Master Plan Bundling IoT + AI

Gateway IoT yang mengumpulkan data dari komputer administrasi, dilengkapi AI Assistant dan Asset Health Basic untuk aset admin dasar.

Memantau konsumsi energi listrik dengan AI Analytics — diagnostic insight, prediksi konsumsi, dan korelasi energi dengan kesehatan aset.

OEE tidak hilang — ia menjadi fitur tambahan dalam AssetGuard™ untuk klien yang sudah mature.

Schema lengkap yang merepresentasikan keseluruhan sistem monitoring dengan AI layer terintegrasi dan AssetGuard™ sebagai Stage 3.

{
  "system_metadata": {
    "version": "3.0.0-ai-assetguard",
    "company": "PT Contoh Manufaktur Indonesia",
    "location": "MM2100 Industrial Town, Cibitung, Bekasi",
    "gateway_id": "PT-ADM-001",
    "gateway_status": "online",
    "ai_enabled": true,
    "assetguard_enabled": true,
    "ai_models_loaded": [
      "anomaly_detector",
      "forecaster",
      "nl_query",
      "predictive_maintenance_admin",
      "predictive_maintenance_production",
      "rul_estimator",
      "spare_part_predictor"
    ],
    "last_heartbeat": "2026-09-10T08:29:45+07:00",
    "uptime_hours": 1247
  },

  "stage_1_admin": {
    "description": "Monitoring Divisi Administrasi + Descriptive AI + Asset Health Basic",
    "ai_layer": {
      "capabilities": [
        {
          "name": "Auto-Generated Summary",
          "type": "llm",
          "model": "gpt-4o-mini-finetuned",
          "frequency": "daily",
          "output": {
            "timestamp": "2026-09-10T08:30:00+07:00",
            "summary": "Sales pipeline naik 8.2% dipimpin segmen otomotif. Finance DSO turun ke 42 hari. HR overtime naik 6.5% — perlu perhatian.",
            "highlights": [
              "Sales: +8.2% (positif)",
              "Finance: DSO 42 hari (di bawah target 45)",
              "HR: Overtime 1,240 jam (di atas threshold 1,200)"
            ],
            "recommendations": [
              "Monitor HR overtime — pertimbangkan rekrutmen tambahan",
              "Sales momentum positif — pertahankan strategi"
            ]
          }
        },
        {
          "name": "Anomaly Detection",
          "type": "statistical",
          "algorithm": "Isolation Forest + Z-Score",
          "detected_anomalies": [
            {
              "division": "finance",
              "metric": "invoice_outstanding",
              "severity": "medium",
              "message": "Invoice outstanding turun 12.3% — di luar pola normal"
            }
          ]
        },
        {
          "name": "Natural Language Query",
          "type": "llm_rag",
          "model": "gpt-4o-mini",
          "sample_queries": [
            {
              "query": "Bagaimana performa sales bulan ini?",
              "response": "Sales pipeline Rp 4.85 M (97% dari target Rp 5 M). Order masuk 142 (94.7% dari target 150)."
            }
          ]
        },
        {
          "name": "Trend Forecasting",
          "type": "time_series",
          "algorithm": "Prophet",
          "forecasts": {
            "sales_pipeline": {
              "current": 4850000000,
              "forecast_7d": 5100000000,
              "forecast_30d": 5400000000,
              "confidence": 0.87
            }
          }
        }
      ]
    },
    "asset_health_basic": {
      "description": "Monitoring aset admin dasar",
      "assets": [
        {
          "id": "server_room",
          "name": "Server Room",
          "metrics": {
            "temperature": 22.5,
            "humidity": 45.0,
            "power_consumption": 12.5,
            "status": "healthy"
          },
          "ai_anomaly_score": 0.05
        },
        {
          "id": "network_main",
          "name": "Main Network Switch",
          "metrics": {
            "uptime_percent": 99.98,
            "latency_ms": 1.2,
            "packet_loss_percent": 0.01,
            "status": "healthy"
          }
        },
        {
          "id": "ups_main",
          "name": "UPS Server Room",
          "metrics": {
            "battery_health_percent": 92,
            "voltage": 230.5,
            "runtime_minutes": 45,
            "status": "healthy"
          }
        }
      ]
    }
  },

