In this digital era, enterprises and Predictive Maintenance go hand in hand. The term “Predictive Maintenance” has been creating a buzz in industries across the globe. The increasing demand for digitization mandates enterprises to adopt Predictive Maintenance for scheduling optimal maintenance activities, improving asset utilization, preventing breakdowns and boosting productivity. This blog will shed light on Predictive Maintenance and its role in transforming enterprises in industry 4.0.
What Is Industry 4.0?
Industry 4.0 or Fourth Industrial Revolution is changing the way businesses produce, modify, and distribute their goods. Manufacturers are incorporating new technology into their manufacturing facilities and processes, such as AI services, Internet of Things (IoT), Machine Learning, Cloud Computing and Analytics. Integrating smart technologies into industrial operations will ensure greater flexibility in processes, better product quality, increase work efficiency and high revenue.
Predictive Maintenance And Its Role In Transforming Enterprises In Industry 4.0
Predictive Maintenance is a comprehensive technology that tracks equipment behaviour in real-time and predicts machine failure, enabling organizations to fix it before it causes any downtime.
All gadgets are susceptible to damage and degeneration in the long run. Their life expectancy rises or falls in direct proportion to the frequency with which they are maintained.
Predictive Maintenance employs condition monitoring via real-time data obtained through the Industrial Internet of Things (IIoT), which is widely considered a key component of the Industry 4.0 revolution. In this way, it efficiently monitors operations, detecting potential future errors and regulating them before they escalate. Now let’s take a look at the different types of Predictive Maintenance technologies.
Acoustic monitoring: In this method, systems that can replicate the hearing abilities of workers are used to detect faults in sound. Although it can be difficult to identify some noises above a facility's background noise, this approach of Predictive Maintenance is widely utilized in industrial operations.
Infrared technology: This entails regular testing of the equipment temperature and enables easy monitoring of operational parameters. This Predictive Maintenance approach can be used to locate "hot spots" in electronic equipment, near-capacity fuses, and defective terminations in electrical circuits.
Vibration analysis: This method detects and examines large deviations from a machine's normal vibration. Typical vibrations will be measured several times to boost accuracy.
Oil analysis: This method entails testing of oil from machinery to detect viscosity, water content, wear particles etc. This strategy is ideal for the transportation industry.
Motor circuit analysis: This method analyzes the rotor and stator of the motor, and detects ground faults and contamination. This is ideal for evaluating new motors before installation and also for evaluating the health of existing motors.
Here is a breakdown of the role of Predictive Maintenance in industry 4.0:
When an aeroplane breaks down, it can cause major complications and cost a lot of money. In most cases, aeroplane maintenance follows a fixed timetable for inspections and repairs. Predictive Maintenance, which employs sensors and a flight data recorder, on the other hand, is capable of forecasting where abnormalities may develop and arranging maintenance schedules ahead of time.
A manufacturing plant may invest in infrared imagers to oversee certain components of assets, such as temperature, to prevent overheating. This Predictive Maintenance strategy aids manufacturing plants in avoiding the overuse of critical equipment, which can lead to unplanned downtime.
Building owners can use Predictive Maintenance technology to control and monitor their facilities from any place. This digital technology will allow building owners to track humidity, maintain a specific temperature range, etc. This monitoring can aid in lowering the building's overall energy costs.
Oil and gas industry
The oil and gas firms lack visibility into the condition of their equipment in remote areas and maintenance personnel will have to visit these sites on a regular basis to inspect the equipment's condition, even if it is not essential. However, with Predictive Maintenance oil and gas firms can monitor the condition of their equipment in real-time and can schedule maintenance only if it is necessary.
As the world moves increasingly towards digital, it becomes critical for industries to embrace Predictive Maintenance to gain insights into their operations. Needless to say, by implementing Predictive Maintenance, enterprises can detect anomalies, enhance processes, reduce the likelihood of failures, maximize equipment lifespan and more. In the upcoming years, the world is going to witness the domination of Predictive Maintenance in solving concrete business challenges.