Operational Risk & Reliability Management

Operating Production in a Resilient and Predictable Manner

Identify risks before they lead to production downtime. With data-driven analysis and a robust cloud infrastructure on STACKIT, you can ensure plant availability, protect sensitive production data, and optimize your operational processes.

Challenge: Identifying Risks Early and Maintaining Stable Production

Industrial companies face the challenge of reliably operating their production under increasingly complex conditions. Unpredictable disruptions, a shortage of skilled workers, and rising regulatory requirements are putting pressure on both operations teams and management alike.

Unpredictable malfunctions and black swan events

Critical components such as main presses or drive trains are often key bottlenecks in production. If unplanned damage occurs here, an entire production line can come to a standstill. Such rare but far-reaching events are difficult to predict using traditional maintenance strategies.

Skills Shortage and Increasing Complexity

Diagnosing plant conditions increasingly requires specialized expertise. At the same time, many companies lack experienced maintenance experts. Without automated analysis, many anomalies in sensor data go undetected.

Protection of Sensitive Production Data

Operational data from machines and systems contains valuable process knowledge. Companies must ensure that this data does not end up in international cloud environments without proper oversight or is processed outside European jurisdictions.

Fragmented IT and OT landscapes

Machines continuously generate sensor data, but this data is often stored in isolated systems. Without a central platform, there is no foundation for developing a consistent risk model for the entire production process based on this data.

Measurable Value: More Stable Production and Better Planning

Data-driven Operational Risk & Reliability Management not only improves the technical stability of production, but also directly impacts key performance indicators such as plant availability, throughput times, and operating costs.

Up to 20% fewer unplanned downtimes: Through continuous analysis of sensor data, the system detects critical patterns early on. Maintenance teams receive immediate alerts about potential disruptions before they lead to a failure.
Higher production output: Even minor interruptions—or so-called “micro-stops”—affect the overall performance of production lines. Automated analyses highlight these effects and help optimize processes in a targeted manner.
Sustainable cost reduction: More precise machinecontrol reduces scrap and energy consumption. At the same time, maintenance costs decrease because repairs can be scheduled in advance.
Scalable production optimization: A standardized technology approach makes it possible to quickly roll out analytics solutions to additional production lines or locations. This generates comparable performance and risk data across the entire company.

Solution: Identifying Risks with AI and Integrated Production Data

Operational Risk & Reliability Management is based on the intelligent integration of sensor data, process information, and analytical models. The platform continuously collects data from machines, control systems, and production systems and consolidates it in a central data environment.

Building on this, AI models analyze the operational states of the equipment. They detect anomalies, wear patterns, or unusual stresses at an early stage and trigger automated alerts. Maintenance teams receive clear recommendations for action and can intervene in a targeted manner before a malfunction occurs. In addition, events, maintenance activities, and operational statuses are systematically recorded and made available to you for internal analyses or to demonstrate compliance with regulatory requirements.

Competitive Advantage: Using Production Data Securely and Confidently

Production and wear data are among the most sensitive pieces of information an industrial company possesses. They contain detailed insights into processes, plant configurations, and production strategies.

Data Sovereignty

STACKIT offers a cloud platform specifically designed for sensitive data. The infrastructure is operated entirely in European data centers and meets high standards for data protection and security. Your production data thus remains under your control and is subject exclusively to European law.

High Scalability

You benefit from a scalable cloud infrastructure that can reliably process even large volumes of data from industrial plants.

High Compliance

Through integrated GRC processes, companies can leverage modern analytics and AI methods while reliably complying with regulatory requirements such as NIS2.

The Foundation: Cloud Resources for Simulation and Data Analysis

Operational Risk & Reliability Management requires a powerful technological foundation. STACKIT provides a scalable cloud infrastructure specifically designed for data-intensive applications.

STACKIT Compute Engine

Scalable computing power for dashboards, analytics workloads, and AI models for OEE optimization.

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STACKIT Object Storage

Cost-effective storage of large volumes of historical machine data for trend analysis, training data, and compliance requirements.

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STACKIT PostgreSQL Flex

Highly available, structured database for reporting, OEE metrics, and automated reports.

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ISV Partner Ecosystem

Seamless integration of edge and multi-site solutions for local data processing at the plant and secure cloud synchronization.

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Frequently Asked Questions (FAQ)

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