Maintaining profitability and boosting margins is always a top priority for many organisations. However, the process of doing so is quite meticulous for heavy-duty industries. Equipment is more prone to damage due to regular operations. Moreover, maintenance teams must constantly be alert to take swift corrective actions. These teams should be well-qualified and knowledgeable to diagnose the exact problem and apply the solution.
The best way to move forward is to use new technologies. Predictive maintenance software is necessary for modern industrial operations due to their large scale and multiple geographical locations. It is a comprehensive software solution that includes various technologies working cooperatively.
An Overview of Predictive Maintenance
Predictive maintenance software combines different technologies. It is a synergy of data analysis, IoT sensors, and cloud computing. Here are the applications of each of these technologies:
- Data Analysis: It processes and examines data to find useful information and support decision-making. The main purpose of data analysis in a predictive maintenance software is to find anomalies that may indicate system failures.
- IoT Sensors: Sensors are devices that measure the output and operations of a system. It directly sends the data to the dashboard for data analysis.
- Cloud Computing: It transports data from one source to another via the internet. Cloud computing is faster than other forms of data transmission.
As opposed to reactive maintenance, predictive maintenance aims to solve issues before they occur. The data gathered from the sensors makes such resolution procedures possible. The system swiftly picks up any anomalous behaviour to alert the respective authorities.
On the other hand, this technology also differs from preventive maintenance. Although the name sounds the same, preventive maintenance has a slightly different protocol. It refers to regular scheduling of equipment maintenance and other systems to prevent failures. When employed with the other strategies, preventive maintenance makes up the total productive maintenance procedure.
How Remote Monitoring Works
The major purpose of predictive maintenance is to monitor plants and machines worldwide remotely. Therefore, this technology is also called a remote machine monitoring system. It provides the following advantages to industrial plants that adopt it:
- Real-time monitoring of the system.
- Real-time data analysis through sensors.
- Early detection of issues to lower the mean time between repairs.
- Reduced downtime to lower the mean time between failures.
Predictive maintenance has the potential to reduce facility downtime by 5–15% and boost worker productivity by 5–20%, according to a 2022 Deloitte research.
Critical Applications of Predictive Maintenance via Remote Monitoring
Manufacturing
Sensors monitor industrial processes and communicate updates to the appropriate parties. This enables proactive and timely decisions. Remote monitoring tracks, analyses, and controls vital assets, therefore preventing unplanned downtime and equipment failures. The technology collects data from vibrational and temperature analysis to detect failures. Visualisation tools also display complicated data in an easily comprehensible way through dashboards.
Energy Generation
Predictive maintenance improves operational sustainability by reducing energy wastage. It optimises asset performance and uptime to save money through oil analysis. Early detection of probable defects leads to fewer failures and less scheduled maintenance. It also reduces frequent unexpected downtimes. Hence, remote machine monitoring system software improves the efficiency of the energy generation process.
Transportation
Suppliers and logistics businesses can discover failure patterns and abnormalities. The system learns from them and forecasts future failures of machine components. Hence, it allows them to be replaced before they fail. This increases the supply chain’s efficiency and maximises equipment availability. The fleet can be optimised entirely to prevent mishaps on the road. It is also essential for fuel conservation and preventing pilfering.
Building Management
Predictive maintenance software monitors the location and handling of high-value equipment in real-time. The sensors monitor assets like:
- HVAC Valves
- Motors
- Pumps
- Conveyors
- Lifts
Proactively monitoring performance reduces downtime and lost productivity. It also analyses condition monitoring data to find patterns and opportunities for improvement. Real-time monitoring of environmental variables and equipment performance allows for detecting possible dangers.
Challenges and Considerations
The various challenges associated with the adoption of a new predictive maintenance system are as follows:
- System infrastructure: Due to the strategy’s complexity, there are significant initial costs. These frequently entail spending on maintenance and data management tools. These costs also include updating and merging antiquated technology and monitoring systems. Capital is invested in the infrastructure supporting the data and systems.
- Employee training: It may be costly and time-consuming to teach staff members how to utilise new equipment, procedures, and data interpretation techniques.
- Requirements for data: Previous performance data can be used to forecast future results. The availability of historical and proxy data is essential for the success of predictive maintenance. Analysing data correlations with comparable equipment types under real-world operating situations is also crucial as it can enhance the prediction power of analytics.
Best Practices for Implementing Predictive Maintenance
Some of the best practices for implementing remote machine monitoring systems are:
- Feed historical data into the system for accurate predictions.
- Train the system properly to avoid unnecessary alerts and notifications.
- Train your employees to adopt the new system and its procedures.
- Integrate the system with your existing systems and processes for smooth workflows.
Predictive maintenance via remote monitoring offers significant benefits for industries seeking to improve profitability. Industries with multiple locations can proactively identify and address potential equipment failures. While there are challenges, the long-term benefits of predictive maintenance often outweigh the initial costs. You can employ the solution with top-notch software like machineCONNECT, which was designed by Prescient Technologies. It is a predictive maintenance software that optimises your maintenance procedures and reduces downtime. It is the first step towards making your business more efficient!
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