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Predict and prevent production disruptions before they happen with Asset Protector

Asset Protector is a powerful AI solution that protects production assets from all types of disruptions and decreases production disruptions by up to 30%! Plant managers, process engineers, shift supervisors, machine operators, and maintenance personnel can use Asset Protector to maximize asset performance to increase production efficiency while maintaining sufficient quality. Asset Protector can be used for all types of production assets in any industry (e.g. bottle filling machine, paper machine, steel furnaces, packaging line, parts assembly line).

The superpowers of Asset Protector

  1. Unmatched efficiency

    Asset Protector can process thousands of sensor signals and terabytes of raw data with ease and is at least 10 times faster than conventional approaches.

  2. Out of the box

    Asset Protector works with unprocessed raw data – no prior data filtering or data preparation and no data science skills are required.

  3. Intuitive and user-friendly

    Asset Protector has an intuitive user interface for everyone: manager, engineer, and operator.

  4. Breathtaking insights

    Asset Protector creates valuable and understandable insight reports challenging and complementing your process knowledge with entirely new perspectives.

Features of Asset Protector

Automated root cause analysis (RCA)

Understand the root cause of disruptions. This is a prerequisite for taking effective countermeasures to prevent the same disruptions from happening again.

AI-generated countermeasures

Effectively eliminate disruptions that have occurred, improve product quality and minimize machine downtime. This is a prerequisite for improving KPI performance.

Risk prediction

Receive early warnings of an impending risk scenario with appropriate recommendations for effective countermeasures.

Optimized centerlining

Use real-time data to optimize KPI performance, such as OEE, machine downtime, waste generation, CO2 emissions and more.

How Asset Protector works

Asset Protector can be integrated with any IT system, from existing data platforms such as IBA or OSI to retrieving data from PLCs and transferring it to our cloud.

Asset Protector is mobile-friendly

Use cases and impact

Use case 1: Avoiding slopping in steelmaking

Challenge:

In basic oxygen steelmaking (BOS), the critical problem of slopping occurs when the foaming slag exceeds the height of the vessel and overflows. This causes metal losses, process disruptions, environmental pollution, and poses a threat to employees. The complexities that lead to slopping are still a challenge, even for experienced operators.

Our impact

  • Asset Protector was able to predict 55% of slopping events, between 1 – 2 minutes  in advance
  • Immediate impact on production
  • €2,4m of potential cost savings per furnace/asset per year

Use case 2: Preventing sheet breaks in papermaking

Challenge:

Disruptions in paper manufacturing are referred to as “sheet breaks”. They can occur at any time and without warning. Once sheet breaks occur, a series of cleaning and retreading procedures are necessary before production can be resumed. Thus, sheet breaks have a significant negative impact on the productivity of a paper machine. Sheet breaks and fiber losses occur thousands of times a year and cause around 2 million euros in additional costs per machine annually.

Our impact:

  • Asset Protector was able to decrease 77% of sheet breaks per day on a paper machine, within 60 min before the incident occurred
  • Immediate impact on production
  • > €2m of estimated cost savings per paper machine per year.

Client references

“Asset Protector has finally made it possible for us to better understand the reasons for disruptions in paper manufacturing, such as sheet breaks. After working in the industry for almost 20 years, this is a real game changer for me!”

Jürgen Käser, Director Process Applications, Voith Group

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    Projects evaluation criteria

    Level of Impact
    40%
    Scalability
    30%
    Transparency
    20%
    H-Factor
    10%

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    2 Days / 3 Nights
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