COMES WITH NO CHARGER What you don’t know that maybe impact in your digital transformation program with focus in asset management

Abstract: This article aims to share personal experiences gained over the past three years while leading multi-disciplinary teams in digital transformation projects with a focus on asset health, asset performance management, and reliability engineering.

Introduction: The world is rapidly changing, with the advent of 5G and the acceleration of remote work due to the COVID-19 pandemic. However, the maintenance and reliability departments face unique challenges in attracting and retaining highly skilled professionals, especially as technology companies and other industries become more appealing to the younger generation. In this article, we will explore the impact of these changes on the maintenance and reliability field, as well as discuss the vital role of digital transformation in addressing these challenges.

Imagine a scenario where a high level of technical skills is required for maintenance and reliability work, but these skills are primarily built through hands-on experience and time in the industry. How can organizations preserve and transfer this knowledge to ensure the next generation delivers excellent results? The answer lies in digital transformation. As a medium and long-term strategy, companies have started investing in digital transformation initiatives to remain competitive, improve operational effectiveness, make better and faster decisions, and prepare their operations for the future.

On October 13rd, 2020, I experienced a profound moment of realization while watching the live transmission of a leading cell phone manufacturer's summit event. As a project manager with 13 years of experience in managing digital transformation projects, I had a vested interest in the latest industry developments. In that particular moment, I had two screens opened—one displaying the summit event and another showing my broker's webpage.

As the cell phone manufacturer announced that their devices would no longer come with chargers, I witnessed a significant drop in the stock pricing of the company. The impact was palpable, and it left a lasting impression on me. It made me reflect on the importance of essential components in unlocking the full potential of technology and the consequences of not having them readily available.

This experience led me to draw a powerful analogy between the absence of chargers in cell phones and the challenges faced in digital transformation projects related to asset health, asset performance management, and reliability engineering. I recalled my involvement in an Industry 4.0 implementation project in 2018 and 2019, where I witnessed a disconnect between sales promises and the reality of deliverables. Customers were often unaware of the extensive steps and effort required to achieve maximum performance from the digital transformation tool.

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In this article, I want to share my personal journey and insights gained from managing digital transformation projects. By reflecting on the stock market reaction to the announcement during the summit event, I realized the importance of addressing critical components and setting realistic expectations. Through this analogy, we can better understand the challenges faced in digital transformation projects and learn how to develop a robust strategy for our own digital transformation journey in the maintenance and reliability field.

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Part 1: The truth that no one mentions

Technology companies are known for selling their products with lofty promises, showcasing phenomenal results and impressive returns on investment. In the realm of reliability engineering, this translates to increased mean time between failures (MTBF), reduced time to repair (MTTR), improved asset availability, cost savings, predictive failure detection using sensors and artificial intelligence, prioritized work orders, risk management, and more.

While these benefits sound enticing, questions inevitably arise: How many resources are needed for full implementation? What is the timeline for completion? How much investment is required for the necessary networking infrastructure? The answers often aim to convince you that adopting this technology will revolutionize your maintenance and reliability department, providing substantial returns and integrating you into the wonders of Industry 4.0 and IIoT.

Assuming you decide to adopt the system, you soon find yourself with all the servers installed, data being collected from numerous sensors in the field, and seamless integration with your computerized maintenance management system (CMMS). You have access to valuable information remotely through the cloud. However, the challenge lies in configuring the system correctly to extract its full value. Without proper configuration, the system may fail to identify issues such as cavitation, vibration, or motor overload. It requires a thorough understanding of equipment design, performance curves, and specifications to ensure accurate and actionable insights

Part 2: Connecting the Dots: The Role of Knowledgeable Engineers as "Chargers" in Digital Transformation

Just as a cell phone requires a charger to unlock its full potential, a digital transformation program focused on asset health, asset performance management, and reliability engineering relies on knowledgeable engineers to serve as the "chargers" for successful implementation. These engineers play a crucial role in configuring the system properly and ensuring that it aligns with the unique needs and challenges of the organization.

Think of these engineers as the experts who possess the deep understanding of equipment, processes, and maintenance practices necessary to leverage the technology effectively. They are the ones with boots on the ground, conducting field inspections, performing predictive maintenance techniques like spectrum analysis, thermography, and lubricant analysis. They troubleshoot issues, align equipment, and navigate diverse operational conditions. Their expertise allows them to read manuals, redesign workflows, and conduct root cause analyses (RCAs), reliability-centered maintenance (RCM), and failure mode and effects analyses (FMEA).

Without these knowledgeable engineers, the digital transformation program becomes akin to a cell phone without a charger—rendered incapable of delivering the desired results. Just as the charger enables the cell phone to function optimally, these engineers bring their expertise to the table, configuring the system to accurately capture and interpret data, identify anomalies, and provide actionable insights for maintenance and reliability decisions.

Their involvement is not limited to the initial implementation phase. Ongoing maintenance and optimization of the digital transformation program require continuous engagement from these engineers. They monitor performance, fine-tune configurations, and adjust algorithms to ensure that the system remains aligned with evolving operational needs. Their knowledge and experience enable them to interpret the data holistically, separating noise from meaningful patterns and making informed decisions to enhance asset health and performance.