  "stage_2_energy": {
    "description": "Monitoring Energi + Diagnostic AI + Energy-Asset Correlation",
    "ai_layer": {
      "capabilities": [
        {
          "name": "Root Cause Analysis",
          "type": "explainable_ai",
          "algorithm": "SHAP + Correlation Analysis",
          "analyses": [
            {
              "id": "rca_001",
              "trigger": "Panel Produksi A power factor 0.89",
              "root_cause": "Beban induktif tinggi tanpa kompensasi capacitor bank",
              "recommendation": "Pasang capacitor bank 50 kVAR — potensi hemat Rp 2.8jt/bulan",
              "confidence": 0.91
            }
          ]
        },
        {
          "name": "Energy Demand Forecasting",
          "type": "time_series",
          "algorithm": "LSTM",
          "forecasts": {
            "total_kwh": {
              "current": 45230.5,
              "forecast_7d": 47100.0,
              "confidence": 0.89
            }
          }
        },
        {
          "name": "Optimization Recommendation",
          "type": "rule_based_ml",
          "recommendations": [
            {
              "id": "opt_001",
              "category": "load_shifting",
              "description": "Geser beban produksi ke off-peak hours",
              "potential_savings_idr": 4200000,
              "priority": "high"
            }
          ]
        },
        {
          "name": "Energy-Asset Health Correlation",
          "type": "correlation_analysis",
          "detections": [
            {
              "asset_id": "motor_b",
              "energy_anomaly": "+12% konsumsi",
              "predicted_issue": "bearing_wear",
              "confidence": 0.78,
              "recommendation": "Cek bearing motor B dalam 7 hari"
            }
          ]
        }
      ]
    },
    "total_consumption_kwh": 45230.5,
    "total_cost_idr": 67845750,
    "total_emission_kgco2": 38445.9,
    "efficiency_percent": 5.77,
    "panels": [
      {
        "id": "panel_main",
        "name": "Panel Utama",
        "status": "online",
        "voltage": 398.5,
        "current": 245.3,
        "power_kw": 98.2,
        "power_factor": 0.92,
        "energy_kwh": 18500.5,
        "ai_anomaly_score": 0.12
      }
    ]
  },

