Transforming manufacturing & supply chains with IoT

Intellias is a software engineering and digital consulting company, empowering top-tier manufacturers to embrace innovation. Intellias has more than 3,200 employees working across 14 global locations.

Roman Pavlyuk, is VP of Digital Services at Intellias, where he leads IT consulting, advisory practices and large-scale projects for emerging and enterprise markets. 

“I play a hands-on role in shaping operational excellence to tackle business challenges and help tech innovators and Fortune 500 companies deliver excellent products and services for billions of users across the globe,” he says. 

Pavlyuk is a founder and dedicated member of the IoT direction, department and community at Lviv Politechnic University.

“I am actively engaged in the Global IoT Community,” he says. “What truly fuels my passion is conducting personal research focused on prototypes, which I carry out in my own lab at home. This subject continuously motivates me and it is precisely this drive that I strive to instil in the Intellias team. Simultaneously, I find immense inspiration from the innovative environment fostered by Intellias.”

Here, Pavlyuk tells us more about using IoT, 

Hi Roman! How do you use IoT in your work?

“Two major aspects of Intellias revolve around IoT: IoT as a practised competence and IoT assets as accelerators. Our team consists of skilled professionals, including architects, and solution leaders, who design, engineer and deploy IoT-related solutions. This encompasses a wide range of applications, from simple sensor implementations to complex systems such as smart farming management or smart building and facility management. Our team takes the customer's problem, leverages the available assets and tools in the market, and swiftly combines them into a comprehensive solution, deploying it as needed. Custom coding is also employed when necessary. This approach reflects our competence and practice in delivering IoT solutions.

“Being a technology company, Intellias also emphasises research and development (R&D). We create accelerators and assets to enhance our offerings. For instance, we recently presented our IntelliTwin prototype, which was developed in our dedicated R&D lab. This asset aims to provide a scenario-driven facility management solution. Additionally, we have assets tailored for the automotive sector and other segments.

“Moreover, in our personal lives, many of us at Intellias pursue IoT projects as well. For example, I personally engage in activities such as home automation in my lab, and I'm not alone in this passion. One of my colleagues has also created a smart home with his own hands. This illustrates how we not only utilise IoT in our professional work but also integrate it into our personal lives. Our genuine enthusiasm and passion drive us to excel in what we do.”

How can IoT help prevent expensive reactive machinery maintenance?

“Predictive maintenance encompasses more than just detecting actual faults; it also aims to eliminate unnecessary service intervals. Let's consider the example of a car and the common practice of changing the oil every 10,000 miles. However, there arises a question: "Do I really need to change the oil?" Perhaps the car hasn't been driven extensively, and the oil is still in good condition. On the other hand, maybe the oil needs to be changed earlier due to a particularly demanding drive. The objective is to determine precisely when maintenance is necessary before any system failure occurs.

“I have been involved in numerous projects where this aspect has been pushed to its limits. For instance, imagine underwater equipment that requires being brought to the surface for maintenance before being submerged again. Such operations are exceptionally costly, so it becomes crucial to know precisely when maintenance is genuinely needed, avoiding unnecessary procedures. This exemplifies the primary goal of predictive maintenance: not only detecting faults but also minimising unnecessary service intervals. By doing so, significant cost savings can be achieved without compromising the quality and performance of the equipment or machinery.”

What is PreFix?

“PreFix, Intellias’ latest predictive maintenance predict-n-fix concept, is designed to help companies maximise uptime and limit potential complications in production. It complements our IntelliTwin platform, specifically addressing the detection of potential failures in industrial facility infrastructure, including elements such as plumbing, wiring, liquid leaks in chemical storage tanks, and other related components.

“Its purpose is to identify issues such as leaks, corrosion, excessive vibrations, or overheating wires. The architecture of PreFix involves an edge device that efficiently captures a significant amount of information, which is a typical setup for various IoT applications. This edge device communicates with the IntelliTwin platform, facilitating the transmission of relevant signals and warnings to operators, alerting them to the imminent risk of critical failure.

“At its core, PreFix incorporates low-level software and edge-controlled algorithms. This enables it to collect the necessary data and perform post-analysis to determine when maintenance is required. By proactively identifying potential problems before they occur, PreFix plays a crucial role in eliminating potential failures and reducing the likelihood of critical disruptions as well as empowers facility operators to take preventive action precisely when maintenance is needed.

“Before implementing a large-scale IoT implementation, companies have the option to evaluate the financial benefits and rapidly validate initial ideas within 2-3 weeks with the PreFix proof of concept (PoC).”

Can this technology help support supply chains?

“No, PreFix is not designed specifically for supporting supply chains. Its primary focus is on detecting potential failures in building infrastructure and signalling the need for maintenance or repairs.

“However, PreFix's detection of a potential failure might trigger the creation of supply orders, which could indirectly contribute to supply chain activities. However, it was not the primary intention behind developing the PreFix technology.”

Can you tell us about some of your partnerships?

“We partner with Intel, SAS, AWS and many other companies. We are also members of the IoT Community.”

What do the next 12 months hold for you?

“We have exciting plans to expand our IntelliTwin platform by incorporating more AI, edge support and feature-rich scenarios. We are also hoping to build a more comprehensive and feature-rich demo for an upcoming event in Saudi Arabia, where we will collaborate with major institutions and showcase our contributions to the cities of the future that they are building. Predictive maintenance, particularly the PreFix solution, will be a key component integrated into the entire ecosystem of services we offer at Intellias.”

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