PRODUCTION RELIABILITY
Production Reliability
Delivered User Validated Outcomes
up to 2% Energy reduction per unit
Reduced Energy
Consumption
Reduced Process
Variability
Higher Yield
and Throughput
Consistent and
Predictable Quality
PlantOS
Intelligence
No Unplanned
Downtime
Lower
Maintenance Costs
Increased
Equipment Life
Faster
Equipment Payback
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
PlantOS
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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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.
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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What is Equipment Reliability?
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
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.
Infinite Uptime
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