How Cognite Data Fusion™ reduces unplanned failures and maintenance costs for manufacturers

Yokogawa used Industrial DataOps software provided by Cognite, including Cognite Data Fusion®, to develop solutions that enable workers to conduct maintenance on equipment based on its actual condition.

Equipped with easy access to live data in the cloud, workers can quickly view alarms and use interactive engineering diagrams.

Data trapped in complex, siloed systems

Many manufacturing companies run their maintenance operations on a schedule, tasking workers to conduct routine inspections of equipment at set intervals.

In addition to scheduled maintenance, workers also conduct reactive maintenance, such as when a sensor alerts them to a potential issue involving equipment.

This approach to maintenance means that workers may spend several hours of their day inspecting equipment that is in good working condition—hours that could instead be spent performing other tasks that generate value for the company.

Applications and solutions powered by contextualized data

Yokogawa and Cognite used liberated, contextualized industrial data stored in Cognite Data Fusion® to build maintenance solutions that help the company realize the value potential in predictive maintenance.

One such solution is an alarm overview that reduces unnecessary inspection of equipment. The overview shows a bird’s-eye view of the manufacturing plant and live sensor data from the pumps on site. If a pump’s vibration exceeds a predetermined threshold, one of Yokogawa’s systems will send a signal to Cognite Data Fusion®, which will visualize it as an alert.

When a user clicks a label associated with a pump on the infographic, the user is taken to an asset explorer page. The user can then view asset metadata, and search and filter time series, events, and documents such as the instruction manual. This enables workers responsible for the plant operation to diagnose the issue and decide whether it needs to be corrected immediately.

Another solution combines the process diagram of the plant’s energy center with live sensor data. By clicking on the individual components that together form the energy center, workers can easily view all the information about the equipment available in Yokogawa’s maintenance system.

The information can also be displayed in convenient charts that reveal how different factors may be connected, for example pump flow rate, temperature, and vibration.

Instant access to data enables manufacturers to conduct maintenance on equipment based on its actual condition, as opposed to running its maintenance program on a set schedule.