Editorial

MICHAEL KAYE APPOINTED GENERAL MANAGER OF THE COMBUSTION ENGINEERING ASSOCIATION

The Combustion Engineering Association (CEA) is pleased to announce Michael Kaye as its new General Manager. With a strong background in mechanical and design engineering, coupled with years of industry leadership, Michael brings both expertise and a fresh perspective to this long-standing trade association and educational charity.

Graduating from Nottingham Trent University with a degree in mechanical engineering, Michael began his career as a design engineer at APV Baker PMC where he honed his technical skills before moving into leadership roles across various industries. His career spans sectors including textile testing instrumentation and bulk materials handling, where he earned a reputation for fostering innovation, building effective teams, and driving business growth. At Flexco, where he also served as General Manager, Michael led initiatives that not only grew the business but also set new benchmarks for industry standards.

In addition to his professional achievements, Michael has also been deeply involved in association work where, as a long-time member and former president of the Materials Handling Engineers Association (MHEA), he gained valuable experience in bringing members together, organising impactful events, and promoting technical excellence, skills that align perfectly with the CEA’s mission.

Commenting on behalf of the CEA, President Mick Casey shared his thoughts on Michael’s appointment: “We are thrilled to welcome Michael as our new General Manager. His leadership comes at a pivotal time for the CEA as we navigate changes across the combustion-related sectors, and his vision for enhancing member engagement and promoting sustainable practices will undoubtedly strengthen our role in the industry.”.

Michael himself expressed enthusiasm for his new role: “The energy sector is undergoing significant transformation as we tackle challenges including the adoption of alternative fuels, decarbonisation and achieving net-zero goals. I see the CEA playing a key role in driving these conversations and supporting our members with practical solutions. Together, we’ll focus on alternative fuels, energy efficiency, and sustainable practices.”.

One of Michael’s immediate priorities is overseeing the CEA’s transition into a Charitable Incorporated Organisation (CIO). He also aims to expand training programs such as the Boiler Operation Accreditation Scheme (BOAS) while building stronger connections with academic institutions to nurture future talent in combustion engineering.

Under his leadership, the CEA also plans to reinvigorate its events calendar with site visits, networking opportunities, and conferences designed to deliver real value to members. The first of these initiatives – a site visit to James Cropper’s paper mill scheduled for February 2025 – will combine technical insights with opportunities for collaboration.

For further information on CEA initiatives or membership opportunities, visit www.cea.org.uk, email This email address is being protected from spambots. You need JavaScript enabled to view it., or call 01740 625538.

Future in the making: Four predictions for Manufacturing in 2025

I speak with hundreds of manufacturing decision-makers and industry experts at industry events about the major trends impacting the global manufacturing industry.

With output set to rise by three percent in 2025, it is clear that the future of the industry is bright. Judging by the conversations I have with people at the manufacturing frontline, this positive development is to a large degree driven by the increasing adoption of Industry 4.0 technologies and practices among businesses around the world.

As the industry grows smarter, here are my four key takeaways from my conversations with leading manufacturers. These major trends and innovations are highly likely to shape global manufacturing in 2025 and beyond.

  1. Advancing Digitalization

In the world of manufacturing, digitalization is often synonymous with automation. This is something that manufacturers have always excelled at. Simultaneously, sensors and endpoints are widespread and their numbers growing, a noticeable upsurge from Gartner's 21 billion estimate back in 2020. What this means is that clearly, businesses can capture data like never before.

I expect that we will see accelerated efforts to augment automation with data to drive even smarter factories and equip decision-makers with unprecedented insights, especially when it comes to enterprise asset management (EAM). We should also expect digital twins—an area predicted to grow at a compound annual growth rate (CAGR) of 30 percent from 2023 to 2027—to play an integral role in this development as businesses look for intelligent ways to transform vast fields of unstructured data into a centralized model that helps visualize complex assets and improve collaboration between departments and functions.

As digitalization picks up even more momentum over the coming years, so will the associated risks. By digitizing processes and value chains, companies are exposing themselves to the threat of data security challenges, including malware incidents, loss of data, or Denial-of-Service (DoS) attacks that have the potential to cripple businesses. Given the magnitude of the risks involved, I believe that we will see increased focus among manufacturing businesses to invest in effective cybersecurity measures. This will, in turn, lead to an industry-wide strengthening of supply chain integrity.

