INFINITE UPTIME

Digitizing Industry
INFINITE UPTIME: A GLOBAL SOLUTION PROVIDER
Infinite Uptime ranked
in the top 10 IoT
solutions globally by
APAC CIOOutlook 2017

R&D, AI, data analytics,

software, PCB design,
firmware

Manufacturing,
assembly,
shipping

Sales, marketing,
distribution,
customer support

An Industrial IoT solution provider harnessing AI for improved

productivity, quality, monitoring and predictive intelligence
 INDUSTRY GAP: LACK OF SCALABLE PREDICTIVE ANALYTICS
20% of breakdown 5% of breakdown
• Hydraulics • Thermal
• Pressure • Temperature
• Temperature • Thermal Mapping
• Flow Rate Standard IoT • Thermal Flux Standard IoT
(sensors + wireless (sensors + wireless
• Contamination transmission) transmission)
• Density

70% of breakdown 5% of breakdown

• Mechanical • Electrical
• Wear • Electronics Life
• Deterioration Very high frequency data • Power surge
• Backlash Difficult to decipher signal from noise • Current Standard IoT
• Increase in clearances Bandwidth limitations • Voltage (sensors + wireless
Storage limitations
• Vibrations Standard IoT does not work :-/
• Power factor transmission)
• Acoustics • Energy Efficiency
 IDE: DIGITIZE ANY EQUIPMENT IN UNDER 1 MINUTE

Installs on any machine within seconds Immediate feedback through visual Monitor remotely and wirelessly, to
1 through a magnetic connection 2 fault-detecting indicators 3 mirror notifications and record data.
 INFINITE UPTIME TECHNOLOGY

Smart sensor system Local machine monitoring Cloud infrastructure with backend
with edge computing software and visualization data analytics and dashboard

Cloud computing with unsupervised learning

CORE IP
Edge Computing + Time
series pattern recognition Edge computing Edge computing

(unsupervised learning / AI)

2 INTERNATIONAL PATENTS FILED

 IDE: DIGITIZE ANY EQUIPMENT IN UNDER 1 MINUTE

Installs on any machine within seconds Immediate feedback through visual Monitor remotely and wirelessly, to
1 through a magnetic connection 2 fault-detecting indicators 3 mirror notifications and record data.
INFINITE UPTIME
Case Study Applications
CASE STUDY: PREDICTION OF PRESS BREAKDOWN
SUCCESS STORY:

▪ Detection of unusual vibrations in the lateral axis of a 1000T press 4 hours

before breakage

▪ Prediction of bolt breakage due to bolt wear-out and failure saved almost 10
hours of downtime

OTHER VALUE ADDITION:

▪ Cycle time optimization by studying the motions of different moving

components of a machine

▪ Detection of unusual vibrations on transfer system to prevent a failure or a

conveyor path / trajectory to pinpoint area of high vibrations

▪ Detection of improper change in acceleration and deceleration in a hydraulic

press indicating improper functioning of proportional valve

PREDICTIVE INTELLIGENCE CAN IMPROVE OPERATIVE KPIS

CASE STUDY: PREDICTION OF DETERIORATION & WEAR
SUCCESS STORY:

▪ Detection of unusual vibrations in the lateral axis of a 1000T press 4 hours

before breakage

▪ Prediction of bolt breakage due to bolt wear-out and failure saved almost 10
hours of downtime

OTHER OPPORTUNITIES:

▪ Cycle time optimization by studying the motions of the ram, transfer arm,
ejector pins at actuals

▪ Detection of unusual vibrations on TES to prevent a TES failure or the Webb

conveyor path / trajectory to pinpoint area of high vibrations

▪ Detection of improper change in acceleration and deceleration in a hydraulic

press indicating improper functioning of proportional valve

PROCESS CONTROL
PREDICTIVE THROUGH CAN
INTELLIGENCE VERYIMPROVE
HIGH FREQUENCY ANALYTICS
OPERATIVE KPIS
CASE STUDY: PREDICTION OF ROLL BREAKAGE
BREAKAGE TOOL REPLACEMENT

