanced analytics play in all of this?

Around 15 years ago, the industry asked, “How do we extract more market value from what we’re doing?” Data and networking were instrumental in this initiative. We needed to tie everything together in order to extract the data.

Now we have an abundance of data that we frequently don’t know what to do with, resulting in data paralysis. More than 75-80% of the data that is stashed away is never analyzed.

That is where an artificial intelligence-enabled solution such as Makoro™ comes in.

Manufacturers use Makoro™ to derive insights and recommendations to improve the performance of its products across multiple geographic locations and to fuel newer, servitization-based business models. Owners and operators use Makoro™ to derive predictions, insights. These recommendations are necessary to build intelligent operations and/or manage asset fleets more efficiently.

With Makoro™, recommendations and insights automatically reach the intended workforce personas based on their role and job responsibilities, and become actionable immediately, without the need for data scientists to interpret the results.

This is transformative – data does not travel, and reports and dashboards do not need to be shared. Recommendations/prescriptions travel and automatically become part of your “golden” playbook to build intelligent operations.

Makoro™ builds on Industry 4.0’s networking and data while focusing on augmenting the experience for the Workforce of Tomorrow (WoT). Thereby extending the definition of Industry 4.0 to the workforce and the environment.

Makoro™’s always-on, secure and scalable asset performance solution powered by #AppliedArtificialIntelligence and #PredictiveRecommendations gives you the edge in the fast-paced #Industry40 and drives frontline adoption.

Sign up for the Makoro™ 10-Day Outcome Challenge and see the results yourself.

May 6, 2021

Predictive analytics: Transforming data into Recommendations

Predictive analytics: Transforming data into Recommendations

Predictive analytics technologies are being used to revolutionize manufacturing operations across all sectors. Not only manufacturers but these technologies are also being used by Asset Owners to derive values based on their data instead of relying on specific OEM’s to deliver “proprietary” value. Throughout the pandemic, these technologies have also been assisting Asset Operators in managing the lifecycle of critical assets distributed across several geographic locations.

Historically, assets of various types – from those on factory floors to those in the field – have exclusively relied on calendar-based management. This meant that decisions were taken, work orders were scheduled, and pieces were ordered simply because a calendar said it was time, rather than because they were actively managed to provide value.

Reactive asset management is costing businesses millions of dollars. The magnitude of the actual impact is even unknown to most asset owners and operators.

The other issue is the siloed focus on maximizing the throughput of an asset, rather than a focus on building end-to-end intelligent operations that cut across different OEMs.

Predictive and prescriptive analytics technologies leverage artificial intelligence (AI) and advanced analytics to develop intelligent operations. These technologies allow manufacturers, owners and operators to predict the operational impact to an asset, the line, the floor or to a location. Here is how Makoro™ leverages predictive and prescriptive technologies in building intelligent operations.

Makoro™ Edges connect with assets and devices on the front end and communicate with Makoro™ Hub on the back end. It transmits machine and process data such as flow rate, oil and water temperatures, vibration measurements, and machine operating hours.

After that, this data is combined with data from different operations and business sources. This is accomplished through Makoro™ Bind, the connector’s interface. After that, it is analysed using a combination of market rules and Makoro™ Mind’s predictive, Al-powered algorithms. While Makoro™ predicts a possible issue, it also does a root cause analysis of the issue. Further, it proactively generates maintenance requests, schedules and assigns the requests, and makes duration, fix and parts recommendations. As data flows through the Hub, Makoro™’s continuous intelligence delivers “unexpected” predictions, insights and recommendations.

Makoro™ learns and evolves as customers engage with the recommendations. And gradually establishing a “golden” operations workflow in which asset management actions are data-driven, traceable, and have been validated by the customer’s workforce.

Through deep-domain artificial intelligence, Makoro™ delivers a rapid time-to-value for customers. It results in higher asset uptime, lower cost of operations, lower maintenance costs and higher workforce adoption.

The ability to anticipate is the competitive advantage in the fast-paced #Industry40 adoption and Makoro™’s #PredictiveRecommendations give you that edge.

