PREDICTIVE MAINTENANCE

& MACHINE LEARNING

Our job is to train computers to learn from data and improve with experience, rather than being specifically programmed to do so.

AI & INDUSTRY 5.0

The integration of Artificial Intelligence in industrial machinery offers a wide range of features aimed at optimizing production processes and reducing production costs. Among the services offered through AI, we can find: • Data analysis for plant diagnostics: A Specialist uses AI to analyze huge amounts of data from plant sensors in order to detect anomalies, predict failures and suggest preventive maintenance interventions. • Drafting of reports for predictive maintenance: Io Specialista generates detailed reports based on the data collected using AI, providing useful information to plan predictive maintenance interventions and reduce machine downtime. • Administration and optimization of processes and consumption: Io Specialista, supported by AI, analyzes production processes and energy consumption to identify areas for improvement and suggest corrective actions to optimize efficiency and reduce operating costs. • Technical and administrative support for access to tax breaks: the Specialist provides technical and administrative support to facilitate access to tax breaks and government incentives available to companies that invest in innovative and sustainable technologies. In summary, Artificial Intelligence integrated into industrial machinery offers significant potential to improve the efficiency, productivity and sustainability of operations, enabling companies to remain competitive in an increasingly dynamic and global market.

Optimized Fields

The application of these new technologies extends across different fields, adapting to the circumstances and environments of use to allow versatile and complete use of the equipment. Some of the consolidated fields of application include: • Industrial mixers/reactors: New technologies can be integrated to optimize the mixing and reaction process in an industrial setting, improving the efficiency and quality of the final product. • Industrial extraction systems (melting furnaces): Advanced technologies can be used to improve the effectiveness of industrial extraction systems, ensuring efficient removal of fumes, vapors and harmful particles from metal casting and processing processes. • Grinding wheel extraction systems and extraction towers: New technologies allow to optimize the efficiency of extraction systems used in industrial environments for the removal of dust, fumes and vapors harmful to health and the environment. • Shooting ranges: Innovative technologies can be implemented to improve the safety and efficiency of shooting ranges, allowing advanced management of ventilation systems, monitoring. • Chemical laboratories: To ensure safer operation of ventilation and alarm systems • Compressor motors and machine and tool motors: New technologies can be integrated into compressor motors and machine and tool motors to optimize performance, reduce energy consumption and extend operating life. • Rolling mills: In rolling processes, advanced technologies can be used to improve the accuracy, speed and quality of material rolling, while reducing waste and downtime. • Industrial plant cooling water pumps: New technologies can be applied to pumps used in industrial plant cooling systems to improve their energy efficiency, wear resistance and automated management of operations. The application of these technologies in a wide range of industries helps improve plant performance, efficiency and safety, enabling companies to achieve higher production goals and remain competitive in the market.

During the design phase of an industrial plant, it is essential to draw up a series of technical documents that outline in detail the key aspects of the project. Below, we briefly list the documents that will be drawn up: 1. Machine and Plant Layout: • This document provides a detailed and accurate representation of the spatial arrangement of the machines and plants within the production area. • It includes a plan of the entire plant, indicating the position of the different production units, assembly lines, workstations and spaces dedicated to warehouses and storage areas. • In addition to the physical arrangement, the layout also considers ergonomic aspects, safety at work, material and personnel flows, space optimization and accessibility for maintenance and repairs. 2. Technical Specifications: • The technical specifications define in detail the requirements and performance of the machines, plants and equipment used in the plant. • This document includes a description of the technical characteristics required for each component, such as power, production capacity, dimensions, construction materials and applicable safety regulations. • The technical specifications serve as the basis for acquiring and evaluating supplier proposals, ensuring that all elements of the plant meet quality standards and the specific needs of the project. 3. Electromechanical Plant Design: • This document details the electromechanical design of the plant, including all systems and components that contribute to the operation of the plant. • It includes the design of electrical power systems, distribution panels, automation and control systems, safety devices, material handling systems (such as conveyors, industrial robots, and cranes), cooling and ventilation systems, and supporting infrastructure. • This document provides technical drawings, schematics, and diagrams that illustrate the layout, operation, and interconnection of all electrical, mechanical, and hydraulic components of the plant. 4. Intranet and Extranet Network Interface Design: • This document describes the design of the network infrastructure required to support internal and external communications to the plant. • Includes the design of local area networks (LANs), structured cabling systems, Internet connections, and virtual private networks (VPNs) for remote access. • Also considers network security requirements, such as protecting sensitive data, ensuring authorized access, and implementing firewalls and intrusion detection systems. • This document provides detailed guidance for implementing and configuring communications networks, ensuring reliable connectivity and secure data management inside and outside the plant. In summary, these documents are an essential part of the industrial plant design process, providing detailed and comprehensive guidance for the creation of an efficient, safe, and functional plant.