Advancing digitalization and automation will naturally influence the workforce. However, rather than replacing those roles filled by humans, technology will instead be used as a tool to help improve the efficiency of personnel to make workdays more productive and flexible. In other words, when digitalization has automated those tasks that do not benefit from human intervention, workers are free to turn their attention to more complex tasks where value can be added.

  1. AI-Powered Predictive Maintenance

As the above-mentioned figures from Gartner indicate, the industry is connecting assets at a furious pace. This increase in available data is the driving force behind an advancement in predictive maintenance initiatives, which I believe will help shape the manufacturing sector in the years to come. The most crucial component of any effort in this area is the EAM solution and how it connects to the company’s installed base of assets. After all, the more interconnected the EAM solution and your assets become, the more imperative it is to predict and project on asset failure. With the help of data-driven insights, predicting when a machine will fail will allow businesses to take measures to prevent this from happening.

The growing interest in predictive maintenance is hardly surprising given the financial incentives. For example, predictive maintenance can save up to 40 percent in costs compared to reactive maintenance and 8–12 percent when compared to preventive maintenance. Predictive maintenance can also extend asset lifespans by 20–40 percent. No wonder the market for these solutions is projected to grow to USD 47.8 billion in 2029 (CAGR 35.1 percent).

Artificial Intelligence (AI) is a key differentiator that will drive all major advancements in predictive maintenance for years to come. Making sense of and operationalizing sensory data, AI models will retain their looming presence in enterprise asset management as companies explore new ways of harnessing machine learning to enhance error detection and prevention, while also increasing energy efficiency.  

  1. Purposeful Production

At the same rate the global population is growing, so is our demand for goods and services. To meet this demand, greenhouse gas emissions have increased by 50 percent over the last three decades. In 2023, according to the US Environmental Protection Agency, the manufacturing and raw materials industries accounted for approximately 23 percent of emissions, while manufacturing consumed some 33 percent of the world’s energy.

As a result of these rather sobering figures, I see a clear shift among manufacturers toward a more purposeful production wherein goods are made in a way that minimizes the environmental footprint, conserves resource and considers both the social and economic aspects of its impact.

What we are seeing now and in the coming years is a global shift to a circular economy that lets us reduce waste and use resources more efficiently. As these new imperatives are becoming reality, manufacturers will need to adopt technology to help implement lean processes, ensure increased productivity, minimize energy consumption, ensure supply chain traceability, enhance workplace safety and much more.

For the manufacturing sector, this is a sea change that imposes increasingly stringent demands on operations - not only in terms of supply chain visibility and raw material sourcing, but also when it comes to the emissions and energy consumption of their factories. For this reason, many businesses will need to overhaul production methods, maintenance practices, and reporting capabilities.

  1. The Changing Workforce, and Skills Shortages

There’s a clear shift in the way maintenance departments operate that will reach a critical inflection point in 2025. As internal processes become increasingly digitized, maintenance workers must become more adept at using different technologies, tools and platforms. New skill sets are required around the collection, analysis and interpretation of data that will assure manufacturers are fit for the future.

The lack of skilled personnel is acute. A third (31 percent) of companies outsource operations because skilled individuals are hard to find, and over half (58 percent) of manufacturing employees have worked in the industry for more than 20 years. 

While manufacturers have been dealing with an aging workforce for some time, they would be wise to start hiring on skill sets that better match the technological requirements and advancements of tomorrow, versus talent that will follow directly in the footsteps of today’s engineers.

Looking further to the future, immersive technologies such as virtual reality (VR), mixed reality (MR), and augmented reality (AR) are set to redefine how all industries function. In the manufacturing sector, metaverse-based tools will unlock new vistas of opportunity. For example, VR technology can help staff to develop their skills without leaving the room. MR and AR can likewise empower workers to solve problems in the field by tapping into a central knowledge repository or by drawing on the skills of remote coworkers. Besides savings in time, cost and effort, reports suggest monumental increases in productivity of up to 20 percent. The business case for immersive technology is compelling.

Immersive technology holds the potential to revolutionize the way manufacturing operates, and the growing reliance on predictive analytics, AR, VR, and other advanced technologies will demand a workforce proficient not just in basic digital skills, but also in using these sophisticated tools in their daily work.