MakoroTM’s dynamic learning framework brings operations management to the next level, allowing sets of validated guidelines with extremely high validity and trust scores to be repeated across several locations to maximise value. So instead of sharing data as reports and dashboards, they share recommendations/prescriptions.

Makoro™’s Recommendations Dashboard tracks asset performance metrics and correlates them to recommendations. Leaders who have embraced Makoro™ have achieved more than 11% improvement in their operations agility.

To get started with Makoro™, sign up for our 10-Day Outcome Challenge.

April 29, 2021

Pandemic has accelerated Industry 4.0

Pandemic has accelerated Industry 4.0

Manufacturers are looking to digitize their activities to meet the demands of the pandemic. The aim is to create a single operating mechanism that spans all available resources on a global scale.

This necessitates consistent structures and standardization, which must be facilitated by emerging technology, agile processes, and data access. It is essential to provide global insights into plant performance combined with business background from enterprise systems.

The greater the amount and the variety of data that learning systems can ingest, the more accurate they become. Digital processes and the capacity to process vast amounts of data are essential components of digital transformation.

A key element of adoption for digital transformation initiatives is value demonstration.

A large percentage of pilots rot in the “Pilot Purgatory” because they do not demonstrate a clear business value.  Makoro™’s dashboard provides a continuous value demonstration of recommendations on specific business outcomes related to assets, maintenance, and workforce. These are quantified values that also act as incentives to continuous asset and process improvement.

Another impediment is workforce adoption.

Deployment of new tools often is too technology-focused. It does not put business capabilities in the hands of the existing operations workforce, the real catalysts who leverage their domain and process knowledge to derive value from these tools. Makoro™ is created for the operations workforce – for operators, maintenance engineers, floor managers, and operations executives. Makoro™ gives recommendations that are seamlessly integrated into their regular task workflows, making them easy to adopt.

We internally say that “Makoro™ solves the issues on the production line that keeps operators up at 8 o’clock on a Friday evening.” Do you really want to call the data scientists at that time to interpret data and drive decision-making? That’s where the natural language recommendations really make their mark.

A third barrier is the high cost of a scalable solution.

It is one thing to experiment with analytics – ingest data from a few machines, run experimental algorithms, and derive value (which is also a necessary step in the lifecycle) but building a scalable solution that works for thousands of assets and hundreds of devices per asset, and supports hundreds of workers across multiple locations needs well-thought-out vision, risk mitigation strategies, and investment plans. Makoro™’s Automated Operations and Continuous Intelligence scales up and down in a frictionless manner across devices, edges, and hybrid clouds to deliver the scalability that businesses need.

We should aim higher, but implementations must start smaller in scale, with an eye on delivering maximum impact. The rollout should be line-by-line and site-by-site, which mitigates risk and delivers value at each stage.

Want to know how Makoro™ can drive adoption, scale, and value in your business? Sign up for a demo.

April 28, 2021

Artificial Intelligence in conventional manufacturing

Artificial Intelligence in conventional Manufacturing

During these times of social and economic distance, the incorporation of Artificial Intelligence into conventional manufacturing, supply chain, and quality management is already proving to be a game-changer across verticals.

AI is not only the trigger, but it is also the wheels. One of the growth drivers in manufacturing, with growing competition and declining margins, is to reduce downtime and improve asset efficiency. However, current asset performance management products and solutions are flawed. As they only offer data views in many shapes and forms without actually recommending solutions.

As a result, asset management is costly, arbitrary, unreliable, and inefficient.

When it comes to managing asset performance, more than 78 percent of our customers tell us that data alone is insufficient. And as the volume and complexity of data increases, it is impossible to dig through data to make the best decisions. There is no transparency in the decision-making process. There is also no validation in terms of acceptance of the decision and its impact on the business outcomes.

Makoro™’s innovative fusion of digital performance twin, artificial intelligence, and recommendations engine extends asset performance beyond reports and dashboards. It delivers real-time recommendations that demonstrate value to business continuously.

