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Prevent unplanned downtime with FLS Asset Health Services

With our experience of the entire flowsheet, as well as artificial intelligence and advanced sensor technologies, our Asset Health Services can provide early warnings to prevent unplanned downtime and take remedial action to ensure work is planned safely and within budget, maximizing productivity.

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Increase uptime and efficiency with asset health services

  • Comprehensive insights help you streamline performance

    Our Asset Health Services cover the full flowsheet. By gathering plant data into one source of truth, you can gain a holistic view of plant performance in a digestible, visual way. Drawing on our decades of materials and process expertise, we analyse your historical and current plant operating data and discover trends that enable us to investigate your plant performance and optimization potentials and provide regular reports with recommendations for improvement.

  • AI and human expert support empowers you to prevent downtime

    By combining 140 years of experience with the latest digital technologies and artificial intelligence tools, we at FLS can monitor our plants around the clock and detect production issues or changes to the optimum behaviour of the plant at an early stage. We alert you with early warnings to enable immediate and effective remedial action, identify the root cause of the problem and prevent consequential damage. By responding early to warning signs and emerging anomalies that could lead to various process issues, costly unplanned downtime is minimized.

  • Maximise uptime and improve your OPEX

    Asset health Service empowers you to take control of your maintenance schedule and go beyond preventive to predictive maintenance. Our Reliability experts help you to identify when to make fundamental maintenance decisions in a proactive and joined-up way. With a historic maintenance review, inventory investigation and a close collaboration with your team, we can do a spare part forecast and develop an optimized inventory management to increase plant efficiency and profitability.

  • Improving safety on site

    Unplanned downtime leads to rushed work being carried out under pressure, which prevents safety from being the number one priority. By using the experience we have gained over our entire installed base FLS Asset Health Services provide the correct information to manage equipment issues and allow work to be scheduled well in advance, with all safety risks duly considered.

Asset Health Insight – Performance transparency for daily mining operations  

  1. Install FLS edge device to monitor and transfer data to FLS cloud.
  2. Automatic analysis of data in AI tool.
  3. Visualise data and automatic generated results.
  4. Enrich data and results with expert comments and recommendations. 

Connecting and visualising process data with our Asset Health Insights Service delivers a single source of truth for improved process transparency, delivering essential data for maintenance and identification of performance gaps. Enriched with expert comments and recommendations to improve equipment production processes. 

Asset Health Condition Monitoring – real-time monitoring for optimised maintenance  

Your plant and site managers, operations managers, and maintenance managers need accessible data and additional data analysis that delivers more than real-time insights and comparable historical trends. Asset Health Condition Monitoring enables you not only to detect potential failures well in advance but also allows you ample time to take preventive action and avoid costly breakdowns. Furthermore, data-driven insights and data-driven predictions also result in reduced operating expenditure. 

  1. Install advanced condition monitoring system and sensors to monitor equipment condition and transfer data to FLS cloud.
  2. Automatic analysis of data in AI tool.
  3. Visualise data and automatic generated results.
  4. Enrich data and results with expert comments and recommendations about equipment condition and potential operational issues.

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Asset Health Reliability – maximised uptime & optimised performance 

Through a combination of operational data, advanced diagnostic software for your specific equipment, and our network of analytics, OEM, and service experts, we identify performance potentials and proactively eliminate operational issues for optimum performance. Our ultimate goal is to increase the EBITDA margin, reduce unit costs and foster sustainable profits through a digital risk-based maintenance plan and proactive inventory strategies.  

  1. Collect reliability referred data, maintenance data, list of equipment failures, inventory data.
  2. Reliability Expert analysis of data.
  3. Visualise data and expert recommendations in report to optimise maintenance and inventory management. 

Improved sustainability with asset health services 

By preventing downtime and maximising productivity FLS Asset Health Services can reduce the overall environmental footprint per quantity of mineral delivered to market.  As a key supporter of MissionZero our services enable equipment to run at the lowest total cost of ownership. 

Asset Health Services allow you to predict failures at an early stage, reduce unplanned downtime and optimise maintenance schedules, use spare and wear parts more efficiently and sustainably, increase plant safety and generally reduce the impact on the environment.  

Avoid energy-intensive stop and start procedures by reducing (unplanned) downtimes and optimised maintenance schedules. 

Better safety by predicting and avoiding catastrophic failures

  • Reduced energy consumption

    By detecting issues such as misalignment and bearing failures at an early stage, condition monitoring helps for well planned maintenance activities, machine operation at optimum performance and reduces overall energy consumption. Well-maintained mining equipment is more efficiently and consume less energy.

  • Longer equipment life

    The environmental footprint can be significantly reduced by extending the life of equipment through continuous monitoring and timely maintenance. This reduces the disposal of equipment to a minimum and requires fewer new raw materials.

  • Optimum condition

    Furthermore, by maintaining equipment in optimum condition, the occurrence of leaks, spills and other forms of waste can be reduced, contributing to cleaner and safer operations.

  • Reliability

    Reliability services and spare parts forecasting and optimized inventory management improved / reduced required storage.

Frequently asked questions

FAQs for asset health solutions

In mining, an asset is a piece of machinery or heavy equipment, like a crusher. Asset health therefore refers to the health of the machinery – e.g. equipment lifetime and usage, mean time between maintenance outages, performance vs expectations, etc.

Asset condition monitoring refers to the use of sensors and the aggregation of high frequency condition data to track and trend asset health. Condition monitoring typically focuses in on specific indicators, such as bearing alignment or vibration, which can signal a greater problem.

Condition monitoring is the capture and analysis of operating and condition data with the aim of perceiving trends in time to take predictive maintenance action.

Specific defined sensors will be installed at all sensitive parts of the different equipments, e.g. vibration accelerometers at motor, speed sensors, ultrasound sensors at bearings, temperature sensors, pressure sensors at lubrication, torque measurement, displacement sensors, etc.

Hardware delivery, installation supervision, cloud storage, monitoring service.