With a third of the manufacturing workforce at age 55 or older, businesses will be forced to make changes in order to attract younger generations of workers. Over the next few years, I believe that a vanguard of manufacturing businesses will start deploying immersive and other emerging technology to appeal to generation-now workers whose digital nativeness and low threshold for adoption will unlock new efficiencies and ways of working.

The Future is Bright

Despite some of the challenges outlined above, I see a bright future for the manufacturing industry. Speaking with customers, partners, and industry experts, it is clear to me that there has never been a more opportune moment to improve, streamline and innovate. Combining the potential of cutting-edge technology with the responsible and sustainable ethos of purposeful production, I am convinced that the manufacturing industry is ready to face the future.

www.ultimo.com

 

Steam Network UK, is a new venture to promote services to the steam industry.

We aim to establish a directory of businesses supporting the steam industry, providing end users with a centralised resource for services, products and expertise. Our easy to navigate website features categorised sections which enables services to be located with ease. Additionally we utilise social media to share members services, products and case studies with a wide audience.

Our mission is to support business and end users of steam and boiler systems across manufacturing, process and industrial environments. By fostering a network that facilitates business to business interactions, we aim to address the growing scarcity of engineering disciplines in todays industrial sectors.

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Our platform is broken down into key elements supporting the generation and distribution of steam. The main categories being:

  • Burner Manufactures
  • Boiler Manufacturers
  • Consultancy Services
  • Training Providers
  • Components and Ancillaries
  • Control and Automation
  • Temporary Solutions
  • Water Treatment
  • Chimneys and Flues
  • Emissions

Softener

So how can Steam Network benefit me?

If you’re a Businesses supplying products, service into the steam industry:

By becoming a member of Steam Network UK offers businesses a unique opportunity to be listed under categories specific to their services and products. We will actively promote your business to our extensive network and end users. As the only directory dedicated to supporting the steam industry, Steam Network UK ensures that your services are showcased to key stakeholders in need of your expertise.

If you are an end user of Steam and boiler systems:

In need of a boiler service engineer, Combustion Engineer, new Water treatment? Then look no further, Steam Network UK has all the contacts you need at your finger tips.

Our website allows for individuals to search the directory for relevant services that they may require. Whether you work in Engineering, Procurement, Management or Health and Safety, you’re sure to find a member that can support your needs.

Whether you are on the look out for a new Boiler, Water treatment services or stack emissions testing, then Steam Network can put you in contact direct with a reputable business to support you and your asset base. Partnering with one of our members provides peace of mind that your assets are in the capable hands of the UK’s leading specialist in their field of expertise.

Visit www.steamnetwork.co.uk today, to find the support you need.

Please contact This email address is being protected from spambots. You need JavaScript enabled to view it. should you have any further questions.

 

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MC Global Solutions and IFS Ultimo Partner to Deliver Real-Time Maintenance for Industrial Businesses

  • New alliance combines expertise at MC Global Solutions with Ultimo’s industry-leading1 EAM platform across Australia, New Zealand and the UK
  • MC Global Solutions’ clients to benefit from Ultimo’s holistic enterprise asset management (EAM) platform
  • Facilities management (FM) and EAM expertise of MC Global Solutions to further simplify industrial asset management

More businesses in Australia, New Zealand and the UK are set to benefit from Ultimo’s Cloud-based enterprise asset management (EAM) platform thanks to a new partnership with EAM consultancy, MC Global Solutions. The company specializes in third-party software integration to automate processes, enhance efficiency and reduce costs. Working for customers such as News Corp Australia and Devro, MC Global Solutions provides an integrated set of software applications backed with superior expertise, to make business systems more efficient and effective.

Steve Martin, Managing Director of MC Global Solutions, emphasizes the importance of EAM as a strategic goal for companies aiming to optimize their maintenance and operational workflows, “Our collaboration with IFS Ultimo enhances the accessibility of asset decision-making within the EAM industry, empowering organizations to manage operations more efficiently, minimize equipment downtime, and ultimately drive improved performance.”

 

James Mansfield, Channel Sales Director at IFS Ultimo adds, “This partnership is about leveraging the strengths of both companies to bring a truly innovative solution to the markets of MC Global. By combining MC Global Solutions’ expertise in EAM and FM software consultancy with our cutting-edge platform, we are creating a solution that transforms asset management from a cumbersome process into an efficient operation.”

