Predictive Maintenance

Predictive
Maintenance
A BearingPoint Accelerator
BearingPoint’s predictive maintenance approach
supports clients to optimize asset availability,
reduce failure rates and minimize downtimes.
Clients will be able to predict breakdowns and
initiate tangible actions to avoid them.
>

Predictive Maintenance | A BearingPoint Accelerator
Contents
Market Drivers
Our Approach
Client Beneﬁts
References
Contact
CLIENT BENEFITSOUR APPROACHMARKET DRIVERS REFERENCES CONTACT< >

Market Drivers
Maintenance and service management are becoming important competitive factors. Optimal asset
availability, low failure rates and short downtimes at an optimum cost are factors that determine the success
and failure of all maintenance-intensive industries.
Competitive pressure
Increased competitive
pressure due to globalization
leads to increased cost
pressure on companies.
Maintenance must ensure the
flexible availability of assets
considering production
demands while improving
efficiency.
Complexity of the value
chain
The complexity of the entire
value-added chain has
increased through global
action. This also affects
maintenance, which has to
deal with new challenges in
order to ensure the
productivity of the company.
Change of customer
behavior
The behavior of customers
has changed due to new
markets. Furthermore, the
product lifecycle has declined
significantly. Customers
require more personalized
services at a lower costs. The
time-to-market has also
declined and thereby creates
pressure for companies in the
long term.
Competitive advantages
Companies have to preserve
their advantages, especially
technology advantages. This
signifies that companies have
to optimize their entire
processes in order to increase
efficiency.
Sustainability
Due to a resource shortage,
rising energy costs and a
changed perception,
companies have to operate
sustainably. Customers
expect companies to act
sustainably.

Market Drivers
New technologies in the context of digitization enable the implementation of innovative maintenance and
service strategies.
Reactive
Maintenance
• Repairs in case of
damage or failures
• Classical approach to
maintenance
Preventive
Maintenance
• Habitually scheduled
maintenance and
inspections
• Classic time or
performance-based
approach
40 % growth in the use
of business networks
over the past 2 years
90% of the data stored
on earth have been
generated over the past
2 years
212 Bil. "Things" will
be connected by the end
of 2020
58% of all companies
see IoT as having
strategic relevance
Remote Monitoring
• Visualization and
analysis via sensors -
recorded M2M data
• Warning messages on
terminals
corresponding to
variable limits
• Reports on machine
health
Predictive
Maintenance
• Prediction of machine
health
• Root-cause analysis for
optimized development
• Error pattern analysis
via unstructured data
Time
Maturityofmaintenance

Our Approach
With BearingPoint’s approach, clients will be able to collect and analyze big data, monitor asset conditions,
predict breakdowns, initiate adequate measures and tangible results in maintenance and service management.
Prediction
System
monitoring
Concrete
actions
and results
Process
data
ERP
data
MES
data
Machine
data
Environment
variables
Log
Files
Increase asset
availability
Optimize
maintenance cycles
Increase process
efficiency
Bundle resources
Technical materials
management
Remote service

Our Approach
BearingPoint provides a lean, agile and scalable approach for digital transformation within maintenance and
service management. This approach yields results within a very short amount of time, investment risks remain
manageable and the acceptance of employees is continuously promoted.
Vision
Mission Statement
Derive
Action Plan
Establish
Prototype
Scale Up
Expand Improve

Client Beneﬁts
Due to the scaling, optimizing and extending of the process, a continually increasing beneﬁt for the customer
is achieved long term. Both direct and indirect cost advantages are achieved, as well as an optimization of the
processes in adjacent business areas.
Scale Up
Expand Improve
Cost reduction
Increase asset availability
Increase process efficiency
Increase customer
satisfaction
Optimize resource
management
Optimize equipment &
assets with R&D

