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Predictive analytics increases production by improving equipment reliability

Every plant will have key equipment that are vital to plant production (E.g. compressors, pumps, reactors and etc). Downtime or underperformance of these equipment will results in massive production losses. Improving and optimizing these equipment, on the other hand, increases production. Most of these equipment will have specialist engineers which rigorously monitors them, typically by manual inspection recorded in spread sheets.
Predictive maintenance
Open-Plant can be used to program this advance monitoring routine to create a predictive maintenance program. A mobile app can be provided for operators to key in visual inspection results to Open-Plant. Combined with advance analytics, an accurate performance or diagnostic parameter can be produced. The results of these monitoring can be sent to SCADA/DCS as real time indicators or via SMS/Email to relevent personnel.
Onsite data entry for inspections

Improving instrumentation minimizes product quality give aways

Certain Instruments (such as analysers, actuators and etc) are used to control the quality of a product. Before a product is sold it needs to meet the specification set by the buyer. For example, selling Petrol needs to meet a specific RON Number (e.g. RON 91, RON 95, etc). Because of the fear of not meeting the buyer's specifications, a higher quality is produced. For example, a RON 91 petrol may be produced at RON 91.05 to ensure compliance. This extra '0.05' RON is a free product give away. Studies have shown that typical plants waste about 0.1% in product give aways. Minimizing this value usually translates to thousands of dollars in cost realization.
Product quality give away
Studies have shown that typical plants wastes about 0.1% in product give aways
Open-Plant can be used to constantly monitor critical instrument paraeters for abnormal behaviors (such as abnormal fluctuations, flat line or lack of correllation). When such occur, Open-Plant can alert maintenance operatives (via email or sms) so they react immediately.
Predictive analytics improves operators confidence on instruments, thus allowing them to better minimize product give aways

Daewoo improves operational safety using Open-Plant's Analytics

Korean based construction company Daewoo needed to improve operational safety for their tunnel boring operations. Unfortunate incidents such as ground collapse is the undesired result of over excavation during tunnel boring operations.
Ground Collapse: A nightmare for tunnel boring operations
One of the problem they had was the lack of real time calculations for crucial operating parameters. Calculations were done manually at an infrequent interval. Engineers believed these calculations cannot be automated as they were too complex.
Open-Plant was able to perform these complex calculations
Open-Plant was able to perform these complex calculations. The direct result was a realtime prediction of a safe envelope for excavation. With this, tunnel operators were able to monitor actual excavation vs the excavation limit in realtime, ensuring the limit is never hit and unfortunate incidents such as ground collapse never occurs.
Open-Plant Analytics used by Daewoo to improve safety
Part of the complexity was the need to have manual input to some of the calculations. Using the Open-Plant APIs, a desktop application was developed to allow manual data entry. 

Open-Plant's ability to accept manual input allowed a seemingly impossible to automate analytic possible. With this, the system was very reliable and practical to engineers.
Open-Plant's ability to accept manual input allowed a seemingly impossible to automate analytic possible
Open-Plant's manual input

Open-Plant powered expert systems improves operations & reduces startup delays

Every delay in mission critical operations (such as plant startup) translates to thousands of dollars in production lost. To make it worst, most of these operations are very complicated. An inexperienced operator may not be up to speed.
What’s preventing the plant start-up?
Open-Plant can be used as the platform for an expert system. The expert system's role is simple. It sits side by side by the operators telling them what to do next. What's preventing the start-up? Which equipment is not working? Time is critical. Every hour translates to thousands of dollars.
Standard Operating Procedures (SOPs) can be digitalized into a live expert system

Robbins saves thousands of dollars avoiding proprietary software

Robbins is a US based company that manufactures Tunnel Boring Machines (TBM), a machine used to dig underground tunnels. With every TBM sale, the company had to include a costly third party TBM software part of their delivery package. The proprietary software had a hefty license cost and a complicated deployment process. This added a significant ammount to the cost of sale. 

Robbins engaged Open-Plant to build their own TBM software application. With Open-Plant's all-in-one solution, such application was done with ease. The overall cost was signifantly lower than a proprietary TBM software application. On top of that, Robbins enjoyed all features that Open-Plant included i.e Excel reports, analytics, historian and etc.
Robbins engaged Open-Plant to build their own TBM software application
Robbins' customized TBM Software developed using Open-Plant
Robbins' customized TBM Software developed using Open-Plant

Open-Plant Industrial IoT remote equipment monitoring improves productivity

In a production stream, not everything is always on site. Some things are off-site and are vital to the production stream. Fault on these off-site equipment will reduce overall production. Due to this, routine maintenance needs to be done on these equipment. As they are located far away, these routine checks can be time consuming and difficult.
Running a technician in the snow to check a gas pipeline isn't always ideal
Open-Plant Connectors can be deployed to remote locations with ease. The connector app is very lightweight and can be installed on existing windows machines. We have even used on small pc sticks like the following:
Open-Plant Connector can be installed on a cheap Intel PC stick
Open-Plant Connector on an Intel PC stick accessed via Team Viewer
Open-Plant Connectors accepts various communication protocols such as MQTT, OPCDA, OPCUA and Restful APIs. IoT sensors can be easily equipped with a SIM card and send data to Open-Plant.
Solar powered IoT devices is possible with Open-Plant

IAT improves customer satisfaction with Open-Plant Historian

IAT Solution is a Singaporean based IT company which develops solutions for various clients. For one of it's clients, IAT used Open-Plant and took advantage of Open-Plant's DotNet API library. The library allowed them to embed the Open-Plant Historian into it's desktop application. The Open-Plant Historian's slick user interface become the primary factor for increased customer satisfaction and subsequent reference sales. One of their clients even mentioned that this is "by far the best Historian they've ever seen".
By far, the best Historian we've ever seen
Open-Plant's Historian slick user interface
Open-Plant's slick zoom animations

IAT reduces mobile app development cost  with Open-Plant 

IAT Solution is a Singaporean based IT company which develops IT solutions for various clients. For one of it's projects, IAT Solution used Open-Plant to develop a mobile app for their client. With Open-Plant, the back end side of mobile app development was fully taken care off. This included database, user mangement, security, analytics, connectors and etc. IAT Solution need only worry about front end development. 

For front end development, IAT Solution utilitzed Open-Plant's comprehensive Web API to show real time data. All-in-all development time became so much faster, ultimately reducing development cost.
With Open-Plant, the back end side of mobile app development was fully taken care off
Mobile App developed using Open-Plant
Open-Plant is a revolutionary Industrial IOT Platform software, used to create and deploy Industrial IT apps/solutions. It is an all-encompassing solution offering both back-end and front-end components i.e. the full stack. From our user's experience, creating and deploying Industrial IT apps became 10x faster and 10x less cost. We serve the mining, energy, oil & gas, construction and manufacturing industry. 

OPEN-PLANT PTY LTD

Perth, Australia

EMAIL

info@open-plant.com
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