With 90 percent of industrial companies acknowledging that improved EAM software is pivotal to their future maintenance strategies, and only 60 percent having adopted it, the collaboration between IFS Ultimo and MC Global Solutions is an important step towards providing the tools they need.

The partnership is expected to drive significant efficiency, cost, and safety improvements for organizations navigating the rapidly evolving digital landscape.

  • Facilities management use cases suggest that enhanced building maintenance efficiency, with task resolution rates increasing by 40 percent can be achieved
  • For manufacturers, decreased unplanned downtime, can lead to improved machinery uptime. In some cases, the solution has sped up quality checks on more than 1,500 assets, achieving time savings of 60-70 percent
  • Healthcare organizations can expect accelerated diagnostics for medical equipment.

To find out more about the joint offering, or to see the industry use cases, contact the companies here.

 

About MC Global Solutions
MC Global Solutions specializes in EAM and FM software consultancy, helping organizations streamline business processes, enhance efficiency, and reduce costs with cloud-based solutions. Learn more at MC Global Solutions.

About IFS Ultimo

IFS Ultimo, an IFS company, energizes the financial resilience, regulatory compliance and operational excellence for healthcare, manufacturing, and logistics businesses through its innovative software-as-a-service (SaaS) enterprise asset management (EAM) solutions. Focused on maintenance, uptime, safety, cost control, and efficiency, the Company is known for rapid deployment, ease of use and an unparalleled time to value. Ultimo supports over 100,000 technicians who manage more than 15 million assets for 2400+ customers worldwide. For further information see ultimo.com.

  1. https://www.ultimo.com/blog/ifs-ultimo-named-an-industry-leader-in-enterprise-asset-management-eam-software-by-independent-analyst-firm/

Early Warning Signs of Conveyor Belt Bearing Problems

It is reported that when Sir John Barbirolli was once conducting the world-famous Halle orchestra in Manchester during a rehearsal, he shouted at the top of his voice…” where’s the piccolo?”.

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A tiny instrument that the player obviously thought would go unnoticed amongst the ensemble of large, loud instruments. A salutary lesson on how a single seemingly insignificant element can affect the entire performance.

Stories like this resonate in industry too. Major manufacturing complexes often contain thousands of industrial components such as hydraulic pumps and industrial gearboxes. Some of these may seem like unimportant ancillary pieces of equipment but they are often vital to production and can bring the whole complex to a grinding halt when they fail.

A good example of this is a quarry where the mined aggregate is conveyed to a ship or loading point through a series of conveyor belts. The belts themselves are driven by electric motors utilizing gearboxes with each conveyor containing a multitude of roller bearings that support the belt itself as the aggregate is transported to its destination.

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These conveyers can sometimes cover huge distances. Take the conveyer belt system between the Mount Saddleback mine and Worsley refinery near Collie, Western Australia, the 31 kilometre flight of the main conveyor is the longest single conveyor belt in the world. The total distance of the complete conveyor system is an incredible 51 kilometres (31.6 miles). It is used to transport 2,700 metric tonnes of bauxite ore per year, from which aluminium is produced. The roller bearings supporting the long belts may seem insignificant elements when compared to huge crushers, graders, screens and major parts of the overall process, and yet if a number of these bearings seize or fail, then the entire production can come to a halt.

Potential failures of these bearings can be identified utilizing thermal imaging cameras, a technique that has been successfully used for many years, saving millions in terms of lost production and catastrophic failure. However, a more recent approach is to utilize acoustic imaging cameras which can provide a much earlier warning signal when it comes to bearing failure.

The latest FLIR Si2 LD acoustic imaging camera has different operation modes, firstly the leak detection mode (LD) that is used for detecting minute gas and air leaks in pneumatic, vacuum or speciality gas systems. Secondly, Mech Mode which can detect mechanical problems with bearings and gears way before they fail. This early warning tool is easy and quick to use meaning that even long conveyor belts with hundreds of support bearings can be analysed very quickly on a regular basis providing an in-depth health check and an early warning system, hence potentially avoiding expensive downtime.

