Pibod: SEAT CODE drives the future of predictive maintenance
At SEAT CODE, we work with an agile, creative mindset and we believe digitalisation and innovative technology solutions are key to improving efficiency. With this dynamic spirit, we create groundbreaking digital solutions such a Pibod, a software that enables predictive maintenance on industrial equipment, maximising availability by the prioritisation of action and decision-making based on condition data.
Pibod arouse from a need detected in the vehicle production lines of SEAT S.A. at the company’s factory in Martorell and other brands of the Volkswagen Group. When specific parts of the machinery wore out, it caused the devices to fail, and production had to be suddenly interrupted due to the need to change or repair these parts. This is a problem that affects various industries, where unexpected equipment failures jeopardise the continuity of operations and increase costs and inefficiencies.
To face these situations, SEAT CODE has developed Pibod with the aim of reducing unnecessary costs by making informed decisions and avoiding interruptions in production. This innovative software stands out for its ability to adapt to different machines, equipment and industries to gather information to prevent incidents.
Maximising equipment availability
The platform compiles data related to equipment performance, studying its relevance and assessing the extent to which it represents the condition of the machinery. Once validated, the data is analysed to identify relevant performance-related behaviours and provide information on the condition of different components in real time, facilitating the identification of issues quickly and clearly to optimise maintenance.
Pibod’s value proposition is based on its modular approach, which allows it to be implemented quickly and grow according to the needs and real value of the data collected, directing resources exactly where they are needed. The solution is differentiated by its use of machine learning, which facilitates the autonomous improvement of the software’s analytics through continuous data collection, increasing its efficiency and accuracy over time.
The solution offers a three-level procedure according to the specific needs of each piece of equipment or installation. The Basic Condition Monitoring (BCM) level, currently in use in several factories, allows you to start collecting and visualising data quickly and detect basic anomalies with a minimum investment to validate whether it is possible to scale up to more advanced solutions. For example, when implemented in a conveyor of the paint shop, Pibod detected the motor had an issue related to gearbox leaking oil, which was then efficiently repaired by maintenance, saving time and money.
The second level, Advanced Condition Monitoring (ACM), currently under development, will use the information from current equipment condition data to identify unexpected behaviour and correct it before errors and outages occur. Some examples of potential tools are:
· Intelligent Alerts: alerts based on applying severity criteria on singles spikes of variable value.
· Health Index: Measure of normality based on clustering several variables behaviour.
· Availability KPIs: key measures for equipment availability based on controller events
The higher-level Predictive Module (PM) envisages using information about expected future behaviour to predict potential failures and act proactively before they occur. Both ACM and PM elaborate data to provide more specific insights into equipment condition to better prioritise maintenance actions and act sooner, faster and based on better decision-making processes.
Pibod’s interface is designed as a single platform to monitor the status and data of all-connected and selected equipment thanks to its compatibility with any manufacturer. Detailed tracking of specific components and simple history checks are possible.
Pibod has been adapted to create ad-hoc solutions successfully implemented at SEAT Martorell and at the Volkswagen plant in Braunschweig (Germany), adjusting to the specifications of the equipment and production lines. The Basic Condition Monitoring module is also used at the German brand’s factories in Puebla (Mexico) and Wolfsburg (Germany).
