Driving Aftermarket Revenue: A Boiler OEM's Digital Transformation with Pulse

Reduction in unplanned maintenance costs

Aftermarket revenue growth

Problem Statement:

Industrial boiler manufacturers often struggle to achieve consistent operational efficiency while increasing service revenue. A global boiler OEM faced significant challenges with their AFBC, CFBC, and PCFB boilers deployed across energy, manufacturing, and process industries. The diverse fuel conditions under which these boilers operated highlighted inefficiencies in real-time monitoring and proactive maintenance. Reliance on traditional reactive maintenance resulted in increased downtimes, limited visibility into operational issues, and lost opportunities for spare parts sales—ultimately hindering business growth and affecting customer satisfaction.


Objective:

To revolutionize boiler operations by implementing a robust, AI-powered solution that ensures real-time monitoring, predictive maintenance, and optimized performance. The aim was to minimize downtime, enhance operational efficiency, and unlock new aftermarket revenue opportunities for spares and services. This transformation would empower the OEM to drive higher customer satisfaction and achieve scalable business growth.

Challenges

  • Limited Visibility: The OEM lacked a centralized system to track the boiler’s performance in real-time, leading to reactive maintenance and inefficiencies.
  • Missed Revenue Opportunities: Without predictive maintenance capabilities, the OEM lost opportunities to local competitors and was unable to make revenues from spares and services, leading to significant revenue losses.
  • Lost Opportunities for Upgrades: The absence of real-time insights hindered the ability to identify and act on sales opportunities for boiler upgrades, limiting business expansion.
  • Inconsistent Operational Efficiency: Variable fuel conditions across different boiler types (AFBC, CFBC, PCFB) made it difficult to achieve consistent performance.

 

Solution

The OEM deployed ExactSpace's Pulse, an industry-leading-edge Digital Twin solution. The solution offers the following:

Centralized Digital Twin Modeling:

Each boiler was digitized with advanced predictive analytics, enabling real-time performance tracking, early alerts for potential tube leaks or degradation, and centralized fleet monitoring through a unified dashboard. This facilitated data-driven decision making and optimized resource allocation.

Real-Time Optimization:

Pulse provided prescriptive insights on fuel efficiency, helping customers lower operating costs and reduce their Total Cost of Ownership (TCO).

Proactive Maintenance:

Predictive insights enabled the OEM to anticipate maintenance needs, reducing unplanned downtime and ensuring uninterrupted operations.

Impact

The deployment of Pulse brought significant benefits to the OEM:

Increase in Aftermarket Revenue:

Real-time insights into customer needs enabled proactive outreach for spares and services.

Enhanced Customer Satisfaction:

By preventing equipment failures and optimizing performance, the OEM built stronger, more trustful relationships with its customers.

Increased Sales Opportunities:

Better visibility into customer operations led to new sales opportunities for boiler upgrades and replacements, contributing to overall business growth.

Improved Operational Efficiency:

Real-time optimization and predictive analytics resulted in substantial improvements in boiler performance and fuel efficiency and reduce failures.

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