The FLIR Si2-Pro acoustic imaging camera comes loaded with a multitude of additional features. The improved performance means the new camera is capable of detecting problems at much greater distances. It shows a 70% improvement in acoustic performance compared to previous Si124 models. The camera is therefore more adapt at detecting multiple mechanical sources thanks to the improved multisource mode. The camera features a 2x and 8x digital zoom which provides images to the 5 inch colour touch screen which boasts a resolution of 1280 x 720 for both video and images with GPS, image tags and comments potentially added to images for further analysis to be conducted. Still images can be produced with both .nlz and .jpg format whilst videos can be formatted in .nlz. Data transfer can be conducted via Wi-Fi or USB with automatic over the air wireless updates ensure the camera is always up to date. Measurement data can be stored on the internal SD card up to 128GB with unlimited cloud storage available with FLIR Cloud. Weather detecting developing faults in high-voltage applications, leaks from pneumatic equipment or speciality gas installations; or mechanical issues such as bearings in conveyors, the FLIR Si2-series of cameras can provide the insights needed to maintain uptime and reduce operational expenditure. For more information on the Si2-Pro and other acoustic imaging cameras in the FLIR range, please contact your local Teledyne FLIR representative or your local FLIR distributor.

www.flir.com

 

 

 

BCAS appoints new Learning Support Officer to further enhance training offer

Fay Hutchinson has joined the British Compressed Air Society (BCAS) in the newly created role of Learning Support Officer.

Working alongside Terry Collier, BCAS’s Learning and Development Officer, the new role will see BCAS further enhance the breadth and range of compressed air and vacuum training courses and approved accreditations available, with particular focus on increasing participation in its compressed air and vacuum technician (CAVT) apprenticeship.

Fay has a wealth of training experience, gained in roles both within engineering and the higher education sector. Starting her career in the stainless steel and aluminium sector, Fay holds a first-class honours degree in business management and a master of business administration (MBA) and has recently completed a level 6 diploma in career guidance and development.

Of particular benefit to BCAS and its members is Fay’s experience gained during her work with higher education institutes.  She has held several employer relationship roles, most recently at the University of Greenwich, where she has secured successful industrial work placements for students during their university studies.  She has also been actively involved in encouraging businesses to offer degree apprenticeships, using their apprenticeship levy where appropriate to either bring new talent into the business or to upskill existing members of staff.

Commenting on the appointment, Ashley Quarterman, BCAS Executive Director said:

“The industry is only too aware that recruiting and retaining skilled staff into the compressed air and wider engineering sector is challenging.  Offering high-quality training, whether through our apprenticeship scheme or one of our many CPD-approved courses, can help to deliver the next generation of engineers that our sector needs.

Continues…

“It is great to welcome Fay to the team and to be able to draw on all her experience in both the industrial and education sectors.  She understands how effective learning environments can be created, alongside the pressures faced by employers to continually train their teams and this will be of genuine benefit to our members.”

Fay added:

“I am really looking forward to using my skills to help further enhance the training support available to our members.  I am already speaking to members about our CAVT apprenticeship and some of the ways we can refine it further through progression routes, as well as being able to advise on the range of bursaries and levy funding that could be available.”

For further information about the British Compressed Air Society please visit https://www.bcas.org.uk

Monitoring Pump and Valve Health with PCB-Based Data Logger

Plant setups need well-maintained pumps and valves. They need to handle fluids, pressure, and flow control smoothly for the sake of a productive operation.

The only way plant engineers can ensure that the pumps and valves operate in tip-top condition is through stringent monitoring. However, the job won't be as easy without PCB-based data loggers.

PCB (printed circuit board) data loggers are small but powerful tools that keep track of pump and valve health. The best ones provide insights that will reduce everyone's headaches, particularly when dealing with maintenance.

PCB-Based Data Loggers

 

Designed to monitor equipment performance, PCB-based data loggers are composed of printed circuit boards and sensors. The use of multi-layer PCB allows a compact build while serving as the core of the system.

These devices process data from sensors in real time. They keep track of the pressure, temperature, vibration, and flow rate. It's the ultimate machine that helps plant managers keep an eye on how their pumps and valves are holding up.

PCB-based loggers are also precise and versatile. They collect data continuously, which means they monitor the performance and raise alarms early before they cause real problems. This level of insight is critical for preventing loss.

What Data Do PCB-Based Loggers Capture?