BEFORE BREAKAGE AFTER BREAKAGE NORMAL

PREDICTIVE INTELLIGENCE CAN IMPROVE OPERATIVE KPIS

CASE STUDY: PREDICTION OF ROLL BREAKAGE
BREAKAGE TOOL REPLACEMENT

BEFORE BREAKAGE AFTER BREAKAGE NORMAL

PREDICTIVE INTELLIGENCE CAN IMPROVE OPERATIVE KPIS

CASE STUDY: OEE IMPROVEMENT
SUCCESS STORY:

▪ Identification of hidden losses by

studying the production characteristics
of a machine

▪ Achievement of record production

within 2 months due to a combination
of operative and predictive analytics

▪ Moving from Preventive Maintenance to

Predictive and Proactive Maintenance
can reduce breakdown by 90% and
improve OEE to record levels

ATTACKING HIDDEN LOSSES CAN IMPROVE OPERATIVE KPIS

CASE STUDY: PUMP AND MOTOR MONITORING

CUSTOMER: VALVE MANUFACTURER IN TOKYO

▪ Identification of faulty equipment by

acoustic, temperature and vibration
monitoring of pumps and motors

▪ Achievement of 50% lower breakdown due

to a combination of FFT and predictive
analytics

▪ Prediction of misalignment, looseness, shaft

eccentricity, and wear out through high
frequency vibrations analysis

ASSET MONITORING FOR HIGH FREQUENCY ACOUSTICS & VIBRATIONS

INFINITE UPTIME
Customer Impact
CUSTOMER: FLUID TRANSMISSIONS MANUFACTURER

PROVEN PLANT EFFICIENCY IMPROVEMENT BY 25%

CUSTOMER: LARGEST FORGING COMPANY IN ASIA

PREDICTIVE ANALYTICS RESULTS IN 15% EFFICIENCY IMPROVEMENT

CUSTOMER: LARGEST FORGING COMPANY IN ASIA

Main Press Ram – Die Holder Screw Breakage Predicted: Jan 5, 2018
CUSTOMER: LARGEST FORGING COMPANY IN ASIA

Everising Cutter Wear Out Predicted: Oct 27, 2017

CUSTOMER: LARGEST FORGING COMPANY IN ASIA

Reduce Roller Brake Looseness Predicted: Dec 25, 2017

 CUSTOMER: LARGEST FORGING COMPANY IN ASIA
• Installed: 2 August 2017, 13 IDE Kurimoto & 13 IDE Jaewoo
Before
• Kurimoto Line success cases: maintenance

• TES Clamp: Breakdown reduced from 18% to 1%

• Predictive maintenance protocol established and every
predictive alert is now responded to within 2 hours
• Conveyor Hanger: Identification of conveyor drive hanger issues
are now detected and action is taken before breakdown, After
protocol is changed mainte
• Spares: Spares inventory is reduced by 30% due to higher nance
reliability of equipment
Planned
• Next Steps: Installed on 12500 T Press and same proven predictive Maintenance
alerting protocol has been established

UNLOCKING A POTENTIAL OF 25% MORE CRANKSHAFTS PER YEAR TOWARDS DIRECT PROFIT
CUSTOMER: LARGEST AUTO SUPPLIER IN INDIA

Actual Bearing Failure actually predicted and detected Bearing Failure Prediction & Detection
On Line-11 Grinder at 4:45 pm on 13 March 2017 using vibration FFT of workhead assembly

PREDICT ANOMALIES IN ADVANCE AND PREVENT POOR QUALITY PRODUCTION

 CUSTOMER: LARGEST AUTO SUPPLIER IN INDIA
• Downtime due to breakdown maintenance in 6 months (from SAP system)= 46 hours
(Line-11, new Grinding M/c)