Procedures and Personnel

The equipment installation procedure involves several key figures, each of which plays a fundamental role in ensuring the correct functioning of the system. These figures can be selected internally or externally to the company and, after adequate training, will be able to proceed with the application of the product on the selected machinery. The main figures required for the operations are: ELECTRICAL: • The electrician plays a fundamental role in the installation of the electrical elements of the system. This includes the correct connection of the PLC (Programmable Logic Controller) safety sensors with the electrical equipment of the system. • His work is not limited to simple wiring, but also involves checking the electrical compatibility between the different components and compliance with the applicable electrical safety standards. • Furthermore, the electrician is responsible for the fine-tuning of the electrical safety systems, thoroughly testing the operation of the sensors and actuators to ensure a reliable response in the event of an emergency. MECHANICAL • The mechanic is responsible for the physical installation of the mechanical elements of the system. This includes fixing the mechanical equipment necessary for the correct functioning of the system. • This role is responsible for precision and accuracy during the installation of mechanical components, ensuring that all parts are positioned and secured correctly to avoid malfunctions or damage during operation. • The mechanic ensures that each component is integrated into the system in a manner consistent with the overall design of the plant, thus contributing to the safety and efficiency of operations. INFORMATION TECHNICIAN • The information technology specialist is responsible for completing the digital integration of the plant with the company network. This includes configuring network devices such as switches, routers, and firewalls to enable communication between industrial devices and company information systems. • This role is responsible for configuring network security settings, ensuring that access to data and devices is limited and protected from external threats such as hacking or malware. • Additionally, the information technology specialist works with specialized personnel to ensure the correct configuration and interoperability of industrial automation systems with company management systems (such as ERP) for integrated and efficient management of operations. In summary, each key figure involved in the installation process plays a unique and complementary role in ensuring the success of the industrial plant integration, combining specialist skills and knowledge to ensure an optimal result.

Data and Application Management

After putting the system into operation, the company will be offered two distinct methods of managing the data generated by the system itself. The two main options are internal and external management: INTERNAL MANAGEMENT In this mode, the company chooses to manage the data internally, entrusting the responsibility for managing and interpreting the data to a specialist trained directly by a Specialized Technician from our Team. EXTERNAL MANAGEMENT In external data management, our specialized technicians take direct responsibility for managing and analyzing the data generated by the system. They offer a series of specialized services aimed at optimizing the use of the data and providing technical-administrative support to the client company. The main services offered are listed below: • DATA ANALYSIS FOR PLANT DIAGNOSTICS: The technicians dedicate themselves to the detailed analysis of the data produced by the system to evaluate the state of health of the industrial plants. This analysis allows for the identification of any anomalies, imminent failures or inefficiencies in the production processes, allowing for timely maintenance or correction interventions. • PREDICTIVE MAINTENANCE REPORT DRAFTING: Specialists draw up detailed reports based on the analysis of the collected data, providing valuable insights for the implementation of predictive maintenance strategies. This type of maintenance allows you to plan interventions in advance, reducing machine downtime and optimizing company resources. • PROCESS AND CONSUMPTION ADMINISTRATION AND OPTIMIZATION: In the context of process and consumption administration and optimization, the use of collected data offers a unique opportunity to propose targeted solutions for improving the efficiency of company infrastructures. Through detailed data analysis, it is possible to identify areas for improvement and implement strategies aimed at optimizing operational efficiency and reducing energy consumption. Below are some of the solutions that can be proposed: > Production Cycle Requalification: • Based on the data collected on the performance of the production cycle, it is possible to identify any inefficiencies or downtime in production. • Through in-depth analysis, solutions can be proposed to optimize the production flow, reduce production times and increase the overall productivity of the plant. > Remodulation of Set-Point Parameters: • Data analysis allows you to evaluate the performance of industrial processes and adjust the set-point parameters optimally. • By modifying the operating parameters based on real conditions, it is possible to improve process efficiency and reduce energy consumption without compromising product quality. > Replacement of Systems with More Efficient Ones: • By analyzing the performance data of plants and equipment, it is possible to evaluate the opportunity to replace obsolete systems with more efficient and advanced ones. • This may include replacing less efficient machinery with newer and more technologically advanced models, capable of ensuring better performance and reduced consumption. > Feasibility Study (Investment Plan): • Based on the data collected and the performance analysis, it is possible to develop a feasibility study to identify the best investment opportunities. • This study may include evaluating the costs and benefits associated with different optimization solutions and defining a long-term investment plan to improve the efficiency and competitiveness of the company. • TECHNICAL-ADMINISTRATIVE SUPPORT FOR ACCESS TO TAX BENEFITS: From the point of view of tax administration, we offer a complete range of services and opportunities designed to optimize the company and maximize the available tax benefits. Through a rigorous analysis of tax regulations and a deep understanding of the regulatory context, these services are: FINANCIAL EFFICIENCY > Single consultancy The Single Consultancy service supports companies in obtaining a specific contribution/call. During the Single Consultancy we will follow you throughout the process of obtaining the benefit from the collection of documents, to the submission of the application and up to the final reporting that will allow you to obtain the requested benefit. > Continuous consultancy The Continuous Consultancy service is designed for all those companies interested in developing a medium-long term investment plan. Continuous Consultancy will allow you to select the most convenient concessions for your company and to have the support of a Consultant dedicated to you throughout the duration of the support. Continuous Vendor Consulting provides a win-win approach: we are committed to helping you achieve a minimum objective thanks to non-repayable grants and/or tax breaks, calls for proposals and structured funds, subsidized financing. OPERATIONAL EFFICIENCY 5.0 > Diagnosis 5.0 Diagnosis 5.0 is the mapping of company processes that allows you to evaluate the degree of maturity of company processes, identify operational inefficiencies and find solutions to optimize processes, defining costs and times necessary for its implementation. > Operational Support Operational Support 5.0 is the solution that allows your company to have a team of professionals to guide the operational efficiency path you have chosen to undertake. Among our areas of intervention: production department, logistics and warehouse etc. > Management Control Management Control is the activity that allows you to monitor economic resources and production factors, detect any cost deviations and introduce a new estimating methodology. > AI Implementation The implementation of Artificial Intelligence to reduce energy consumption and expenses represents an innovative corporate strategy aimed at optimizing operational efficiency and promoting environmental sustainability. From a personnel perspective, this initiative is of crucial importance as it requires careful planning and adequate management of organizational change. In particular, it is essential to actively involve personnel through targeted training and awareness programs, in order to promote a corporate culture oriented towards sustainability and the adoption of new technologies. At the same time, it is essential to ensure effective internal communication, providing clear guidelines and constant support to encourage the adoption and integration of Artificial Intelligence in daily activities. Through a holistic and participatory approach, the company can maximize personnel involvement and ensure the success of the implementation of Artificial Intelligence in pursuing the objectives of reducing energy consumption and expenses. ENERGY EFFICIENCY > Energy Diagnosis The Energy Diagnosis is a snapshot of the company's energy consumption. It is the first necessary step to start an energy efficiency plan. Through Energy Diagnosis, in fact, it is possible to acquire information regarding the company's energy consumption, understanding which systems consume the most and when. The goal is to obtain a complete picture of the consumption trend before starting the development of an energy efficiency project. > Energy Management Energy Management is the analysis, monitoring and optimization of a company's energy resources for the correct management of consumption and the achievement of economic and environmental benefits. Energy Management consists in the development of an energy efficiency plan aimed at the rational and conscious management of energy sources.