 

PCB-based data loggers track key performance metrics, which are as follows:

  • Pressure and Flow Rates: Fluctuations in pressure or inconsistent flow indicate blockages or leaks.
  • Temperature: PCB-based loggers also check rising temperatures that indicate friction, poor lubrication, and other mechanical issues.
  • Vibration Levels: High or unusual vibrations are often the first sign of misalignment or imbalance.
  • Operating Cycles: Tracking how often pumps and valves cycle on and off helps gauge overall efficiency.
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PCB-based data loggers monitor these factors, ultimately giving plant engineers a clearer picture of equipment performance and whether it needs attention.

Why Use Data Loggers for Monitoring?

 

Manually checking pumps and valves isn't cost-efficient. Plant managers use data loggers to make monitoring seamless and accurate. Here's why they're worth it:

  1. Continuous Monitoring: Loggers work 24/7. This ensures you never miss a potential issue.
  2. Early Problem Detection: Catching anomalies early prevents costly breakdowns.
  3. Data-Driven Maintenance: Real-time data lets you schedule maintenance when it's actually needed. There is no need to guess when to call the crew.
  4. Improved Efficiency: With actionable insights, you can optimize operations and reduce energy use.

Integrating PCB-Based Data Loggers

 

Surprisingly, installing loggers to plant systems is incredibly easy. Most of the units are designed to attach directly to pumps or valves.

Once connected, the sensors feed data to the PCB. From hereon, data collection begins. Some loggers even sync with your plant's monitoring systems, letting you access data through dashboards or alerts.

When setting them up, plant engineers must configure the logger correctly. Make sure you're tracking the right metrics and setting thresholds for alerts. This way, you'll know when something is off without constantly checking the system.

PCB-based data loggers save plant engineers from a lot of guesswork. This technology provides a reliable way to track performance and spot issues before they blow up. It's all about working smarter, not harder, and these tools are a step in the right direction.

Standardized and corporate-wide maintenance processes: Bahlsen relies on IFS Ultimo for cloud-based Enterprise Asset Management

Europe's leading manufacturer of sweet biscuits implements preventive maintenance with Ultimo / Cross-site introduction planned

More than 100,000 tons of sweet biscuits per year, delivered to over 80 countries worldwide: Bahlsen is the leading biscuit manufacturer in Germany and one of the leading suppliers in Europe. The company uses IFS Ultimo for Enterprise Asset Management (EAM) to optimize maintenance management for its systems, achieve maximum uptime with preventive maintenance and standardize processes in four plants. 

In February 2023, Bahlsen introduced the cloud-based software solution at its production site in Berlin. A blueprint for desired maintenance processes was developed and tested here. Initially, 24 users used the Standard Asset Management. An important part of this is the integration of production, whose employees can report failures directly in the system or resolve reported failures straight away. The aim of the pilot project was to define the requirements for the system solution and establish common KPIs, which are then measured at group level. Ultimo was then transferred to the company's other plants using the experience gained in Berlin. Ultimo is also to be implemented at the logistics site. As a result, Ultimo is used to implement, centrally monitor and optimize standardized maintenance processes across the company. 

"Bahlsen produces bakery products in a total of five plants. With IFS Ultimo, we achieve the greatest possible transparency across all sites regarding the condition of our equipment and improved reporting and monitoring of maintenance activities. This data enables us to move from reactive to preventive maintenance and thus reduce downtimes due to unplanned maintenance to a minimum", says project manager Aimal Khan, Digital Manager at Bahlsen regarding the introduction of Ultimo.

Necessary downtimes can be efficiently planned and managed with Ultimo. Operators, maintenance staff and management access the same centrally managed data. In the long run, Bahlsen also intends to use the integrated Long Term Asset Planning module (LTAP). This enables maintenance staff to draw up long-term budget plans for their equipment based on the condition of the assets and the costs of maintenance, renovation and replacement. 

This allows informed decisions on maintenance measures and the implementation of preventive maintenance with maximum cost efficiency.

Heike Roth, Team Lead Inside Sales, IFS Ultimo, adds: "With IFS Ultimo’s cloud-based EAM software, Bahlsen benefits from shared maintenance KPIs that are defined, measured and monitored at group level. Together with the wide range of asset management functions, this maximizes productivity and efficiency. This strategic approach underlines the company's high standards of quality and innovative strength."

