Industry 4.0

According to experts of the largest audit companies, the share of projects on predictive analytics at industrial enterprises amounts to 80% from the total number of projects introducing digital technologies.

Industry 1.0
Ordinary loom, steam engine
1784

Industry 2.0
First production line. Large-volume production using electricity
1870

Industry 3.0
First programmable logic controller. Use of electronics and information technology for further automation.
1969

Industry 4.0
Cyber physical systems (connection of real objects with information processes or virtual objects through information networks and the Internet).
Present days

Assumptions of predictive analytics implementation

Organization of an effective MRO strategy provides significant
(up to 30-40%) reduction of cost, caused by the main production assets maintaining

ECONOMIC COMPONENTS

INCREASED PRODUCTIVITY (up to 10-15%):

  • productivity gain (technical process change),
  • prevention of unplanned downtimes,
  • cutting the time of scheduled downtime,
  • extension of the run between repairs;

REDUCTION OF MRO COST (up to 30-40%):

  • MRO terms and scope planning,
  • maintenance and repair cost-cutting,
  • transition to more efficient MRO strategies,
  • optimization of spare parts depot;

GENERAL IMPROVEMENT OF MANAGEMENT EFFICIENCY (8-12%):

  • Increase of the availability factor(ОЕЕ),
  • reduction of cost intended for assets maintaining

SECURITY

  • Increase of operational integrity,
  • accident prevention

ENVIRONMENTAL PROTECTION AND LEGISLATIVE INITIATIVES

The economic effect of predictive analytics

PETROLEUM REFINERY
Cumulative annual savings referred to 1 proc. line – 30 M$
(reduction of repair funds, increased productivity,
reduced energy consumption, prevention of loss of raw materials)

NUCLEAR FACILITY
Reduction of maintenance costs by 3 M$
Increased profits as a result of increased productivity by 19 M$

METALLURGICAL COMPLEX
Annual maintenance cost reduction by 2,5 M$

CHEMICAL INDUSTRY
Reduction of spare parts by 3 М$
Reduced total maintenance costs by 10 M$

Sayano–Shushenskaya Dam
August 17 , 2009

EFFECTS :
As a result of the accident, 75 people died, serious damage was caused to the equipment and premises of the station. Electricity production has been suspended. The consequences of the accident affected the ecological situation of the water area adjacent to the HPP, as well as the social and economic spheres of the entire region.

REASONS :
“… The constant monitoring of the technical condition of the equipment by the operating and maintenance personnel was not properly ensured (…).
The main reason of the accident was the failure to take actions to stop the second hydraulic unit and find out the causes of vibration”

Source: the final report of the parliamentary commission for investigation of circumstances related to the occurrence of the accident at the Sayano–Shushenskaya Dam