Topics In Demand
Notification
New

No notification found.

Enhancing Maintenance with Internet of Things (IoT) Technology
Enhancing Maintenance with Internet of Things (IoT) Technology

July 21, 2023

IOT

75

1

The Internet of Things (IoT) has found its way into the maintenance industry, revolutionizing the way assets are managed. By utilizing sensor technology, IoT enables real-time monitoring and analysis of asset health, benefiting both predictive maintenance (PdM) and preventive maintenance (PM) strategies. However, implementing IoT doesn't necessarily require an existing maintenance plan, as its advantages can be leveraged independently. In this article, we will explore the ways in which IoT can enhance asset maintenance.
 
Improving Maintenance with the Internet of Things

1. Real-Time Data Analysis

The IoT takes machine-to-machine (M2M) communication to the next level by incorporating data analysis. By creating a virtual network that aggregates and analyzes machine data, original equipment manufacturers (OEMs) can generate accurate predictive analytic models. Instead of waiting for a system to fail, manufacturers can predict failures by monitoring operating conditions and identifying trends that deviate from specifications. This enables OEMs to design more reliable products, reduce warranty claims, and improve customer satisfaction.

2. Accurate Performance Metrics

IoT technology enables the automatic calculation of performance metrics such as availability, reliability, mean time between failures (MTBF), and mean time to repair (MTTR). This eliminates human error in capturing downtime data and ensures the accuracy of the collected information. Moreover, analyzing reliability metrics from various customer sites can identify best practices that can be implemented globally.

3. Increased Adoption of Predictive Maintenance

Predictive maintenance is a key application of IoT in asset management. Instead of relying on routine inspections and calendar-based component replacements, predictive techniques monitor equipment for impending failures. Embedded sensors continuously check for abnormal conditions and trigger work orders when safe operating limits are breached. Predictive maintenance optimizes maintenance activities by performing them only when necessary, reducing costs associated with parts and labor. With the growing number of systems equipped with internet connectivity, the concept of predictive maintenance is expected to expand exponentially through IoT.

4. Recommended Repair Actions

When equipment failure occurs, IoT enables the collection, aggregation, and real-time analysis of failure data from various sources. The system can automatically initiate repair options and recommend actions to technicians, providing them with all the relevant information needed to make effective decisions. This includes system operating conditions, past repair data from computerized maintenance management systems (CMMS), wear patterns, and operational data from the equipment fleet. To ensure actionable information is presented in a user-friendly manner, it is crucial to deploy a CMMS with an application programming interface (API) that can connect with IoT devices.

5. Improved Parts and Inventory Control

Efficient inventory control plays a vital role in reducing equipment downtime and managing maintenance budgets effectively. Connected stockrooms equipped with proactive monitoring capabilities optimize inventory movements and stock levels, ensuring that the facility only holds necessary parts. Through predictive maintenance and data analysis, OEMs can optimize recommended spare parts lists, freeing up capital and increasing customer satisfaction.

How to Implement IoT Technology for Maintenance Improvement?

Implementing IoT technology can be complex, but understanding common pitfalls can help you avoid them. Here is a guide to successfully introducing IoT technology in your facility:

1. Start with a Single Example Asset

To demonstrate the initial value of IoT technology, begin with a single asset. This approach allows you to address any challenges before a full-scale implementation. It also enables fine-tuning of data-gathering processes and provides a history of data, which can be presented to secure managerial buy-in. The data collected can offer insights into areas where maintenance efforts can be improved.

2. Monitor a Single Data Channel

Monitoring data effectively is crucial for IoT technology. In an industrial environment, numerous variables can be measured, but it is important to select one specific data channel to focus on during the testing phase. For instance, monitoring vibrations, noise, or heat in a non-critical motor can help maintenance teams diagnose issues accurately. By gathering substantial data on the motor, you can create a maintenance plan based on common failure patterns.

3. Out Slowly and Purposefully

Attempting to interconnect every asset in a facility simultaneously can lead to failure. It is impractical to network every asset and gather an excessive amount of data, as it would create information overload. Instead, gradually roll out IoT technology, allowing for a smooth implementation and the early resolution of any issues. Focus on specific pieces of equipment that truly benefit from sensor monitoring, as not all assets require the same level of data collection.

Challenges of Transitioning to IoT Technology

Implementing IoT technology for maintenance comes with its challenges:

1. Cost

IoT sensors can be expensive, emphasizing the importance of selective implementation on purposeful equipment rather than trying to monitor an entire facility. However, as technology advances, the cost of sensors is expected to decrease, making IoT more affordable in the future.

2. Data Overload

Gathering vast amounts of data is only beneficial if it can be effectively analyzed and utilized. Data overload can make it challenging to derive meaningful insights. Developing analytical algorithms and capabilities to digest and interpret the collected data is essential for successful IoT implementation.

3. Security

Integrating networking capabilities into various assets introduces security risks. With a large volume of interconnected equipment, it is crucial to prioritize network security and implement IoT cybersecurity measures. Monitoring for potential security breaches and compromises becomes as important as monitoring data itself.

Despite these challenges, the adoption of IoT in maintenance will continue to grow as the need for specific, detailed data drives maintenance efforts forward. As costs decrease and analytical capabilities improve, IoT will play an increasingly pivotal role in enhancing asset maintenance.


That the contents of third-party articles/blogs published here on the website, and the interpretation of all information in the article/blogs such as data, maps, numbers, opinions etc. displayed in the article/blogs and views or the opinions expressed within the content are solely of the author's; and do not reflect the opinions and beliefs of NASSCOM or its affiliates in any manner. NASSCOM does not take any liability w.r.t. content in any manner and will not be liable in any manner whatsoever for any kind of liability arising out of any act, error or omission. The contents of third-party article/blogs published, are provided solely as convenience; and the presence of these articles/blogs should not, under any circumstances, be considered as an endorsement of the contents by NASSCOM in any manner; and if you chose to access these articles/blogs , you do so at your own risk.


images
Lindsey Walker
Sr. Marketing Manager

Lindsey Walker is the marketing manager for NEXGEN, a leader in designing advanced CMMS systems and asset management software tools.

© Copyright nasscom. All Rights Reserved.