Overview
A mining company was in the process of updating its data quality in their enterprise asset management (EAM) software (Maximo). The company rolled this update out across three separate facilities. They were capitalizing on the features and value of Maximo’s processes and systems, and recognized that the completeness of their asset register in the system was lacking.
In the process of updating the asset register, challenges presented themselves early. Some of the information on the facilities’ assets was over 50 years old. It was unclear if the information still reflects what was out in the physical plant, and how much loss had resulted in gaps in the registry. Attempts to audit their data and close gaps would be difficult, time-consuming and expensive. Closing the gaps would require many manhours from operators and old-hands, who still had their day jobs, to tap into their their tribal knowledge and local solutions (Excel e.g.) for this important audit.
Challenges
Without a different approach, these significant challenges created a long timeline to accurately rebuild the asset registry.
- Overlooking existing equipment not listed in Maximo, leaves errors and gaps in the asset register.
- Difficulty in determining parent-child relationships within the register, due deterioration of data quality over time, and different philosophies regarding location hierarchies applied by different stakeholders.
- Inability to validate the asset register against in-field equipment, due to the time-sensitivity of the project and the need to have the asset register updated to support operations
These challenges amount to greatly increased review time.
Solutions
ReVisionz’s solution was to utilize reality captures with laser scans of their facilities, visualize them with VEERUM, and use the models to establish a digital version of their as-built facilities. From there, ReVisionz audited their data and closed gaps within the asset register. This could be done without nearly the on-site man-power required in the original .
By partnering with VEERUM, the mining company and ReVisionz delivered a 3D model of the facilities to compare against their asset registry.
ReVisionz deployed technical experts with decades of experience to:
- Utilize the scans of the facilities, focusing on major equipment and assets critical for operations
- Work directly with subject matter experts (SMEs) to obtain the necessary information to help update the asset register
- Compare the asset registry to the facility models
- Place objects in the 3D model to reflect plant layout
- Facilitate virtual facility walkthroughs to confirm asset registry update
The solution involved close collaboration with VEERUM and the client to represent the facilities digitally and match the register to the information gathered from the scans.
Outcomes
Identified Inconsistencies
The VEERUM visualization identified several inconsistencies with the asset register, including:
- Duplicate assets in the register
- Missing assets from the register
- Incorrect hierarchies for assets
Improved Asset Registry Structure
By working with SMEs and comparing the register against the 3D model, ReVisionz was able to correct these errors. Hierarchies and parent-child relationships were established and validated, duplicates were removed, and missing assets were added to the registry.
Moreover, the improved structure of the registry reflected the as-built facilities.
60% Cost Savings
This resulted in 60% cost savings versus the previous methods of correcting and updating the asset registry. It was further improved through applying industry-leading standards. This model will establish the proper deployment of future system upgrades.
Successful Implementation of New Digital Systems
In addition, the company is now using VEERUM for additional operations and maintenance functions, including shutdowns, planning and scheduling, safety reviews, and many more use cases. High visibility to information is improving safety and increasing asset uptime.
Overall, this update included a successful implementation of new digital systems for the mining company.
Mitigated Risk of Unmaintained Equipment
The benefit of an asset registry is to mitigate the risk of unmaintained equipment. The risk exposure can vary from major industrial incidents, safety, loss of production, to underperforming equipment.
The asset register is the foundation on which enterprise asset management relies, and the Institute for Asset Management (IAM) estimates savings of 1 to 5% of total business expenditure resulting from improved asset information. The Asset Register is a key foundational element to achieve this magnitude of savings.