Start with the critical few
Together with your reliability team we choose the equipment whose failure costs the most, and the failures that have happened on it before.
Operational & production analytics
Predictive maintenance (PdM)
Pumps, compressors and cracker furnaces usually show warning signs days or weeks before they fail: a vibration that grows, a bearing that runs warmer, a pressure that drifts. We combine those sensor readings with your maintenance history to estimate which critical equipment is heading for failure, so the work can be planned instead of forced by an unplanned shutdown.
Typical first version
8 – 14 weeks
Stated as a range. The two-week assessment narrows it.
The problem
Where it hurts today
- Maintenance is scheduled by calendar, or done after a breakdown.
- Sensor data is recorded in the historian but rarely read until something has already gone wrong.
- Reliability engineers cannot watch hundreds of signals across every unit at once.
Data we bring together
- Process historian tags (vibration, temperature, pressure, flow)
- Maintenance work orders and failure history
- Equipment register and criticality
- Operating mode and throughput
- Inspection and oil-analysis reports
How Azico builds it
Four stages, each one usable on its own
Signals made comparable
Sensor data is cleaned, aligned to operating mode and joined to the maintenance record, so the model learns what “normal” looks like for each machine.
Health score and forecast
Each asset gets a health score and, where the history supports it, an estimate of time to failure, always with its confidence stated.
Into the work order system
When a score crosses an agreed level, a notification, or a draft work order in your maintenance system, is raised with the evidence attached.
What your team sees
- +Health score for every monitored asset
- +Trend of the signals that drove each warning
- +Forecast window for likely failures
- +Warnings raised, actioned and confirmed, to keep the model honest
Questions it answers
- “Which pumps should we look at during next week’s turnaround window?”
- “Is this vibration normal for the throughput we are running?”
- “How much warning did we get before the last failure?”
What we need from you
- Read access to the historian
- Two or more years of maintenance records
- A reliability engineer to agree failure modes and thresholds
- A short list of critical assets to start with
Operational & production analytics
Other solutions in this group
Insights
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Azico Analytics is a Bangalore-based team of experienced data professionals. Share how your data is managed today, how your reports are produced and the challenges you face. We will assess your requirements objectively and set out where we can add value, with a practical approach tailored to your business.