Challenges on an Asset Health Index Calculation

In the current era of Industry 4.0, we find ourselves in the midst of a profound transformation in the industrial landscape. This new era brings with it a host of challenges and problems, particularly in relation to the effective capture and processing of data. The success of this revolution hinges on our ability to harness data in a meaningful way, but achieving this goal is no small feat.

At the core of this data-driven revolution lies the critical importance of capturing data accurately. However, in many companies, this proves to be an incredibly complex problem. It is not simply a matter of capturing as much data as possible from the moment an asset or system is initiated. Rather, the focus is on acquiring a minimum amount of data that is sufficient to enable proper processing and analysis. This requirement presents a unique challenge in itself, as it often necessitates estimating this minimum data requirement based on a solid and reliable foundation of existing information.

The consequences of lacking adequate information can be far-reaching. Insufficient data availability inevitably leads to deviations in the processing and analysis of the captured data. However, this limitation also offers an opportunity for comparison. By examining assets of the same type that face similar challenges in data capture and processing, valuable insights can be gained. For instance, consider the scenario of comparing the health index of multiple transformers located in different electrical substations and operating under diverse conditions. If the data capture relating to the operational and maintenance variables is equally deficient across these transformers, and similar estimation techniques are employed, it becomes possible to compare the overall health of these equipment units.

To delve deeper into this topic, let us explore the specific example of calculating the Health Index for different pumps. In this particular case, the challenge arises from the fact that the start-up of these pumps predates the availability of operation and maintenance data. Consequently, due to this lack of information, a different approach must be taken. The estimation of various fundamental variables becomes necessary to facilitate the calculation of the Health Index and derive meaningful insights into the condition and performance of the pumps.

In conclusion, the advent of Industry 4.0 has brought forth a range of challenges and problems in the realm of data capture and processing. The ability to obtain and process data accurately is a critical factor in the success of this revolution. However, the complexity of the task lies not only in capturing a substantial amount of data but also in determining the minimum data requirements for meaningful analysis. Despite the difficulties posed by limited information, the comparison of similar assets facing data capture challenges can provide valuable insights. Through a specific example involving pump health index calculations, we can further understand the importance of addressing data estimation and processing in the context of Industry 4.0. Throughout this paper, the example of calculating the Health Index of different pumps will be developed in which the start-up of these goes back to times prior to the date of capture of the operation and maintenance data. Due to this lack of information, it will be necessary to start from the estimation of different fundamental variables for the processing of the data to be calculated.