Total draw now
145 kW
+5% above baseline
Active anomalies
1
HVAC-A +12% draw
Energy efficiency
83%
Target: 88%
Asset health (twin)
HVAC-A
Weibull Pf: 62%
CO₂ equivalent
87t
Month to date
Energy monitor — SCADA live feed
5% above baseline
ISO 50001
HVAC systems
Plant B · anomaly detected
42 kW
▲ 12%
Bogie press line
BP-1 only · BP-3 offline
26 kW
▼ 28%
CNC machining
CNC-1, CNC-2 · CNC-3 reduced
29 kW
▼ 3%
Welding stations
WLD-1, WLD-2
22 kW
= 0%
Compressors
COMP-1, COMP-2
16 kW
▲ 8%
Total now
145 kW
Baseline
138 kW
Flag at
155 kW
Gap to flag
10 kW
24h trend
Anomaly detection
1 active
HVAC Motor-A — draw +12%
High
Current: 42 kW vs baseline 37.5 kW. Pattern consistent with bearing friction or refrigerant leak. Cross-referenced with Digital Twin: MTBF drop of 22% and Weibull Pf at 62%. Action recommended before next shift.
→ View Digital Twin → Raise PdM job
Compressor 1 — draw +8%
Medium
Current: 16 kW vs baseline 14.8 kW. Minor deviation. Monitoring. No corresponding MTBF change detected in Digital Twin.
Auto-monitoring · No action required yet
SCADA live tags
Connected
09:41:03HVAC-A.POWER42.3 kW▲
09:41:03HVAC-A.VIBR8.4 mm/s▲
09:41:02HVAC-A.TEMP82.1 °C!
09:41:01BP3.STATUSOFFLINE✗
09:40:58CNC3.POWER9.2 kW✓
◈ Digital Twin — HVAC Motor-A
At Risk · Pf 62%
Asset event timeline
Full history ↗
!
Energy anomaly — draw +12% above norm
3h ago
SCADA flagged sustained over-draw on HVAC-A. Cross-correlated with bearing vibration rise to 8.4 mm/s (spec max: 7.1). Root cause: possible bearing friction or refrigerant leak.
Energy trigger → PdM alert
▼
PdM alert — MTBF down 22%
3h ago
MTBF dropped from 312h to 243h over 3 cycles. PdM engine suggests moving PM from biannual to quarterly. Weibull Pf now 62%.
Auto-raised by PdM engine
✓
PM completed — filter & belt replacement
14 days ago
Biannual PM. Filters replaced (P/N: HVF-042). Belt tension set to 42N. Power draw normalised to 37.5 kW post-service. Next PM was scheduled in 180 days — now overridden to 90 days by PdM engine.
PM closed · MTTR 2.1h
C
Calibration — vibration sensor VB-04
21 days ago
Certified calibration completed. Certificate #CAL-2026-0312. Valid until 21 Sep 2026. Reading accuracy: ±0.05 mm/s confirmed.
ISO 9001 MSA compliant
✗
Breakdown — compressor seal failure
2 months ago
RCA-007 closed. Root cause: NBR seal at 80°C operating temp. Replaced with HNBR seal. MTTR: 3.2h. Part sourced from contingency supplier (OEM-Auto). PM interval adjusted as corrective action.
RCA-007 · 5 CAs raised
Asset health sensors
At risk
Run hours
4,820
hours total
Service life: 8,000h
MTBF current
243h
mean time between fail
▼ 22% vs target 312h
Vibration
8.4
mm/s RMS
Spec max: 7.1 mm/s
Bearing temp
82°C
operating temperature
Warn above 80°C
Power draw
42kW
current consumption
+12% vs 37.5kW base
Weibull Pf
62%
failure probability
Intervention needed
Weibull failure probability
PdM engine
Pf > 50% = immediate inspection recommended · Pf > 75% = pre-emptive shutdown
Digital twin schema
PostgreSQL
CREATE TABLE Asset_Telemetry (
reading_id BIGSERIAL PRIMARY KEY,
asset_id INT REFERENCES Assets,
recorded_at TIMESTAMP,
power_kw DECIMAL, -- SCADA
vibration DECIMAL, -- mm/s
temperature DECIMAL, -- °C
run_hours DECIMAL,
anomaly_flag BOOLEAN DEFAULT FALSE
);
CREATE TABLE Asset_Timeline (
event_id SERIAL PRIMARY KEY,
asset_id INT REFERENCES Assets,
event_type VARCHAR(20),
-- PM/Breakdown/Calibration
-- PdM/Anomaly/RCA
occurred_at TIMESTAMP,
detail TEXT,
weibull_pf DECIMAL,
linked_job INT REFERENCES Job_Cards,
linked_rca INT REFERENCES RCA_Reports
);