Dynamic Installed Base Analysis for an optimized instrumentation lifecycle management
Digitally enabled transparency for smarter lifecycle management
How to manage complexity and risk with clear insights into an installed base? How can digitalization help achieve operational and maintenance goals?
Process instrumentation serves as the eyes and ears of any process. Understanding and managing the installed base is essential for maintaining control over production operations. Endress+Hauser’s Dynamic Installed Base Analysis is a strategic service that provides full transparency so that device data can be turned into actionable insights.
With centralized device data, a digitized plant structure, and transparent asset visibility, documentation becomes organized, accessible, and securely stored. Combined with continuous assessment of the instrumentation landscape, this service enables informed decision-making, optimized maintenance with proactive instrument lifecycle and migration planning.
©Endress+Hauser
©Endress+Hauser
Benefits of Dynamic Installed Base Analysis
Digital twin creation : Real-time view of the installed base thanks to on-site or remote asset collection and registration, enabling enhanced asset visibility and efficient planning. Streamlined asset base maintenance with digitalization : Regularly updated plant structure instantly reflecting new or replaced devices for efficient management. Centralized & digitized asset information : Secure, accessible and up-to-date location for consolidated device data and documentation, forming the digital backbone for effective asset management.Continuous expert recommendations : Regular, tailored insights in line with evolving operational goals for strategic decision-making and continuous improvement.
Application example: Power & Energy
Challenge
A power plant was operating with a vast and diverse range of transmitters and electrical devices—many of which were outdated and sourced from multiple suppliers. This complexity not only introduced potential safety risks but also demanded a large and costly inventory of spare parts to maintain operations, making efficiency and standardization difficult to achieve.
Solution and outcomes
Endress+Hauser’s Dynamic Installed Base Analysis enabled a thorough assessment of the existing asset base. The service identified suitable Endress+Hauser alternatives and supported the development of a migration plan to modernize measurement technology. This approach streamlined the spare parts inventory and laid the groundwork for standardization across the plant.
The modernization initiative gave the power plant a clear competitive edge. Operations became more efficient and less time-consuming, with improved safety and reduced maintenance overhead—demonstrating the tangible value of strategic asset management.
What did digitalization bring?
Through Endress+Hauser’s Dynamic Installed Base Analysis and the implementation of digital twin creation plus expert recommendations, the plant gained full visibility into its installed base. This enabled a targeted modernization plan, helped streamline spare parts inventory, and standardized technologies across the site. As a result, the plant significantly reduced complexity, improved safety— demonstrating the tangible value of strategic digital asset management.
Digitalization played a critical role in addressing the power plant’s challenges by transforming a fragmented and outdated asset landscape into a streamlined, efficient system:
Enhanced visibility : By creating a digital twin of the installed base, the plant gained a clear, real-time view of all assets, enabling better planning and decision-making. Simplified inventory : Centralized asset data allowed for the identification of redundant or obsolete components, reducing spare parts complexity and cost. Standardization : Digital insights supported the selection of compatible instrumentation alternatives, laying the foundation for a unified technology strategy. Improved safety and efficiency : With accurate data and expert recommendations, the plant reduced operational risks, minimized maintenance overhead, and boosted overall performance.
©Endress+Hauser
Application example: Food & Beverage
Challenge
A major food and beverage manufacturer faced a critical risk due to the obsolescence of over 80 flowmeters in their production lines. These aging instruments raised serious concerns about compliance with industry standards and posed potential cost implications for future upgrades. Without visibility into the obsolescence status of their installed base, the customer was effectively blind to the scale and urgency of the issue.
Solution and outcomes
With Endress+Hauser’s Dynamic Installed Base Analysis, the customer initiated a comprehensive assessment of their instrumentation. This began with gaining full transparency into the installed base, followed by an evaluation of each asset’s maintainability and criticality. The insights enabled the design of a tailored obsolescence management and migration plan, aligned with operational priorities and budget constraints.
The consultancy-led approach provided clarity on the status of each asset, empowering the customer to standardize their instrumentation. This not only improved process reliability and availability but also reduced maintenance complexity and risk. The implementation plan gave confidence to stakeholders and ensured a structured transition toward a more robust and compliant setup.
What did digitalization bring?