In addition to the flexible and powerful modules for planning, optimizing, executing and monitoring maintenance activities, the integration of Ultimo into intelligent Asset Performance Management (APM) platforms was also a reason for the decision to use IFS Ultimo for Enterprise Asset Management. The two companies work closely together in a strategic partnership to enable customers to make fast, accurate and data-driven decisions and to help the industry improve its operational performance and sustainability.

Ultimo is a cloud-based Enterprise Asset Management software with numerous modules for managing assets, work orders, projects, maintenance, and health, safety and environmental (HSE) issues. It helps to map and manage processes transparently and to simplify their execution. All data is centrally available to users in Ultimo and can also be used on the move thanks to the cloud-based solution - whether on a PC or laptop or the operator's or maintenance manager's mobile device directly at the equipment. For this purpose, dedicated Android and iOS apps are available.

www.ultimo.com

 

ACC Accelerates EV Battery Manufacturing Maintenance with IFS Ultimo

  • Enterprise asset management (EAM) system manages and maintains manufacturing assets
  • Improved operational efficiency with mobile-enabled engineers, better resource allocation, and predictive maintenance
  • Powering ACC to increase production volume and support the automotive sector’s energy transition

Vehicle battery manufacturer, Automotive Cells Company (ACC), has implemented enterprise asset management (EAM) software from IFS Ultimo to drive the development and industrialization of the first French battery for the automotive industry. By managing and maintaining more than 20,000 manufacturing assets with the EAM system, the Mercedes and Stellantis-owned company has improved operational efficiency and enabled both corrective and preventative maintenance.

Powering the energy transition through sustainable, affordable, high-capacity, and longer-life batteries for electric vehicles (EVs), ACC expects to manufacture batteries for 150,000 Stellantis vehicles by the end of 2025, with the first block currently in ramp-up. With its machines running for longer periods, the software-as-a-service (SaaS) EAM system allows ACC to repair assets quickly, saving time and money, and ultimately increasing production volumes.

François Carrot, Information System Director at ACC, explains, “Price competition is the first challenge for ACC. To win this battle and become a key player in the European energy transition, ACC focuses on scrap reduction and increasing overall equipment effectiveness. Our team understands the importance of adopting a modern and efficient EAM to manage and maintain the industrial assets that are critical to our strategic ambition. Better resource allocation and responsiveness underscore the operational efficiency at ACC, which is pivotal to the commercial performance of manufacturing businesses.”

Delivered by integrator Inoteam, the system setup includes plans and photographs for each ACC machine. Using mobile applications on tablets, engineers simply scan a QR code to access documentation associated with each of the 20,000+ assets. This includes information on periodical maintenance, the history of all operations performed, along with comments from the people who have worked on it. Being mobile-enabled allows ACC engineers to conduct maintenance rounds and record various values ‘on-the-go’. The centralized EAM also manages stock to ensure the availability of parts during repairs.

Johan Made, CEO at IFS Ultimo adds, “It is our mission to be easy to do business with. That requires us to deliver solutions that are easy to use and fast to deploy. With ACC, we saw a young company poised for growth that needed to catalogue all the machines in its facilities, including tracking all corrective and preventative maintenance to avoid breakdowns. They needed an EAM to provide a reference system. And they needed it fast. Rolled out to users in just six months, the engineers find it intuitive and rich in data.”

ACC’s digital transformation journey with IFS Ultimo will progressively continue, with the addition of functionality for purchasing, as well as health, safety, and environment (HSE) with permits.

About ACC

Automotive Cells Company (ACC) is poised to become the European leader in automotive batteries. Backed by TotalEnergies-Saft, Stellantis, and Mercedes AG, with robust support from European authorities, particularly in France, Germany, and Italy, we are committed to developing and industrializing the next generation of cleaner energy sources for transport through sustainable, affordable, high-capacity, and longer-life batteries.

As a competitive high-tech company, we are investing billions in the early stages of our development. Our R&D Excellence Center is operational in Bruges (Bordeaux, Nouvelle-Aquitaine), alongside our state-of-the-art pilot plant in Nersac, France (Angoulème, Nouvelle-Aquitaine). Our first gigafactory in Billy-Berclau Douvrin, Hauts-de-France, the first of its kind in France, was inaugurated in May 2023 and is ramping up large-scale production. Over the next few years, we will further enhance our innovation and production capacities with a second block starting in 2026 in Billy-Berclau Douvrin. We have already established a global network of R&D associates, industrial partners, and suppliers.

