As a process engineer with over 20 years of experience in production environments, I've learned that the ability to effectively compare asset performance is the cornerstone of operational excellence. The new Asset Comparison Bar Chart+ for AVEVA PI Vision transforms how we visualize and analyze equipment performance data, making it easier than ever to spot trends, identify issues, and drive improvements.
Key Benefits
- Instantly compare multiple assets side-by-side to identify underperforming equipment
- Dynamic sorting capabilities help prioritize maintenance and optimization efforts
- Customizable thresholds with intuitive color coding for rapid status assessment
- Flexible application across any asset type - from pumps and motors to entire production lines
- Easy configuration and integration with existing PI Vision dashboards
- Real-time updates for immediate decision-making support
Real-World Applications
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Equipment Health Monitoring
- Compare vibration levels across your pump fleet to predict maintenance needs
- Monitor temperature patterns across similar machines to spot developing issues
- Track bearing wear indicators across multiple motors to prevent unexpected failures
- Identify equipment operating outside normal parameters compared to its peers
- Compare performance degradation rates to optimize maintenance schedules
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Energy Optimization
- Identify motors consuming significantly more power than their identical counterparts
- Compare heat exchanger efficiency to optimize cleaning and maintenance schedules
- Spot energy-intensive equipment for targeted improvement projects
- Track energy consumption patterns across similar units to identify best practices
- Monitor power factor across motor groups to optimize electrical efficiency
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Production Performance
- Compare OEE (Overall Equipment Effectiveness) across parallel production lines
- Monitor quality parameters between similar processes in real-time
- Track uptime/downtime patterns across asset groups to identify bottlenecks
- Compare production rates between similar units to standardize performance
- Analyze yield rates across multiple process lines to identify optimization opportunities
Here's an example of an OEE Chart:
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Maintenance Planning
- Visualize mean time between failures across your equipment fleet
- Compare maintenance costs between similar assets to identify outliers
- Track repair frequency across equipment groups to optimize maintenance strategies
- Monitor spare part consumption rates to identify problematic equipment
- Compare maintenance KPIs across different facilities or production areas
Success Story
Recently, we implemented the Asset Comparison Bar Chart+ to monitor our facility's 24 primary process pumps. Within the first month, the chart helped us identify three pumps operating at 20% higher power consumption than their peers. Investigation revealed early-stage bearing issues that, if left unchecked, could have led to catastrophic failures. This early detection not only prevented unplanned downtime but also saved approximately $45,000 in potential repair costs.
Implementation Tips:
- Start with critical assets where performance variations have the biggest impact
- Create multiple views comparing different parameters for comprehensive monitoring
- Set up meaningful thresholds based on equipment specifications and historical performance
- Use the dynamic sorting feature to focus on both best and worst performers
- Integrate with existing maintenance and reliability programs
Whether you're focused on reliability, energy efficiency, or production optimization, the Asset Comparison Bar Chart+ provides the insights needed to make data-driven decisions. It transforms raw data into actionable information, helping maintenance teams prioritize their efforts and engineers optimize their processes.
For process engineers and maintenance professionals looking to enhance their asset monitoring capabilities, this addition to PI Vision is truly a game-changer. It's not just about collecting data anymore - it's about presenting it in a way that drives action and improvements.
Remember: In today's competitive manufacturing environment, the ability to quickly identify and address performance issues can make the difference between profit and loss. Asset Comparison Bar Chart+ gives you that capability in an intuitive, powerful package.
You can get Asset Comparison Bar Chart+ as part of the Vision Library+ Symbol Package for AVEVA PI Vision.