In the context of reliability engineering and asset management, the importance of knowledgeable engineers cannot be overstated. They are the ones who bridge the gap between technology and its successful application in the industrial setting. They ensure that the promises made during the sales pitch are fulfilled by configuring the system in a way that aligns with the organization's specific needs and goals. Their expertise adds value beyond what technology alone can provide, allowing organizations to achieve the desired returns on investment and stay ahead in the ever-evolving industrial landscape.

To conclude, as you embark on your digital transformation journey with a focus on asset health, asset performance management, and reliability engineering, remember the significance of knowledgeable engineers as the "chargers" for the success of your program. Just as a cell phone needs a charger to function optimally, these engineers bring their expertise to configure and optimize the system, ensuring that it delivers meaningful insights and empowers your organization to make data-driven maintenance and reliability decisions. Invest in the development and retention of these professionals, and you will unlock the true potential of your digital transformation program.

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Part 3: Unlocking Success in Your Digital Transformation Journey - Key Recommendations for Maximum Impact

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1.???Getting Started

• Start Early: Begin your digital transformation journey as early as possible to capture and preserve valuable tribal knowledge before it is lost due to retirement or turnover.
• Assess Mill Maturity: Evaluate your organization's readiness for the digital transformation journey by assessing your current state of maturity. Understand your existing capabilities and identify areas for improvement.
• Assess Software Integration Capabilities: Evaluate the feasibility of creating APIs or other integration methods for existing software systems to ensure seamless data exchange and collaboration with your Industry 4.0 solution.
• Ensure Integration Compatibility: Prioritize hardware devices that support open protocols to facilitate integration with your Industry 4.0 solutions and enhance interoperability.

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2.???Building the Foundation

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• Define a Pilot Area: Select a specific area or department within your organization to serve as a pilot for your digital transformation initiatives. This allows you to test and validate the effectiveness of your strategies and technologies on a smaller scale before scaling up to the entire organization.

• Implement Short-Term Solutions: Prioritize the implementation of digital transformation initiatives that can deliver short-term results and immediate value to your organization. Start with smaller, manageable projects within the pilot area to demonstrate the benefits and build momentum.

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• Define a Roadmap: Develop a comprehensive roadmap that outlines the necessary steps and milestones to achieve maximum implementation of digital transformation solutions. Align it with your organization's goals and objectives, focusing initially on the pilot area and gradually expanding to other areas of the organization.

• Align with Business Strategy: Ensure that your digital transformation efforts align with your overall business strategy. Identify how digital technologies can support and enhance the core processes within the pilot area and contribute to your competitive advantage.

• Engage Stakeholders: Involve key stakeholders from the pilot area in the digital transformation journey. Seek their input, address their concerns, and secure their support to foster a collaborative and inclusive approach. Their active participation and feedback will be crucial in driving the success of the pilot initiatives.

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3.???Driving Success

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• Build Cross-Functional Teams: Establish cross-functional teams comprising individuals with diverse skills and expertise. Encourage collaboration and knowledge sharing to leverage the collective intelligence of your organization.

• Continuously Monitor and Evaluate: Regularly monitor and evaluate the progress of your digital transformation initiatives. Collect feedback, measure performance against set goals, and make necessary adjustments for ongoing improvement.

• Foster a Culture of Innovation: Encourage a culture of innovation and experimentation within your organization. Embrace new ideas, encourage calculated risks, and reward innovation to drive continuous improvement.

• Invest in Talent and Skills Development: Provide training programs and opportunities for your workforce to acquire the necessary digital skills. Foster a learning culture that empowers employees to adapt to technological advancements.

• Foster Partnerships and Collaboration: Seek partnerships with technology providers, industry experts, and research institutions. Leverage external expertise to accelerate your digital transformation journey and stay abreast of emerging trends.

• Data Democratization: Embrace "data democratization," where the information and insights obtained through digital transformation are made readily available and understandable to all relevant stakeholders, regardless of their personal knowledge and background. This inclusivity fosters collaboration and informed decision-making across multiple generations (e.g., individuals from the 50s, 60s, and 2000s) within the organization.

• Define Clear Rules and Responsibilities: Establish clear rules and responsibilities to hold individuals accountable for their roles in the digital transformation program.

• Implement a Formal Workflow: Set up a formal workflow to streamline processes and ensure efficient execution of tasks related to digital transformation initiatives.

• Set Proper KPIs: Define and measure key performance indicators (KPIs) to assess the success of your digital transformation project and track progress towards your goals.

• Create Visibility: Make your digital transformation program visible across the entire organization to foster support and engagement from all stakeholders.

• Properly Configure and Utilize CMMS: Ensure that your Computerized Maintenance Management System (CMMS) is properly configured and effectively utilized to optimize asset management and maintenance processes.

• Review, Optimize, and Configure Maintenance Routes: Optimize and configure maintenance routes within your CMMS to ensure efficient and effective asset inspections and maintenance activities.

• Leverage Data Analytics: Utilize data analytics and advanced analytical tools to derive meaningful insights and make data-driven decisions.

• Ensure Data Security: Implement robust data security measures to protect sensitive information and prevent unauthorized access to critical systems