About IFS Ultimo

IFS Ultimo, an IFS company, energizes the financial resilience, regulatory compliance and operational excellence for healthcare, manufacturing, and logistics businesses through its innovative software-as-a-service (SaaS) enterprise asset management (EAM) solutions. Focused on maintenance, uptime, safety, cost control, and efficiency, the Company is known for rapid deployment, ease of use and an unparalleled time to value. Ultimo supports over 100,000 technicians who manage more than 15 million assets for 2400+ customers worldwide. For further information see ultimo.com.

IFS Ultimo accelerates troubleshooting and slashes mean time to repair through AI integration

AI boosted Enterprise Asset Management software will significantly improve employee productivity and maximize asset performance

 

Enterprise Asset Management (EAM) software provider IFS Ultimo has integrated AI functionality into its next-generation EAM platform to enhance troubleshooting, and enable organizations to reduce the mean time to repair (MTTR) of their assets. By leveraging AI, EAM toolsets will be more intuitive, accessible and predictive, therefore driving unprecedented efficiency and effectiveness in asset management practices. The new AI features will be unveiled on Wednesday, October 16, 2024, at IFS Unleashed, Orlando, Florida, USA.

AI will take EAM to the next level. Our vision for AI is to focus on real world use cases. When considering what AI to integrate into our platform, we are only embedding features which will add significant value for our customers and improve their user experience”, says Chris van den Belt, Head of Product Management, IFS Ultimo.Infusing our EAM platform with AI functionalities will radically improve employee productivity and maximize asset availability.

 

Many AI technologies are geared towards predicting and preventing failures and incidents. However, for the majority of organizations, these technologies are more of a long-term goal than a short-term reality. Reactive maintenance will continue to feature prominently in most organization's maintenance strategies. With this in mind, IFS Ultimo has made the conscious decision to harness the powers of AI to significantly reduce time spent on reactive maintenance. Realizing these short-term benefits starting today puts long-term objectives within arm's reach.

Use of AI minimizes downtime and boosts productivity 

It is estimated that 80 percent of time in MTTR is spent on diagnosing a problem. The biggest chunk of time wasted is due to a lack of communication and detail in failure reports. With Ultimo's built-in AI capabilities, organizations can realize tremendous value with each percentage point reduction in MTTR. This is not chump change: the average cost of downtime in manufacturing often exceeds $100K per hour. Beyond the clear financial stakes, the productivity impact is also profound, especially in an industry where skilled labor is already hard to come by. Furthermore, the immense increase in overall data quality unlocks a wide array of new and exciting possibilities for achieving operational excellence.

The newly integrated AI functionality provides better quality of failure reporting. Having to spend less time on diagnosing a problem means skilled employees will benefit from increased wrench time, increased asset availability, reduced admin time, improved collaboration and improved employee satisfaction.

More accurate failure reports accelerate troubleshooting

Front line workers spend the majority of their working day close to the assets they know so well. Any changes to the way these assets look, sound, smell or feel will not pass them by. Using a large language model (LLM), Ultimo detects the asset in question and provides a series of tailored suggestions that the reporter can easily add to the failure report without having to type. In doing so, all of the sensory observations are captured on the report accurately, providing maintenance teams with complete and accurate information to quickly solve the issue and increase asset availability and reliability.

This same approach will be used elsewhere in Ultimo to empower the faster resolution of diagnosed issues and enhance the accuracy of completed work activities registered in the system. The overall benefits include a substantial reduction of time spent on administration, severe improvements to data quality and a boost to employee satisfaction. Furthermore, Ultimo is working on integrated AI features that will greatly improve user experience, such as photo-based meter readings, auto-generated image and document captions and auto-translated multi-lingual data.

Chris concludes: “We are dedicated to developing our products to help users do their jobs more easily with our best-of-breed EAM software. AI has the capability to enhance EAM in future-ready and efficient ways - empowering employees, improving asset performance, and reducing costs. We are very excited to bring these new AI functionalities to our customers while making sure all relevant data protection is in place.”

For more information visit www.ultimo.com/ai.

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