Data analysis for system diagnostics

The function of data analysis for plant diagnostics is of fundamental importance in ensuring the correct operation and safety of industrial equipment. By acquiring and processing data emitted by the plant, our specialized technicians can access a wide range of information that is crucial for evaluating performance and detecting any anomalies. Some of the parameters monitored and analyzed include: • Energy Consumption: Our technicians can closely monitor the energy consumption of the plant, analyzing data relating to the consumption of electricity, gas or other fuels. This allows you to identify potential inefficiencies and implement strategies to reduce energy costs and promote environmental sustainability. • Machine Stress (temperatures, vibrations, etc.): The data collected allows you to monitor the health of the machines and equipment, including parameters such as operating temperatures, vibrations and other operating conditions. The analysis of this data allows you to detect signs of overload, overheating or excessive wear, which could indicate potential impending failures or the need for preventive maintenance. • Utilization Coefficient: The utilization coefficient provides information on the frequency and intensity of plant use. This parameter is crucial for evaluating operational efficiency and resource optimization, allowing you to identify any under- or over-utilization of the plant and take the necessary corrective measures. • Reported Anomalies: Data analysis allows you to identify and document any anomaly or warning reported by the plant. These anomalies may concern malfunctions, system errors or other critical situations that require careful attention and timely intervention by technicians. Once this information has been extracted and processed, several opportunities open up for their strategic use such as: • Identification of machine operating Set-Point values: The Set-Point values represent the optimal operating parameters of the plant. Using the data collected, technicians can identify and optimize these values to maximize efficiency and reduce energy consumption. • Analysis and intervention on any anomalies found: The anomalies detected can be reported and carefully analyzed to determine their cause and extent. When necessary, technicians can intervene directly on site to verify the structures and identify appropriate solutions. • Reporting: Anomalies can be reported for further analysis or intervention. • On-site intervention to verify the structures: This type of intervention can occur for several purposes: • Data collection survey: To obtain additional information or confirm observations collected by sensors. • Troubleshooting by maintenance personnel: If necessary, technicians can work with maintenance personnel to resolve identified problems, ensuring optimal operation of the system. Ultimately, analyzing data for system diagnostics allows our technicians to monitor the performance of the system, identify potential critical issues and intervene promptly to ensure efficient and reliable operation.

