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Digital Blanket® DB AUTOmate helps Increase uptime and how they impact the bottom line. These include approaches to maintenance in industrial facilities, such as factories, commercial facilities, power plants, or other installations where the proper maintenance approach can prevent catastrophic failures.

However, maintaining the bottom line requires one to consider reliability, security, power dissipation, fault detection, and professionally designed equipment to meet industry standards.

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Downtime directly impacts Productivity and Revenue

Unexpected downtime in factories can be extremely costly, as loss of industrial output has a direct, negative impact on revenue.

An unexpected factory shutdown can cause loss of work in progress, wasted resources, and potential future losses if a restarted production line does not immediately produce output that meets specifications.

Production facilities take days to stabilize after a restart before the output product qualifies for release. If the downtime is due to a catastrophic failure, there could be consequential environmental pollution, collateral damage, legal ramifications, injuries, and even loss of life.

In Process led manufacturing individual items are assembled or fabricated on production lines. This can include anything from cell phones to automobiles. Certainly, some of these lines move very quickly so uptime is critical.

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Digital Blanket® Condition Monitoring aims to enhance the system uptime with predictive fault detection, extend the asset life and improve system efficiency to provide energy savings. In condition monitoring, we simulate multiple operating scenarios of any rotary equipment like chillers, pumps, colling towers etc. Then we link such simulated performance curves to the current performance to identify possible conditional variances and, hence developing faults. These developing faults are thus early indicators of performance issues, energy imbalances and systemic failures. These are the root causes of underperformance and lower asset life, which if addressed provides significant value.

Digital Blanket® (DB AUTOmate) provides an AI based Condition Monitoring that takes data from AUTOmate for advanced continuous performance optimization. Our solution keeps track of asset condition, performance and efficiencies on a Real Time basis, tracks deviations from Best Efficiency Point and helps restore the dynamic operating point closer to the BEP. By consistently enhancing the asset health and efficiency, the natural effect is to improve energy efficiency and improve uptime. This is achieved by analysing the machine and baseline data with near real-time temperature and energy data. It tracks minute deviations in performance and conditions of machines and engages a process of continuous commissioning, bringing out actionable analysis on an ongoing basis, tracked through a Plan-Do-Check-Act cycle of continuous improvement.

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Condition Monitoring can be combined as a unified process for continuous improvement in tune with the best practices for

  • Energy Management (ISO 50001)
  • Asset Management (ISO 55001)
  • ESM, and Performance Measurement & Verification (IPMVP) providing measurable and verifiable outcomes.

Digital Blanket® for Energy Management and Optimization benefits:

  • Automated energy monitoring solution helps build energy consumption baseline that can be tracked. As per our experience, the cost per sq. Ft. varies by industry, machines, production, number of shifts etc.
  • Energy goal setting and planning tool available on Digital Blanket® platform helps facility team set energy consumption goals and then track it in an intuitive manner using green, amber, red colour coding for each day.
  • Energy consumption varies based on seasons, climate, holidays and the same can be optimally configured on Digital Blanket® for planned savings.
  • Power factor monitoring can also assess power quality and identify any inductive load that is leading to wastages. E.g., Power factor of 0.85 can typically mean 18% higher utility bill for a 100 Kw load. If we can optimize this through regular monitoring and relevant corrective steps, it can reduce utility bill.
  • Load wise (HVAC or UPS or Air Compressors or Hydraulics) or machine wise energy consumption segregation is not normally measured or analysed. Energy consumption correlation with machine utilization or machine productivity will make real estate/ factory establishments smarter with least investments.
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