Shape: transforming heavy asset data into business value

The success of industries deploying heavy assets hinges on the operational efficiency of their equipment. Industry players seek technologies capable of monitoring and maintaining their assets to minimize operational disruptions, mitigate maintenance expenses, and enhance safety and reliability. They aim to achieve these goals without overhauling their existing infrastructure and equipment, which may not always be technically and financially feasible.

Shape, a technology company, is at the forefront of using cutting-edge solutions designed to preemptively address heavy equipment issues, while preserving existing infrastructure. It brings the combination of AI and technology with extensive real-world industry experience into the heavy engineering industry to deliver substantial business value to clients.

It harnesses advanced AI-powered solutions and data analytics to develop software that empowers clients to predict equipment failures, minimize downtime, reduce greenhouse gas emissions, and enhance overall operational safety and efficiency. While its primary focus is on the oil and gas industry, it extends its services to diverse sectors, including but not limited to pulp and paper, metals and mining, and power generation.

As a spinoff of MODEC, one of the world’s foremost floating production storage and offloading (FPSO) operators, Shape elevates client productivity sustainably while concurrently driving down costs. The company achieves this through a synergistic blend of data and cutting-edge technology.

"We go beyond selling technology to the heavy asset industry; we deliver tangible business value to our clients," says Caio Sene, VP of Operations.

The team at Shape primarily delivers two SaaS solutions - Shape Lighthouse and Shape Aura. Shape Lighthouse is a smart real-time asset monitoring platform that empowers clients to oversee asset performance, health, and reliability to mitigate downtime and lower operational costs. It centralizes, organizes, and contextualizes all available data from plant to equipment level, classifying equipment and subsystems based on their health status.

A set of predictive maintenance models within Shape Lighthouse generates alarms for the monitored equipment, enabling clients to take immediate actions that prevent downtime and ensure operational continuity.

Shape Lighthouse has demonstrated its effectiveness in Brazil’s FPSO industry by achieving a remarkable 15 percent reduction in downtime for MODEC’s fleet.

These pieces of equipment already had an impressively high uptime of more than 95 percent, making the double-digit reduction a substantial one. In addition to the uptime upside, Shape Lighthouse also generated over one million USD per plant of savings in maintenance and operational costs.

While Shape Lighthouse focuses on maintenance and reliability, Shape Aura places a strong emphasis on sustainability. It helps companies improve their energy efficiency and reduce greenhouse gas emissions through recommendations that optimize the operation without affecting production or equipment reliability.

Through automated systems, it identifies opportunities to minimize energy consumption and issues recommendations to the operations team. The notifications are delivered through a user-friendly application tailored for the operators’ use. This simplifies the process and reduces costs, enabling the assets to remain in a consistently optimized state.

We go beyond selling technology to the heavy asset industry; we deliver tangible business value to our clients

Implementing this solution, Shape and the client witnessed around five percent reduction in CO2 emission without requiring additional capital expenditures in upgrading or replacing equipment.

Shape is aware that creating robust software is futile unless it is effectively used to generate substantial value. It addresses this crucial aspect through its Implementation and Value Assurance areas. Within this framework, the company maintains a specialized team of engineers collaborating with clients’ engineering teams. Employing proper change management, this team assists clients in implementing necessary actions to ensure the insights generated by the software solutions translate into significant business value.

Dedicated to maximizing client benefits, Shape facilitates end-to-end digital transformation, from collecting data to capturing values by executing recommended actions. It transcends the role of a conventional technological partner to become a value-driven ally as it guides the heavy asset industry through this transformation.