  "stage_3_assetguard": {
    "description": "🛡️ AssetGuard™ — Predictive Maintenance Unified (Admin + Production)",
    "ai_layer": {
      "capabilities": [
        {
          "name": "Predictive Failure (Admin)",
          "type": "classification",
          "algorithm": "XGBoost + Random Forest",
          "predictions": [
            {
              "asset_id": "server_room",
              "asset_type": "admin",
              "prediction": "overheating_risk",
              "probability": 0.72,
              "estimated_time_to_failure_hours": 6,
              "features_used": [
                { "feature": "temperature", "value": 28.0, "threshold": 25.0, "importance": 0.65 },
                { "feature": "humidity", "value": 55.0, "threshold": 50.0, "importance": 0.35 }
              ],
              "recommendation": "Cek AC server room sekarang — potensi downtime ERP 4-8 jam",
              "potential_downtime_avoided_hours": 8
            }
          ]
        },
        {
          "name": "Predictive Failure (Production)",
          "type": "classification",
          "algorithm": "XGBoost + LSTM",
          "predictions": [
            {
              "asset_id": "motor_b",
              "asset_type": "production",
              "prediction": "breakdown_imminent",
              "probability": 0.87,
              "estimated_time_to_failure_hours": 48,
              "features_used": [
                { "feature": "vibration_rms", "value": 4.2, "threshold": 3.5, "importance": 0.45 },
                { "feature": "temperature", "value": 78.5, "threshold": 75.0, "importance": 0.32 },
                { "feature": "current", "value": 156.8, "threshold": 150.0, "importance": 0.23 }
              ],
              "recommendation": "Lakukan maintenance preventif dalam 24 jam",
              "potential_downtime_avoided_hours": 4
            }
          ]
        },
        {
          "name": "Remaining Useful Life (RUL)",
          "type": "survival_analysis",
          "algorithm": "Weibull + Cox Proportional Hazards",
          "predictions": [
            {
              "asset_id": "motor_b_bearing",
              "rul_hours": 720,
              "rul_days": 30,
              "confidence": 0.82,
              "recommendation": "Pesan spare part bearing SKF 6205 sekarang"
            }
          ]
        },
        {
          "name": "Root Cause Analysis (Asset)",
          "type": "explainable_ai",
          "algorithm": "SHAP",
          "analyses": [
            {
              "asset_id": "motor_b",
              "root_causes": [
                { "cause": "misalignment", "impact": 0.65 },
                { "cause": "bearing_wear", "impact": 0.35 }
              ],
              "recommendation": "Lakukan alignment + ganti bearing"
            }
          ]
        },
        {
          "name": "Spare Part Prediction",
          "type": "time_series",
          "algorithm": "ARIMA + Inventory Optimization",
          "predictions": [
            {
              "part_id": "bearing_skf_6205",
              "predicted_demand_next_month": 4,
              "current_stock": 2,
              "recommendation": "Order 2 unit tambahan"
            }
          ]
        },
        {
          "name": "Maintenance Recommendation",
          "type": "rule_based_ml",
          "recommendations": [
            {
              "priority": "high",
              "asset_id": "motor_b",
              "action": "Ganti bearing dalam 24 jam",
              "cost_idr": 2000000,
              "potential_downtime_cost_idr": 50000000,
              "roi": "25x"
            }
          ]
        },
        {
          "name": "Auto-Generated Maintenance Report",
          "type": "llm",
          "model": "gpt-4o-mini",
          "frequency": "daily",
          "output": {
            "timestamp": "2026-09-10T08:30:00+07:00",
            "summary": "3 aset memerlukan perhatian: Motor B (breakdown 48 jam), Server Room (overheating 6 jam), Panel A (PF rendah).",
            "critical_assets": ["motor_b", "server_room"],
            "recommendations": [
              "Ganti bearing motor B dalam 24 jam",
              "Cek AC server room sekarang",
              "Pasang capacitor bank Panel A"
            ]
          }
        }
      ]
    },
    "asset_summary": {
      "total_assets_monitored": 142,
      "admin_assets": 58,
      "production_assets": 84,
      "assets_healthy": 127,
      "assets_warning": 12,
      "assets_critical": 3,
      "overall_asset_health_score": 91
    },
    "assets": [
      {
        "id": "motor_b",
        "name": "Motor B - Lini Produksi B",
        "category": "production",
        "type": "electric_motor",
        "status": "warning",
        "health_score": 68,
        "metrics": {
          "vibration_rms": 4.2,
          "temperature": 78.5,
          "current": 156.8,
          "power_factor": 0.85,
          "runtime_hours": 12500
        },
        "ai_predictions": {
          "breakdown_probability": 0.87,
          "estimated_time_to_failure_hours": 48,
          "rul_hours": 720,
          "recommended_action": "Ganti bearing dalam 24 jam"
        }
      },
      {
        "id": "server_room",
        "name": "Server Room - Gedung A",
        "category": "admin",
        "type": "data_center",
        "status": "warning",
        "health_score": 72,
        "metrics": {
          "temperature": 28.0,
          "humidity": 55.0,
          "power_consumption": 12.5
        },
        "ai_predictions": {
          "overheating_probability": 0.72,
          "estimated_time_to_failure_hours": 6,
          "recommended_action": "Cek AC server room sekarang"
        }
      },
      {
        "id": "pompa_a",
        "name": "Pompa A - Utility",
        "category": "production",
        "type": "pump",
        "status": "healthy",
        "health_score": 94,
        "metrics": {
          "vibration_rms": 1.8,
          "temperature": 62.0,
          "flow_rate": 45.2,
          "pressure": 4.5
        },
        "ai_predictions": {
          "breakdown_probability": 0.05,
          "estimated_time_to_failure_hours": 2160,
          "rul_hours": 4320
        }
      }
    ],
    "optional_modules": {
      "oee_monitoring": {
        "available": true,
        "price_per_month": 2000000,
        "description": "Add-on module untuk klien mature"
      },
      "traceability": {
        "available": true,
        "price_per_month": 1500000,
        "description": "Add-on untuk tuntutan principal"
      },
      "quality_analytics": {
        "available": true,
        "price_per_month": 2500000,
        "description": "Add-on untuk analitik kualitas"
      }
    }
  },

  "notifications": [
    {
      "id": "notif_001",
      "level": "critical",
      "category": "assetguard",
      "title": "🛡️ Predictive Maintenance Alert",
      "message": "Motor B: Prediksi breakdown dalam 48 jam",
      "ai_generated": true,
      "ai_recommendation": "Ganti bearing dalam 24 jam — hindari downtime 4 jam",
      "timestamp": "2026-09-10T08:25:00+07:00"
    },
    {
      "id": "notif_002",
      "level": "warning",
      "category": "assetguard",
      "title": "🛡️ Asset Health Alert",
      "message": "Server Room: Suhu 28°C — risiko overheating",
      "ai_generated": true,
      "ai_recommendation": "Cek AC server room sekarang",
      "timestamp": "2026-09-10T08:20:00+07:00"
    }
  ]
}