Maintenance 4.0

Predictive maintenance on an air treatment station

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The maintenance of facilities and of industrial equipment is a dynamic, competitive market currently being transformed by digital technologies. The core ingredients to effective maintenance are a strong commitment to measurable performance, stability in service provision and cost efficiency. Digital technology, ranging from the Internet of Things (IoT) to advanced analytics, opens new possibilities to enhance service quality whilst delivering cost efficiencies.

Innovative Solution

In this context, Bouygues Energies & Services has developed Maintenance 4.0, a global solution to collect and analyse industrial equipment data in order to surface valuable insights. Maintenance 4.0 includes three steps :

  1. Collect industrial equipment data (vibration, temperature, pressure, flaws etc.) by means of both IoT (via fully autonomous, easy to deploy connected objects) and live dataflows from existing equipment management systems.
  2. Analyse collected data via AI-powered algorithms.
  3. Surface insights in a user-friendly format via Client and Operator views on a central dashboard.

Maintenance 4.0 brings together hardware solutions for receptors and networks, as well as a software solution including machine learning and analytics technologies.

Data receptors are deployed onsite for the Vélodrome de Saint Quentin en Yvelines in order to monitor a wide range of technical equipment (air treatment station, heat pumps etc.) A digital platform subsequently enables data analysis; at this time AI algorithms are under testing in order to automate insights into potential equipment breakdowns.

The current POC will be extended to additional sites in 2021 in order to further enhance the predictive capabilities of the Maintenance 4.0 platform.

Client and User Benefits

  1. Maintenance 4.0 delivers two types of benefits:Maintenance cost reductions, due to effective incident prevention: 
    • Decrease in equipment replacement costs, including spare parts 
    • Optimised workflows: more efficient maintenance processes, resource deployments and lower staff travel costs 
      Decrease in equipment replacement costs, including spare parts 
    • Minimised risk of regulatory penalties in case of equipment malfunctions.
  1. Higher satisfaction with maintenance services for both site owners and operators, given more efficient and effective collaborations: 
    • Improved visibility of equipment maintenance patterns and improvement opportunities for clients and operators
    • Higher efficiency and lower stress levels amongst technical teams performing onsite maintenance

Key Results

The POC currently underway has already enabled BYES teams to identify two potential issues – unusual stop-and-start patterns on an air treatment station and incorrect functional parameters on a double pump –, and subsequently prevent incidents by informing the site operator and performing preventive maintenance.

Maturity Level

Level 1 : Proof of Concept or lab test
Level 2: Tested under real life conditions
Level 3: Commercial solution

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