What is the Importance of Predictive Maintenance in Industry 4.0?

A rundown on the importance and implementation process of predictive maintenance.

On a long day at work with deadlines looming around, how would it feel to detect a technical fault in one of your machines that halts the production temporarily? How long might it take to rectify the error and resume production? Wouldn’t it have been nice to predict this occurrence and completely prevent it from happening? This uncertainty and sudden mishaps proved problematic in all industries and thanks to predictive maintenance.

With predictive maintenance, real-time data while the equipment is running can be collected and possible faults can be detected much earlier avoiding all the sudden and last-minute hassles. This was one of the very first implementations of Industry 4.0 and there’s no looking back. Read how Artificial Intelligence drives Industry 4.0. This method collects necessary data including various parameters, also connecting to the life cycle of a machine and alerts the operators regarding any discrepancies in the near future.

Predictive vs Preventive Maintenance

Though it is advisable to have a mix of both, preventive and predictive maintenance follow different strategies. Preventive maintenance is based on the expected life of equipment while the other is more dependent on the current working condition of the equipment.

Predictive maintenance is more complex and inclusive than preventive maintenance. It is a continuous process that depends on the usage of equipment rather than the life of the equipment dictated by the manufacturer at the time of buying. This makes it more effective and assists in cost reduction massively.

The Working Capacity of Predictive Maintenance

IoT plays a major role in predictive maintenance. It connects all the assets and systems, shares, analyzes and provides data in real-time without disrupting the process. Condition-monitoring equipment evaluates the asset’s performance and alerts in case of any change in the reading. There are options to send emails or indications automatically when the readings go beyond the recommended range.

For instance, IoT uses predictive maintenance sensors for vibration analysis, oil analysis, thermal imaging, equipment observation, etc. Predictive Maintenace helps build Smart Factory with the help of Artificial Intelligence and IoT.

A Business Case for Predictive Maintenance

1. Patience is the Key

As discussed, this process of maintenance results in cost-effective and highly efficient processes. However, it should be kept in mind that the implementation of predictive maintenance is a long process as it requires more effort and time for the data to be collected and placed in cloud computing. Businesses also should invest in training the employees to interpret the data correctly so that necessary and immediate action is taken when required. These initial investments must be made to ensure a longer running time of equipment and better production.

2. Get Everyone Involved

To make this a success, the commitment to implement it should come from the top down. Everyone should be committed to making it a part of the normal process. All operators must be educated and involved in the implementation and conducting the required checks when needed. To reap its benefits, it must be understood that it should be a norm as soon as possible for a better effect. Operators must understand the repercussions of poor maintenance.

3.Anywhere and Everywhere

While predictive maintenance is usually seen in bigger and costlier machines, they can also be used in smaller, everyday appliances like coffee machines, printers, postage metres, etc.

How Predictive Maintenance Impacts Industry 4.0?

With IoT playing the biggest puzzle piece in this, the key is to understand its importance and take the leap of faith in implementing it immediately as there is guaranteed ROI. AI also plays a major role in predictive maintenance. If an organization wishes to implement Industry 4.0, this should be one of the first steps to take them in the right direction.

Rootquotient is actively looking at the Industry 4.0 space to research & contribute to the greatest revolution. If you are looking to leverage the power of AI and IoT and automate your business process, reach out to our experts.