Innovation in the Use of Technology and Systems 2014

This Award recognises the best technology innovation in FM.

Overview

Winner: Integral uptimeplus
Initiative: Galileo – meeting the needs of condition-based maintenance
Sponsor: GSH

Best practice learning points

> Moving to condition-based monitoring is more than technical innovation- it requires cultural change, change management and the need to let go of the old ways of doing things
> Information about asset condition must feed into an effective data management system which is then available to operational staff in a timely and useful way
> Well-designed procedures are needed to convert information into action
> Strategic issues (critical risk engineering and risk management) must be understood ahead of moving to condition-based monitoring
> Expected benefits must be great enough to justify the investment
> Any business case must be detailed enough to secure enterprise-wide acceptance and senior management recognition
> Analyse the total costs associated with the different maintenance regimes you are running – be it corrective (fixing what has broken); preventative (scheduled tasks designed to prevent typical failure modes); predictive (condition monitoring) and proactive (root cause analysis of trends).

About

Developments in microprocessors are taking much of the guesswork out of maintenance of plant and assets. Computer chips now make it possible to monitor the operating condition of plant equipment, machinery and systems and provide the opportunity to manage maintenance-related operations in real time. According to the company, one third of all maintenance costs is wasted as a result of unnecessary or improperly carried out maintenance so now perhaps for the first time it is possible to do something about this. Galileo is about providing the required reliability and availability delivered effectively at the lowest cost.

Galileo is a wholly owned software product which has been designed specifically for the FM market. Clever algorithms analyse data and come up with a maintenance schedule based on the condition of individual assets. The tool makes it possible for users to understand how quickly assets are ageing and work out how effective the current levels of maintenance are proving to be. As a tool, Galileo increases the probability that critical assets or components will provide the levels of resilience they are designed for over their entire life-cycle.

Galileo is both a management approach to maintaining critical assets as well as an underlying software technology which:-

> Improves asset reliability and quality
> Delivers direct cost savings
> Reduces risks around compliance and legislation
> Provides visibility of asset operational status
> Manages and monitors the performance of life critical assets
> Supports organisational transition to new maintenance approaches

The company states that Galileo is a reliability-centred maintenance platform (RCM). It focuses on identifying those operational, maintenance and capital improvements that manage and mitigate the risk of equipment failure effectively. With Galileo, maintenance tasks are performed only when is required based on data which is being received and used to determine Predictive (PdM) and Preventive (PM) inspection intervals.

Mobile tools, rather than fixed sensors, are used to provide the condition readings, which are then interpreted by the systems algorithms for interpretation and forecasting. A predictive planner programs the asset maintenance schedule. The system interprets when an asset is going to fail; what its failure pattern is likely to be; how long there is to perform remedial actions; what the expected number of failures will be and therefore the asset’s reliability. The maintenance regime can be flexed to take into account an asset’s failure pattern; age and operational life.

Integral is able to show how they have improved ‘availability’ with less unplanned outages and improved reliability. The client has seen extended equipment life resulting from the reduced wear and tear because there is less need to disassemble and reassemble equipment with the problems this can cause. Maintenance costs have been reduced because there is fewer unplanned and un-needed maintenance and therefore better use of resources and need for overtime.

The Judges said

Galileo is a system that uses lifecycle algorithms to enable the introduction of reliability/condition-based maintenance. Benefits to clients include: improved asset availability; enhanced equipment life and significant savings on maintenance costs. We have selected Galileo as the winner as the system has the potential for wide application within the FM field.