Traditional asset performance management (APM) is breaking under the weight of modern industrial complexity. Today’s industrial environments generate orders of magnitude more data across far more complex, distributed operations than the systems managing them were ever designed to handle. This creates a growing gulf between the data enterprises generate and their ability to act on it. At the same time, industrial manufacturers face mounting pressure from all sides: volatile market conditions, rising costs, tighter margins, net-zero emission targets, and uncompromising safety requirements. Many enterprises have set ambitious goals towards achieving digital transformation and Industry 4.0 initiatives, yet the reality of day-to-day operational challenges hinders progress.
Triple Modular Redundancy (TMR) architectures with 2-out-of-3 (2oo3) voting are designed to tolerate a single hardware fault without interrupting processes. However, an unexpected Gas Turbine Generator (GTG) trip occurred when only one of three safety controllers failed. This case study analyzes the event, demonstrating the critical distinction between fault tolerance and fail-safe behavior when safety integrity is compromised.
In the late 1990s, handing your entire IT infrastructure to an outside vendor sounded reckless. Why would a Fortune 500 company give away its technology backbone? The answer was simple. Technology wasn't their core business. IBM Global Services, EDS, and Accenture proved enterprises could shed the operational burden of IT and get better service from specialists who did nothing else. By the early 2000s the argument was over. TCS, Infosys, and Wipro scaled fast after Y2K, proving even mission-critical work could sit outside if governance and metrics held up.
Most articles about IoT-enabled maintenance focus on the win: a sensor catches a failure early, downtime gets avoided, everyone’s happy. Fewer people write about what a plant looks like eighteen months in, after the dashboards have filled up and technicians have quietly started ignoring half the alerts on them.
It’s worth talking about, because it’s common, and because it’s avoidable.
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When reliability, maintenance and asset management professionals gather at the Gaylord Opryland in Nashville this August 17–20, they won't just be trading notes with peers — they'll be learning directly from the people running some of the most complex, high-stakes operations on the planet. This year's MaximoWorld speaker roster spans space exploration, national defense, global finance, healthcare systems, and the fast-food counter down the street, proof that asset reliability is a universal language.
Modern distribution centers, parcel hubs, and airport baggage operations have become highly automated and highly interdependent. That interdependence is a double-edged sword: it drives efficiency, but it also means a single failed asset—a conveyor, a sorter, a control cabinet—can bring an entire operation to a halt. Product backs up behind the failure point, downstream teams run out of work, and in a 24/7 environment, lost throughput isn't recovered later. It's simply gone.
Many reliability professionals have encountered a frustrating situation. A vibration alarm appears on a critical machine, maintenance personnel begin investigating a potential fault, and days later the machine is found to be healthy. The elevated readings were caused not by equipment degradation but by changing operating conditions. The data was correct. The diagnosis was not.
Mechanical seals are often small compared with the pump, driver, coupling, baseplate, piping system, or control system. Yet anyone who has spent time around rotating equipment knows that seals can have a much larger impact than their size suggests. A mechanical seal is not just a wear part. It is a containment device, a reliability component, an emissions-control device, and in many services, a critical safety barrier. At its simplest, a mechanical seal contains process fluid where a rotating shaft passes through a stationary casing. In real plant operation, that simple function becomes extremely important. A seal may be the only component preventing a hydrocarbon, toxic fluid, hot liquid, corrosive chemical, or environmentally sensitive product from leaking to atmosphere.
Industrial Internet of Things (IIoT) technologies continue to be deployed across industries to improve asset visibility, support predictive maintenance initiatives, and enhance reliability performance. Over the past several years, I have been involved in deploying connected asset technologies across large industrial fleets operating in North America, South America, Asia, and the Middle East.
In today’s technological era, data science is playing a critical role for making decisions and supporting management and engineers to achieve the optimal solutions based on technical and financial analysis. The data can be defined as facts or numbers that is usually collected, analyzed and utilized to make useful decisions. On the other hand, information is knowledge that is obtained from data through analysis and studies. With newly developed high tech and IT solutions such as IR4.0, IoT and other applications, data is coming more important and useful in reliability engineering applications and science.
Talk to a maintenance lead at any enterprise and the same theme comes up: they know their team generates real value, but they struggle to make it visible in numbers the CFO trusts. The operational story the data tells is not what actually happens on site. Notifications come in half-filled, time bookings get rounded to the hour, schedules live in Excel and reconcile to SAP once a week, and downtime is not assigned to the correct entity. That gap between reality and SAP (the world's most popular EAM platform) is what makes maintenance look like a cost line in the budget even when it is carrying revenue, reliability, and labor productivity.
Resilience is easy to talk about and hard to deliver. For water and wastewater utilities, it means sustaining safe, reliable service despite aging assets, workforce transitions, regulatory pressure, and increasing operational risk. That is exactly what the Water Industry Reliability Forum set out to unpack in a practical way during the Reliability Conference, in a full-day workshop co-hosted in collaboration with MaxGrip and Reliabilityweb. This is a recap of those sessions and discussions with the audience.