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ASSET PERFORMANCE MANAGEMENT ASSET PERFORMANCE MANAGEMENT – IN DETAIL
Process & Control talks to Pratibha Pillalamarri, AspenTech, about all things related to asset performance
management (APM) and its role in the process industries
: Firstly, can you give an explanation of what asset performance management (APM) actually is, and give examples of the types of assets you're referring to? A: Asset Performance Management (APM) refers to a strategic approach focused on optimising the performance, reliability, and availability of physical assets throughout their lifecycle. APM aggregates data from diverse sources, including sensors, yield metrics and product quality parameters, and applies advanced analytics to evaluate risks, improve asset and process health, reduce downtime, increase operational efficiency, and ensure safety and compliance. The goal is to maximise the return on investment (ROI) of these assets while ensuring they operate within the desired performance parameters. In asset-intensive industries these assets typically include (but are not limited to) pumps, compressors, turbines, motors, and other equipment crucial for the manufacturing process along with automation, control, and safety systems. Q: You describe APM as an investment that 'gradually yields results', and not an 'instant solution' or 'miracle cure'. Can you explain more? A: Fully realising APM’s benefits requires a long-term strategic process. Simply implementing new software is not enough - APM requires seamlessly integrating predictive analytics into daily operations and maintenance planning workflows across an organisation.
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This transformation takes time to properly implement and gain adoption. Additionally, the results APM aims for - like reducing costs and downtime - are the culmination of numerous optimised decisions across various functions. Coupled with all this, the implementation of a new APM solution is an adaptive change to the organisation, which necessitates businesses putting in place a process of change management to ensure that users understand and accept why APM needs to be implemented and are fully up to speed on the new approach.
Given all the above, tracking key metrics over quarters and years clearly demonstrates
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how APM gradually improves performance steadily over time, as its strategic approach takes effect in processes and decision making. Q: APM is suited to improving management, maintenance and operational processes. Taking each area separately, can you explain how? A: APM significantly aids management, maintenance, and operational processes in the following ways: Management: APM provides a
comprehensive view of process, operations, and maintenance health across entire plant or facilities, enabling informed decision-making at the management level, and providing the insights needed for leaders to take rapid action. It aligns the organisation's maintenance and operational strategies with broader business goals, ensuring that asset investments are optimised for maximum return while mitigating risks. Maintenance: APM complements existing maintenance strategies, enabling a shift in the maintenance approach from reactive to proactive and predictive approaches. Leveraging data and advanced analytics, it predicts equipment failures before they occur and recommends mitigation strategies. For every mitigation option input by the user, the solution conducts a financial impact assessment, furnishing the user with informed recommendations designed to minimise disturbances to production and delivery commitments. This foresight allows for timely intervention, minimising unplanned downtime, extending the lifespan of assets, and reducing maintenance costs. It also helps in optimising spare parts inventory, thereby reducing capital locked in unused inventory. Operations: APM enhances operational
efficiency by continuously monitoring asset and process performance and identifying areas where performance can be optimised. Real-time insights enable operational adjustments to ensure consistent product quality, improve process yields, or make operational adjustments to avoid equipment degradation. As a result, APM solutions improve productivity, enhance product quality, and reduce energy consumption and waste, contributing to sustainable operations.
Q: Which industries/applications are best suited to the use of APM technology, and are you able to give any examples? A: The asset-intensive industries, those that rely heavily on expensive and long-lasting physical assets for their core operations, are generally best suited to the use of APM solutions. That is largely because they rely on complex, interconnected equipment and processes, requiring high reliability and availability to meet product delivery commitments. Industries like oil and gas, chemicals, metals and mining, power generation and polymers are prime candidates as unexpected downtime or unplanned events can be very costly across these markets. Additionally, discrete manufacturing sectors such as automotive, electronics and heavy machinery also benefit from APM.
For instance, OCP Ecuador utilised an APM solution to enhance the availability and reliability of pumps and generators, resulting in a 20% increase in uptime and a 25% reduction in maintenance expenses.
Furthermore, a Latin American pipeline company successfully deployed APM for comprehensive system modelling and maintenance strategy assessment, safeguarding substantial value. These examples underline the versatility and effectiveness of APM solutions across various industries, highlighting their role in improving operational efficiency and reducing costs. Q: Does APM technology work independently, or does it have to be integrated with other manufacturing/control software? A: While an APM solution can function independently, its integration with other manufacturing and control solutions can substantially enhance its capabilities and the value it delivers.
When an APM solution operates independently, it can still provide insights into asset and process health, predict potential issues, quantify the impact of those issues and suggest remedial actions. However, the real power of APM is unlocked when it is integrated with other systems and solutions. Integration allows for a more holistic view of operations,
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