Imagine a world where assets never fail unexpectedly, operate at peak efficiency over longer lives and deliver optimal value from the resources used to build, maintain and operate them. That’s the world ECS is aiming to create, by driving proactive maintenance using data.
Equipment Condition Supervisor (ECS) is made for Reliability Engineers and Condition Monitoring Analysts who are responsible for identifying and managing risks that affect asset reliability and operations. ECS combines industry-leading data analysis with human input in order to offer a condition-monitoring capability that can be trained and tailored.
Our mission is to equip maintenance and reliability teams with the ability to make a tangible difference to equipment reliability and productivity. We do this by eliminating the transactional and manual processes that have typically been a large part of an engineers’ analysis work, thus freeing up time for humans to focus on the proactive aspects of keeping equipment in optimal condition.
Reduced maintenance costs
By proactively monitoring and addressing component conditions in real time, organisations reduce overall maintenance costs. In the UK alone, $180 billion is spent per year fixing faulty equipment.
Reduce unscheduled downtime
Avoiding unscheduled downtime means less equipment output is sacrificed. Time spent fixing issues also cuts into time spent serving other areas of the business.
A commitment to sustainability
Using ECS, companies responsible for heavy equipment can ensure the equipment is functioning in a way that better supports environmental and sustainability goals.
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Accurate data analysis
A constantly updated pool of information and recommendations based on big data allows organisations to make better decisions, set KPIs and measure operational outputs effectively.
A global intelligence network
The technology behind ECS is developed on a global scale meaning learnings from one asset class can be utilised for the next. Knowledge of assets is gathered globally and ECS learns from this in order to benefit all clients.
Knowledge gained and shared
Condition monitoring decisions are shared across teams and captured for future analysis. There is less reliance on the skills of individuals and knowledge is not lost when they leave.
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Clients leveraging the power of ECS
ECS has helped organisations move from transactional, manual data collection to proactive condition monitoring led by insights that aim to constantly improve and increase operational productivity.
We are currently used across dozens of sites in Australia and Zambia, and in total, ECS manages more than 800 heavy industrial assets.
Client Stories/ Use Cases
Global Miner - Condition Monitoring Automation
The Brief: This Global Miner was looking to optimise the performance of critical mobile assets and extend component life.Enabling this capability is estimated to unlock $130m in savings on one fleet of ultra class haul trucks, through component life extensions alone.
The Approach: Deloitte was engaged to support the global miner to develop and verify prognostic rules based on condition monitoring data (oil analysis, onboard sensors) and use these rules to automate a significant proportion of reliability decision-making.Once a current state assessment of haul fleet life cycle cost was performed, objectives for component life extensions through better reliability decisions were quantified. The approach followed was to think big, test small, and scale fast.
$5 million estimated component savings after phase 1.
3,000 prognostic rules generally applicable to diesel drive mobile mining equipment set up.
Semi-automated 60% of condition monitoring decisions based on oil analysis and data analytics.
See ECS in action
We gatherA vast amount of data in real-time from a multitude of sources. Including on-board sensors and lab-based oil sample reports.
We processThe ECS prognostics engine sits at the heart of our technology. It captures and analyses data from a multitude of sources and uses intelligent analysis to interpret and generate recommended proactive maintenance interventions. This allows for human agency to approve, deny or give further feedback.
We assistBy combining advanced data and AI analysis skills with equipment- specific subject matter expertise, we can recommend proactive maintenance interventions, which then become Work Orders. Think of ECS as a machine-supported decision-making process: your intelligent assistant in supervising equipment condition.
A few words from our clients
“My personal belief is that ECS shifts oil analysis from an activity of specialists trying to guess what is wrong to a systematic risk reduction framework while also facilitating the capture of corporate knowledge. Our understanding and maturity around oil samples increased significantly through the use of the system mainly by getting more people involved in the process”