Efficient Plant Jan./Feb. 2024 - 14

feature | IIoT Strategies
eff ectiveness of these maintenance programs.
Lower repair and maintenance costs: By proactively identifying
and addressing potential production problems before equipment fails,
plant managers can reduce the cost of repairs and maintenance. A study
by IBM found that the average downtime cost businesses $1.5 million,
but that unplanned stoppages were 35% more expensive (ibm.com/
downloads/cas/L57KW7ND).
More-effi cient service scheduling: Managing and scheduling plant
maintenance is a tricky undertaking. Plant managers must coordinate
repair/maintenance team schedules and make sure parts and equipment
are on hand to complete assignments. Unplanned downtime disrupts
that scheduling, which could cause delays in routine maintenance
for a business's other machines. Th rough real-time condition monitoring,
needed work can be identifi ed and carried out during planned production
scheduling. Digital repairs and maintenance technology also
allow team members to access equipment remotely, potentially cutting
service time to minutes or hours instead of days or weeks, particularly
if a specialist is needed. Th e technology has another scheduling benefi t:
A company's maintenance staff may spend less time repairing assets,
which could help alleviate the shortage of skilled workers.
Improved manufacturing effi ciency and product quality: Assets
that are operating at peak effi ciency are more profi table and generally
produce higher-quality products. A comprehensive maintenance
program using predictive analytics and cutting-edge equipment sensors
can alert managers when machines are not operating at optimal levels.
Simplifi ed monitoring through secure cloud solutions: When
machines are connected to a cloud-based network, plant managers can
quickly view performance and assess machine condition. Th e technology
can send alerts to managers, indicating when repairs or maintenance
should be performed, before a problem occurs. If asset measurements
deviate from historical data, self-learning algorithms are eff ective
at spotting those anomalies and generating predictive-maintenance
recommendations.
Creating or upgrading a digital preventive-maintenance program
that leverages the power of predictive analytics can be challenging.
Here are four tips to help minimize the time to launch the initiative
and maximize the return on investment:
Develop a comprehensive data-collection strategy. Plant managers
oſt en rush to connect all machines and industrial sensors, and then
collect lakes of data. Th at data, however, is of little value if it cannot be
organized, analyzed, and presented to managers in a way that allows
them to make optimal decisions. A clearly defi ned data-collection
strategy that includes identifying the KPIs that are most relevant to the
company's manufacturing processes, converts raw data into actionable
information. It provides managers with valuable insight into equipment
14 | EFFICIENTPLANTMAG.COM
health and better maintenance strategies.
Establish a baseline for performance measurement. KPIs are only
useful if decision makers have a reference point to compare data. Th e
historical data collected will help plant managers identify equipment
use patterns, trends, and anomalies to establish baseline performance
levels for their machines. Th e data can also be analyzed to help determine
factors that may have contributed to non-planned downtime due
to equipment failure. With a clear understanding of historical machine
performance, managers will be in a better position to forecast when
machines may need repairs and maintenance. Th e data will also help
them experiment with ways to improve the effi ciency of their machines
and related equipment.
Prioritize maintenance goals. When creating or enhancing a
predictive-maintenance program, it's easy to fall into the trap of taking
on too many projects. Do not try to do everything at once. Start small
and move forward. Prioritize your projects and the accompanying
goals. Plant managers should also ensure that maintenance goals align
with company manufacturing objectives. By looking at the production
schedule, downtime impacts, and available resources, decision makers
can create an integrated program that better maintains and helps
improve the effi ciency of mission-critical assets.
Ensure secure connectivity and data protection. Make sure you
implement the latest security standards when you connect assets to
your IT network. Collaborate with your company's chief technology
offi cer or cybersecurity partner to identify and address potential vulnerabilities
and ensure a seamless fl ow of information. Protecting your
assets with current cybersecurity technology is essential to maintain a
secure digital ecosystem for your company. A security breach likely will
cause material, fi nancial, and reputational damage.
Th e factories of the future will be increasingly connected and
powered by continued innovation in hardware and soſt ware. With a
modern, digital, predictive-maintenance program, plant managers
can mitigate the risk of unplanned downtime, so the business's
machines are operating at peak, profi t-generating effi ciency. EP
John Gaddum is Factory Automation Service Manager, North America,
for Bosch Rexroth, Hoff man Estates, IL (boschrexroth.com).
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