Makoro™’s always-on, stable, and scalable asset performance solution is driven by #AppliedArtificialIntelligence and #PredictiveRecommendations. It gives you a competitive advantage in the fast-paced #Industry40 while lowering downtime and maintenance costs.

Schedule a demo to see how we do it.

April 27, 2021

Moving towards Smarter Manufacturing

Moving Towards Smart Manufacturing

The term “Industry 4.0” is often used interchangeably with “Smart Manufacturing.” Despite widespread public confusion and initial business reservations about Industry 4.0, the benefits appear to be very promising. It is expected that over the next five years, an AI system will be able to run computers autonomously.

Additionally, AI benefits businesses by improving operating efficiency. It can further shorten time to market and reduce factory safety incidents. By connecting business data end-to-end, from supply chains to manufacturing, delivery, and use, AI will alert employees to both possible challenges and opportunities.

The first step in Implementing Smart Manufacturing in real scenarios is to collect data from a variety of structured and unstructured sources. It could be from IoT and IIoT systems, HMIs, PLCs, ERP, and CRM systems, as well as manual data records. Integrating data on raw materials, processing, manufacturing, shipping, distribution, and transportation all the way down to the customer level adds increasing value across the entire manufacturing supply chain.

But data collection and aggregation is the first step. The real value is realized by what businesses do with the data. Some go down the path of data visualization to understand data better. But advanced AI systems like #MakoroAI aggregate, correlate, and analyze this data in order to make recommendations that directly impact business outcomes and drive workforce adoption.

Makoro™’s always-on, secure and scalable asset performance solution.  It is powered by #AppliedArtificialIntelligence and #PredictiveRecommendations gives you the edge in the fast paced #Industry40. Thereby reducing the downtime and maintenance costs.

Sign up for the Makoro™ 10-Day Outcome Challenge and see the results yourself.

April 23, 2021

Connected Asset Management

Asset management IIOT

The transformation from linear plant setups to dynamic and interconnected systems is one of the greatest challenges for manufacturing today.

The Industrial Internet of Things (IIoT) is accelerating the pace of change around connecting machines, yet less than 30% of manufacturers have extensively adopted Industry 4.0 technologies.

Unfortunately, current asset management tools do not recommend solutions, they simply show views of data from assets, maintenance, and operations.

And that data is not enough to drive asset performance.

You need to look beyond data so you can deliver a faster value for your business.

Makoro™ takes asset performance beyond data, reports, and dashboards. It correlates and analyzes data from machines, and enterprise, and operations systems and recommends solutions to improve asset performance and lower maintenance costs, and drive workforce adoption.

See what Makoro™ can do for your business – schedule a demo.

April 22, 2021

Upskilling workforce for Industry 4.0

Upskilling work force for Industry 4.0

Despite the fact that continuously updated skills training is a well-recognized facet of the digital transformation, many industry observers see the current situation as dire. This issue is exacerbated by a wave of retirements on the one hand, and a lack of enthusiasm for manufacturing among young people on the other.

Moreover, educational programs aimed at helping new employees acquire the skills they need to enter the manufacturing field are not always as effective in addressing the need for the current workforce to continually update its skills, as digital transformation often brings rapid alterations to prevailing work processes.

Fortunately, much of the same technology facilitating Industrial Internet of Things data interchange can also be used to foster digital knowledge transfer by enabling workers to access unified databases of training materials and other content from any location.

Recommendations from Makoro™ extend beyond asset performance and operations and maintenance to the operations and maintenance workforce.

Additionally, through its #DynamicLearning capabilities, #MakoroAI helps you capture the #TribalKnowledge from your experienced and retiring workforce, which is then used to guide the younger workers entering the workforce. This facilitates worker onboarding, increases worker productivity, and drives #WorkforceEngagement.

To find out how the workforce of tomorrow – #WoT – can leverage the augmentation capabilities of Makoro™ to excel in their job responsibilities, schedule a demo today.