PlantOS

PRODUCTION RELIABILITY

At Infinite Uptime, we understand that contextualising insights from multiple equipment processes – user persona wise in realtime – makes or mars the decisions taken from the Plant floor to the Corporates. PlantOS unlocks Production Reliability by driving Equipment & Process Reliability outcomes, across all real-time decisions made by:
Frank CFO
Chad COO
Peter Production Manager
Disha Digital Transformation Manager
Mike Maintenance Manager
Emaad Energy Manager

Production Reliability

Delivered User Validated Outcomes

77,104* additional production hours
up to 2% Energy reduction per unit

Reduced Energy
Consumption

Reduced Process
Variability

Higher Yield
and Throughput

Consistent and
Predictable Quality

PlantOS

Manufacturing
Intelligence

No Unplanned
Downtime

Lower
Maintenance Costs

Increased
Equipment Life

Faster
Equipment Payback

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PlantOS Manufacturing Intelligence

A single platform with 5 functional modules, combining Equipment Reliability and Process Reliability, to baseline, monitor, analyse and prescribe recommendations, and assist interventions for optimizing critical, rotating, auxiliary, static equipment and processes.

Production
Reliability

Unlocked by

PlantOS

Manufacturing
Intelligence

Sense &
Ingest

Outcome based selection, installation and ingestion of equipment and process data from parameter to plant level.

Administer
& Configure

Enables users to perform administrative tasks and access various Infinite Uptime applications within the PlantOS platform

  • Platform Support
  • Device Configurator
  • Admin Service

Diagnose & Analyze

Employs artificial intelligence to identify equipment faults & process variance.

  • Equipment Diagnostic Toolbox
  • Process Analytics Toolbox

Act & Resolve

Empowers process and reliability teams with actionable insights to maximize availability and optimize efficiency & quality.

  • Digital Reporting System
  • Control Room View
  • Equipment Reliability View
  • Production Reliability View

Collaborate & Integrate

Features an AI driven applications for answering plant, equipment, and process related queries and provides API documentation for seamless integration with third party applications.

  • Nity Ai
  • Nity Mobile App
  • API Documentation
  • Integration Module

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By leveraging the power of Device Agnostic Sensing, Collaborative AI, and Human intelligence & Domain Expertise, PlantOS helps make your production reliable by driving outcomes like 99.99% equipment and process availability and up to 2% energy reduction per unit produced.

Plant Os

Manufacturing
Intelligence

Human Intelligence &
Domain Expertise

Industry
Specific
Consultant

24x7 Remote
Monitoring

Field Service team
for adaption &
engagement

PlantOS

Manufacturing
Intelligence

Collaborative AI

Prescriptive
insight

Conversational
AI

Widest Equipment
Coverage

Role based
acess control

99.99% AI
Accuracy

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Equipment Reliability

Equipment Reliability, a critical component of overall Production Reliability, refers to the capability of your machinery and systems to operate efficiently, without succumbing to unexpected failures or prolonged downtime. The implications of Equipment Reliability extend far beyond the shop floor, directly influencing your ability to meet production targets and maintain stringent quality standards.

What is the path to achieve Equipment Reliability?

PlantOS offers a one-stop real-time view of all critical, rotating, auxiliary, and static equipment and the process around them. Enabling easy identification of potential faults, assessing their severity, and providing actionable recommendations to optimize performance.

Equipment Reliability

Failure
Begins Here

Vibration Monitoring
Detects Problem Early

Vibration ( piezo
electric / MEMS )

Vibration Monitoring
Detects Problems Early

Oil
Analysis

Thermography

Non - Destructive
Testing

Audible
Noise

Energy Performance
Data

Hot to
Touch

Collaborative AI

Equipment
Fails Here

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With Equipment Reliability, you gain a clear, real-time picture of your equipment’s baseline, enabling you to make informed decisions to benchmark & optimize your equipment’s performance.
At Infinite Uptime, we have developed a comprehensive framework to guide you on the path to achieving Equipment Reliability:

What is Equipment Reliability?

and the path to achieve it?