• Causes of highest breakdown time that can be prevented are belt slippage, pulley
damage, motor wear-out, bearing wear-out due to high replacement time

• Approximate ratio of breakdown time that can be prevented on all machines per year
through predictive analytics = 60% of breakdown time

• Potential additional crankshafts produced per year by implementation on Industry 4.0 =

28% more components (assuming 10% hit rate ONLY)

UNLOCKING A POTENTIAL OF 28% MORE OUTPUT PER YEAR TOWARDS DIRECT PROFIT
CUSTOMER: FLUID TRANSMISSIONS MANUFACTURER

CUSTOMER VOICE OF PROVEN VALUE ADDITION TO PLANT EFFICIENCIES

 INFINITE UPTIME
Customer Study And Analysis:
Largest Tobacco Manufacturer in India

Customer Problem: Unreliable quality due to Temsec

Cylinder
VIBRATION MONITORING: VELOCITIES IN MM/S

TW Combining Roll MW Drive Roll

UNSTABLE VELOCITIES IN ALL 3 AXES INDICATING UNSTABLE EQUIPMENT

VIBRATION MONITORING: VELOCITIES IN MM/S

Anomalous zones causing

system alarms

UNSTABLE VELOCITIES IN ALL 3 AXES INDICATING UNSTABLE EQUIPMENT

VIBRATION MONITORING: VELOCITIES IN MM/S

CONDITION REFLECTED IN EQUIPMENT HISTORY

UNSTABLE VELOCITIES IN ALL 3 AXES INDICATING UNSTABLE EQUIPMENT

FFT ANALYSIS: FFT IN ALL THREE AXES

Observations:

• Very irregular FFT spectrum for the Z axis for

the Tesmec Cylinder Gearbox

• Anomalous harmonics in the 2x and 3x regions

(first even and first odd harmonics) – indicating the
onset of misalignment or looseness

• Very large peak in the frequency spectrum for

the dominant frequency indicating a very clear
misalignment and immediate need for dynamic
balancing

AUTOMATIC “FFT ON DEMAND” OR AT PRE-DEFINED REGULAR INTERVALS

 INFINITE UPTIME
Customer Study And Analysis:
Largest Refinery in India

Customer Problem: Erratic Failure of Sundyne Pumps

TIME SERIES DATA: TEMPERATURE (DEG C)

Observations:

• Widely varying temperature profiles which have

a continuous repeatable pattern

• Sharp peak / increase in temperature on 28

August which is tagged as anomalous by the
system

• Average temperature of around 50 degrees but

high standard deviation indicating a loading and
unloading pattern or varying load patterns

• 2 peaks a day seem to recur repeatedly

CONTINUOUS DATA MONITORING AND ANOMALY DETECTION

VIBRATION MONITORING: VELOCITIES IN MM/S

Anomalous zones causing

system alarms

UNSTABLE VELOCITIES IN ALL 3 AXES INDICATING UNSTABLE EQUIPMENT

FFT ANALYSIS: FFT IN ALL THREE AXES

Observations:

• Very irregular FFT spectrum for the Z axis for

the Sundyne Pump

• Anomalous harmonics in the 2x, 3x and 4x

regions (first two even and first odd harmonics) –
indicating the onset of misalignment or looseness

• No large peak in the frequency spectrum for the

dominant frequency indicating a clear
misalignment or eccentricity in the system in the Z
axis about the X-Y plane

AUTOMATIC “FFT ON DEMAND” OR AT PRE-DEFINED REGULAR INTERVALS

 INFINITE UPTIME
A smarter future for industries
INFINITE UPTIME, INC.
2150 Shattuck Avenue,
Berkeley, CA - 94704 USA
contact@infinite-uptime.com
Ph: +1-510-862-0328
INFINITE UPTIME INDIA PVT LTD
J-194, MIDC Bhosari,
Pune – 411026, MH, India
contact@infinite-uptime.com
Ph: +91-8380013129