Digitalization played a critical role in addressing the manufacturer’s challenges by turning a hidden obsolescence risk into a clear, actionable strategy:
Enhanced visibility : By digitizing the installed base, the manufacturer gained full transparency into over 80 aging flowmeters, revealing the scale and urgency of the obsolescence issue. Asset valuation simplified : Digital tools enabled maintainability and criticality recommendations, helping prioritize upgrades based on operational impact and risk. Tailored migration planning : Insights and records of the obsolescence status supported the creation of a structured obsolescence management and migration strategy aligned with budget and compliance goals. Standardization and reliability : The consultancy-led approach empowered the customer to standardize instrumentation, improving process reliability and reducing maintenance complexity.
©Endress+Hauser
Application example: Chemical
Challenge
A chemical manufacturer required expert guidance to establish a solid maintenance and support strategy for their instrumentation. The challenge included managing a controlled spare parts inventory and ensuring the availability of proper tooling to maintain operational efficiency and safety. Without a clear overview of their installed asset base, planning for long-term reliability and compliance remained a significant hurdle.
Solution and outcomes
Endress+Hauser’s Dynamic Installed Base Analysis provided the customer with the transparency needed to make informed, data-driven decisions. By analyzing the composition and condition of the installed assets, the service laid the foundation for a future-proof maintenance strategy focused on reliability, continuous improvement and plant safety.
The result was a comprehensive recommendation list detailing maintenance and calibration priorities. This enabled the customer to align with business conformity requirements, reduce the risk of equipment failure, and minimize material loss—ultimately enhancing operational stability and cost efficiency.
What did digitalization bring?
Digitalization played a critical role in helping the chemical manufacturer prepare for future maintenance and planning challenges using full transparency of the instrumentation base to set a proactive, data driven maintenance strategy:
Enhanced transparency : Digital tools provided a clear and updated overview of the full instrumentation installed asset base, enabling informed decisions on maintenance and support needs. Improved maintenance planning : Through Dynamic Installed Base Analysis, the manufacturer shifted from reactive interventions to structured, forward-looking maintenance strategies.
©Adobe Stock/ Kalyakan
Leveraging Dynamic Installed Base Analysis and digitalization for increased performance
Discover how Dynamic Installed Base Analysis and digitalization helped to maximize a premium manufacturer's operations.
Dynamic vs. static analysis: A strategic advantage
Industrial customers operate in constantly evolving environments and conditions—shifting between phases of cost reduction, regulatory compliance, production capacity increase needs, or transformation. As business priorities change, so do the requirements for equipment, and spare parts. Continuous assessment helps align instrumentation management with evolving operational goals, ensuring readiness for current demands and future needs. This supports smarter investment decisions, reduces risk, and ensures operational agility in a competitive landscape.
Managing obsolescence risks
Industrial environments face growing challenges from aging equipment and unsupported technologies. A dynamic installed base analysis helps identify obsolete assets and potential failure points, enabling informed decisions on replacements, lifecycle extensions, and spare parts strategies. Integrating this into maintenance planning improves reliability, ensures compliance, and minimizes costs caused by obsolete components —supporting smarter investments and long-term operational stability.
Unlocking efficiency through equipment standardization and inventory optimization
Inconsistent equipment types, brands and configurations across industrial sites can lead to unnecessary complexity and inefficiencies. A comprehensive instrumentation base analysis helps uncover these discrepancies and identifies opportunities for harmonization. By aligning preferred technologies and simplifying spare parts management, companies can streamline training, reduce emergency purchases and make well-informed stocking decisions. This approach enhances operational efficiency; controls inventory costs and ensures the availability of critical components throughout the asset lifecycle.
©Endress+Hauser
Partnering with Endress+Hauser means aligning with a global leader in process automation who brings more than just measurement science — we bring commitment, expertise and long-term value. Our deep knowledge of instrumentation technology and industrial application processes, combined with a strong service culture, ensures that every service is tailored and optimized to your operational goals.
Endress+Hauser’s service portfolio delivers end-to-end support across the entire lifecycle of industrial process instrumentation—encompassing expert consulting, commissioning, calibration, maintenance, diagnostics, support, education and digital services— designed to optimize performance, reduce complexity and drive sustainable success.
Our global network of experts and service professionals works closely with you and bring their competencies to deliver consistent support, whether you are standardizing assets, improving plant availability or accelerating your digital transformation.
With Endress+Hauser, you gain more than a supplier—you gain a strategic partner dedicated to helping you navigate challenges, seize opportunities and stay ahead in a rapidly evolving industrial landscape.
Want to know more?
Our consultants can answer all your questions.
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