Predictive Maintenance Report Writing

Through an in-depth analysis of the data obtained, it will be possible to develop a detailed assessment of the operational status of the industrial equipment. This assessment will be based on a sophisticated probabilistic analysis, using weighted averages to obtain an accurate representation of the plant conditions. The main results that will be obtained include: • Wear status of the equipment: An in-depth analysis of the wear status of the industrial equipment will be conducted, considering various parameters and indicators. The structural integrity of the equipment will be assessed, with particular attention to critical components such as bearings, gearboxes and other elements subject to wear. Any signs of deterioration or corrosion on the metallic components will be examined, as well as the presence of visible damage or anomalies in the contact surfaces. Signs of degradation in non-metallic components, such as seals, belts and plastic components, which can affect the performance of the equipment, will also be taken into account. System anomalies: Any system anomalies that can affect the correct operation of the equipment will be identified and analyzed. These anomalies may involve software malfunctions, calibration errors, or compatibility problems between components. Particular attention will be paid to sensor reading errors, signal losses or failures in automatic control systems, which can compromise the safety and efficiency of operations. Out-of-range parameters: Data will be analyzed to identify operating parameters that deviate from the optimal ranges defined for the equipment. These parameters may include temperatures, pressures, rotational speeds or other specific indicators of operating conditions. Identifying out-of-range parameters may indicate the need for adjustments, calibrations or corrective maintenance to bring the equipment performance back within acceptable limits. Excessive consumption: Energy consumption data will be analyzed to identify situations of overuse or inefficiency in the use of resources. Any abnormal peaks in energy consumption or significant variations from reference levels will be assessed, which may indicate efficiency problems or energy losses in the plant. Abnormal wear (bearings, gearboxes, etc.): A specific analysis will be conducted to detect signs of abnormal wear on critical components such as bearings and gearboxes. Particular attention will be paid to abnormal noises, excessive vibrations or localized overheating, which may indicate wear problems or damage to mechanical components. This detailed analysis will provide a complete view of the health status of industrial equipment, allowing any critical issues to be identified and addressed promptly and ensuring reliable and safe operation of the plant. • Predictive maintenance setup In terms of predictive maintenance setup, the following activities will need to be carried out: Maintenance scheduling and coordination with other machines: Predictive maintenance activities will be planned based on the data collected during the plant analysis. The timing and methods of carrying out preventive maintenance operations will be defined, taking into account the specific needs of the plant and the equipment involved. Maintenance activities will be coordinated with other machines or systems in the plant, ensuring integrated and synergic management of operations to maximize the overall effectiveness of maintenance activities. Definition of maintenance priorities: Priorities will be given to the various maintenance activities based on the criticality of the equipment and components involved. Equipment or components requiring immediate or urgent intervention will be identified to ensure operational continuity and plant safety. Objective criteria will be established for the classification of maintenance priorities, taking into account factors such as the impact on plant performance, the risk of failure or malfunction, and the availability of resources required for the intervention. These activities will allow predictive maintenance operations to be planned and managed effectively, ensuring timely and targeted preventive maintenance that will help reduce the risk of failure and optimize the overall performance of the plant. • Plant optimization methods In terms of plant optimization methods, the following strategies will be implemented: Process Analysis and Identification of Inefficiencies: A detailed analysis of the production processes and plant operations will be conducted in order to identify any inefficiencies or areas for improvement. Activities or processes requiring optimization will be identified to maximize the overall efficiency of the plant. Staff Training and Continuous Improvement Culture: Investment will be made in staff training to ensure proper understanding and adoption of new practices and technologies implemented. A culture of continuous improvement will be promoted, encouraging active involvement of staff in identifying optimization opportunities and implementing innovative solutions. Implementing these plant optimization methods will maximize operational efficiency, reduce production costs and improve the overall competitiveness of the company.

ACCESS TO THE DEDICATED WEB PORTAL

Predictive maintenance is a type of preventive maintenance that is performed following the identification of one or more parameters that are measured and processed using appropriate mathematical models in order to identify the time remaining before failure. To this end, various methodologies are used, such as trichological analysis of lubricants, vibration measurement, thermography, analysis of absorbed currents, detection of abnormal vibrations and many others. To predict when maintenance will be necessary, it is based on the actual conditions of the equipment, rather than on average or expected life statistics. A variation in the measurements taken compared to the normal operating state will indicate increasing degradation and, ultimately, will allow the timing of failure to be predicted. ACCESS CREDENTIALS: USER: areamanager@motive.it PW: Fermai2023!