References
Challenges
• Due to faulty maintenance programs in
production there are unexpected breakdowns
and there is a 10-14% higher need of energy
• Predictive maintenance should increase the
efficiency of electro motors and avoid
unplanned breakdowns
• Due to obsolete lubricant or lack of
maintenance electric motors lose efficiency
This leads to an increase of energy
consumption and unexpected breakdowns
Our Approach
BearingPoint took part in the development of a
maintenance log about every individual electro
engine, which included all historical
maintenance activities and all necessary
parameters concerning the assets (e.g.
manufacturer, model, serial number,
environment data).
By linking this data with real time data (Internet
of things) and the use of predictive analytics, the
customer was able to recognize inefficiency or
even breakdowns of the engine in the future
Client benefits
The tool and optimization of the process
facilitates the customer in many cases to
forecast the optimal time for maintenance
This data is always available online for the
customer
Due to this, customer satisfaction increased
dramatically and unexpected breakdowns were
reduced by ~25 %
Leading automobile manufacturer
Challenges
• Bottlenecks in the production line
• Shutdowns without obvious reasons: complex
issues require expert knowledge
• Disorders affect profit dramatically and
just-in-time deliveries failed. Therefore,
penalties were the consequence
Our Approach
Optimization of the useful life of an expensive
grinding wheel. The result of the failures are high
downtimes for the production line.
Data from all possible sources: maintenance,
supplier, manufacturing, materials, layers,
upstream production sensors, etc.
Output / target variables: Breaking / no breaking
Client benefits
Pairwise arrangement of certain types of
grinding wheels (vibration test) with specific
process parameters resulted in insufficient results.
Preventive adjustments of the maintenance plan
on the existing limit beyond: savings ~ 0.4 M € /
year
Specialized engineering company

References
Challenges
• Deterioration of network quality
• Difficult to research reasons for power failures
• Only reactive actions possible in case of
failures
Our Approach
BearingPoint assisted the customer in achieving
short-term and long-term solutions:
• Short-term solution
Implementation of early warning dashboards
to shorten response times and to identify
problems in the network faster
• Long-term solution
Create extensive data warehouses
Implementation of data mining technology
and methodology
Client beneﬁts
Through BearingPoint’s solution the customer
was able to:
• Identify network failures before they
happened
• Systematically detect critical software /
hardware setups
• Detect faults in the network, as well as late
ticket creation
• Perform preventive maintenance and increase
of customer satisfaction
German network provider
Challenges
• Faults will be eliminated after customer calls
the service center
• System information is not analyzed
continuously
• Erosion of the plant can only be detected and
eliminated by on-site inspections
Our Approach
BearingPoint provided a solution with three
features:
• E-Diagnostic to recognize and diagnose
problems and reduce mean time to repair
• E-Inspection to carry out remote maintenance
and reduction of on-site services
• E-Monitoring to monitor the live feedback of
elevators and analysis of faults
Client beneﬁts
The solution helps the customer to minimize
downtimes through proactive and continuous
care of plants, provide reliable information for
the customer via different channels and
reduction of pre-inspections due to solving
problems by E-intervention
Leading equipment manufacturer

Contact
About BearingPoint
BearingPoint consultants understand that the world of business changes constantly and that the resulting complexities demand intelligent and
adaptive solutions. Our clients, whether in commercial or ﬁnancial industries or in government, experience real results when they work with us. We
combine industry, operational and technology skills with relevant proprietary and other assets in order to tailor solutions for each client’s
individual challenges. This adaptive approach is at the heart of our culture and has led to long-standing relationships with many of the world’s
leading companies and organizations. Our global consulting network of 9,700 people serves clients in more than 70 countries and engages with
them for measurable results and long-lasting success.
For more information, please visit: www.bearingpoint.com
© 2017 BearingPoint. All rights reserved
Frank Duscheck
Partner
BearingPoint Germany
frank.duscheck@bearingpoint.com
CLIENT BENEFITSOUR APPROACHMARKET DRIVERS REFERENCES CONTACT<
Sven Gehrmann
Manager
BearingPoint Germany
sven.gehrmann@bearingpoint.com

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