Achieving 100% Uptime: SCGC Unlocks Plant Potential with "DRS by REPCO NEX "Digital Solution"

In today’s fiercely competitive industrial landscape, a single hour of machine downtime can mean costly disruptions, impacting sales, product delivery, and even the entire supply chain. For many industries, from oil and gas, petrochemicals, and power generation, to even consumer goods like food and beverages, operational reliability and peak efficiency are the heart of success.

In response, SCGC has developed Digital Reliability Solutions (DRS) by REPCO NEX, designed to elevate the standard of machinery maintenance, reduce emergency shutdowns, and transition plant maintenance to a predictive model. Powered by AI and advanced data analytics, these solutions enable 100% operational continuity and are now being offered as a service to external industrial operators.

From Real-World Experience to Industry-Grade Solutions

SCGC’s transformation toward AI-powered machinery maintenance for the petrochemical industry was not an overnight success but the culmination of more than four decades of experience. REPCO NEX originally served as the internal maintenance division for SCGC. However, as it was restricted itself to internal maintenance, it was unable to help elevate the competitiveness of Thailand’s broader industrial sector. This led to the strategic decision to spin off the unit as REPCO NEX, a standalone company dedicated to serving external clients using its long-accumulated knowledge and experience.

From Preventive to Predictive: A Leap Forward with AI

Initially, SCGC utilized preventive maintenance and quality management systems like TPM (Total Productive Maintenance) and TQM (Total Quality Management) to push reliability from 80% to over 90%. However, this was insufficient for an industry demanding continuous production. As such, SCGC broke through this ceiling by developing a predictive maintenance system, which uses sensors to measure machine frequencies and signals, which are then processed by a custom-designed AI algorithm. This system allows SCGC to forecast risks in advance, enabling the prevention of failures before they occur and achieving 100% machine availability.

DRS by REPCO NEX: From In-House Success to a Service for All

This success was not confined to SCGC’s own plants but has been extended into Digital Reliability Service Solutions (DRS) by REPCO NEX, a commercial service now available to all industries. Its key strength lies in combining over 40 years of expertise with large-scale machinery and the capability to develop and train AI on real-world data. The result is a solution that is not only accurate but also capable of addressing the practical needs of the manufacturing sector.

The Proprietary Sensor: A Key to Predictive Power

While many sensors exist on the market, the DRS by REPCO NEX sensor is specifically designed to isolate complex signal frequencies in great details. Used in combination with the AI algorithm, this data makes it possible to predict machinery health with high precision.

The AI learns each machine’s operational patterns and continuously analyzes incoming signals. If the AI detects an increase in a component’s risk level, it will be flagged either in red, indicating it may fail within a month and requires immediate attention, or in yellow, signifying a medium-term risk and suggesting the component has a few months of operational life left. Green signifies the equipment is operating normally.

DRS by REPCO NEX: More Than Just Sensor Installation

“We aren’t just selling sensors. We are designing a specific solution for each type of machinery. Every plant has its own different challenges and contexts, so the algorithm is tailor-made to suit that specific equipment,”

The process begins with a deep understanding of the client’s needs, whether it’s a power plant, a beverage factory, or another industrial facility. At this stage, the DRS team conducts an on-site survey, analyzes critical machines, and designs the sensor installation layout. Once the system installation is complete, the AI is trained to learn the actual behavior of the machinery in that specific plant.

The result is a system that reports machine status using easy-to-understand “green-yellow-red” alert levels. Clients can either manage the system themselves via a real-time dashboard or engage the DRS team for a full-service package, covering everything from monitoring and analysis to on-site intervention to ensure smooth operations.

“What we want to offer our clients is not just maintenance, but also production stability and consistency to enable business owners to focus on designing new products, reducing costs, and building their competitive edge in the market,”

Beyond Petrochemicals: Clear Results from DRS by REPCO NEX

Leading food and beverage conglomerates in Thailand: Production efficiency is increased from 80% to 90%. While major power generation groups in Thailand and the region: A gas turbine’s maintenance cycle is extended from 6 to 9 years, a 50% increase in operational availability, through proactive risk prediction.

For operators in any industry with large-scale machinery, DRS by REPCO NEX helps ensure continuous plant operation, reduces the risk of disruptions, and boosts production efficiency. It is ideal for industries such as oil and gas, petrochemicals, power generation, food and beverage, and public utilities.