Failure Modes
& Effects Analysis

Risk Based
Inspection

Asset Management
Strategy

Critical / Rotating Equipment

Online Diagnostics
& Recommendation

Turbine & Turbo
Machine Monitoring

Online Oil
Analysis

Auxiliary / Static Equipment

Manual Periodic Diagnostics
and Recommendation

Thermography
Non-Destructive Testing

Manual Oil
Analysis

RCFA / Defect Elimination
( proactive maintenance )

CMMS (task & Schedule
management with workforce
task assignment)

Lube
Management

Process
Induced Faults

Re-FMEA and
E-scheduling

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  • Failure Modes & Effects Analysis (FMEA): Failure Modes and Effects Analysis (FMEA) is a structured approach used to identify potential failure modes in a system, process, design, or service, and then assess the risk associated with those failures. The goal is to prioritize issues based on their severity, likelihood, and ability to detect them, so you can address the most critical problems first.
  • Risk-Based Inspection (RBI): Risk-Based Inspection (RBI) is a powerful maintenance planning method used mostly in industries like oil & gas, chemical, power generation, and manufacturing. It helps prioritize inspection efforts based on risk, rather than doing inspections on a fixed calendar schedule.
  • Asset Management Strategy: It’s a strategic plan that aligns asset management activities with the organization’s overall business goals, aiming to maximize value, reduce risk, and optimize cost over the asset’s life cycle.
  • CRITICAL & ROTATING EQUIPMENT
    • Online Diagnostics and Recommendations: Our AI-powered system continuously monitors your critical and rotating equipment, providing real-time diagnostics and recommendations for optimal performance.
    • Turbine and Turbo Machine Monitoring: PlantOS offers specialized monitoring capabilities for turbines and turbo machines, ensuring their reliability and efficiency.
    • Online Oil Analysis: We integrate online oil analysis to detect and prevent lubrication-related issues, extending the life of your equipment.
  • AUXILIARY / STATIC EQUIPMENT
    • Manual Periodic Diagnostics and Recommendations: PlantOS covers auxiliary and static equipment, providing periodic diagnostics and recommendations for comprehensive reliability.
    • Thermography and Non-Destructive Testing: Our system incorporates thermography and non-destructive testing techniques to identify potential issues without disrupting your operations.
    • Periodic Oil Analysis: Regular oil analysis helps optimize lubrication and prevent premature wear and tear of your equipment.
  • Root Cause Failure Analysis (RCFA) and Defect Elimination: We conduct thorough RCFAs to identify the root causes of failures and implement proactive maintenance measures to eliminate defects.
  • Lube Management: PlantOS helps you establish an effective lubrication management program, ensuring the right lubrication at the right time for your equipment.
  • Computerized Maintenance Management System (CMMS): Our system integrates with your CMMS to streamline task and schedule management, ensuring efficient execution of maintenance activities.
  • Re-FMEA and Re-scheduling: We continuously revisit and update FMEAs and maintenance schedules based on the latest data and insights, fostering a culture of continuous improvement.
  • Process Induced Faults: Contextualize process parameter and equipment condition to proactively manage and avoid process induced faults
By prioritizing Equipment Reliability, you unlock a host of benefits i.e. reduced maintenance costs, increased availability & operational efficiency, enhanced safety, and improved overall equipment effectiveness (OEE).

Process Reliability

Process Reliability is the heartbeat of your operation – ensuring that your production flows smoothly, without bottlenecks or breakdowns. Process Reliability, another critical component of Production Reliability focuses on minimizing process variations, eliminating waste, and optimizing production flow to achieve consistent product quality and meet production targets.

What is the path to achieve

Process Reliability?

Deploy Data
Integration Unit

Integrate all
Process Data

Built all key
metrics & KPIs that
contribute to
process costs

Improve the
actual costs per KPI

Process Variance
Analysis & Improvement

Future Scenario
Simulation & Planning

Data Driven
Production Planning

Quality
Prediction

Yield
Optimization

Energy Management
& Optimization

Batch
Genealogy

Process
Monitoring

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  • Process Monitoring: Real-time tracking of machine and process parameters to ensure operational efficiency and detect anomalies early.
  • Batch Genealogy: Tracing and recording the production history of each batch for quality assurance, traceability, and regulatory compliance.
  • Energy Management and Optimization: Monitoring and analysing energy usage patterns to reduce waste, improve efficiency, and support sustainability initiatives.
  • Yield Optimization: Leveraging data analytics and machine learning to maximize output quality and quantity by minimizing process variability and waste.
  • Quality Prediction: Predicting product quality outcomes to enable proactive adjustments.
  • Data-Driven Production Planning: Utilizing real-time and historical data for dynamic and optimized production scheduling and resource allocation.
  • Future Scenario Simulation & Planning: Simulating various production scenarios using digital twins and AI to evaluate impacts and support strategic planning.
  • Process Variance Analysis and Improvement: Analyzing deviations in processes using data analytics to uncover root causes and implement continuous improvements.
Let's create great
Possibilities
Together.