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Industry 4.0 - Predictive plant maintenance and safety inspections (Cloud + Mobile Apps + AI + IOT + MES + SAP ERP)

Industry 4.0 Predictive Maintenance

The increasing number of industrial applications, such as manufacturing, mining and construction is adding to the workload of the plant operators and maintenance personnel. The pressure to provide efficient production is also driving up the demand for preventive maintenance services at each plant. As a result, retooling needs to adapt more quickly than ever before with predictive technologies that take a proactive approach toward monitoring equipment health from outside or inside the plant site. By incorporating data analytics applied across different business operations like marketing and production control with predictive machine learning models that have been trained with data about how one part of the operation operates on another – we can achieve new levels of sustainable productivity in our plants.

For example, a plant operator might know a particular machine blade is worn but remain unsure how the machine operates in the long run. In fact, even when an operator sees a fault occur, it may be impossible to predict when the next fault is likely to occur. Predictive maintenance can help operators and maintenance teams manage their plant equipment more effectively and efficiently; this results in increased production levels sustained over the longer term. It enables operators to foresee any potential faults or failures based on real-time data analysis from “smart” sensors that assess equipment performance.

In addition, predictive maintenance also helps reduce unplanned downtime by giving operators an advance warning of planned downtime in order to avoid unnecessary unscheduled downtime. This approach has a cost-saving impact on the plant and equipment operator. They might also be able to perform planned maintenance during planned downtime or produce more on their equipment since it is in more predictable condition.

The application of predictive maintenance solutions gives operators better visibility into the performance and condition of their machinery. With this insight, they are able to make informed decisions about when and where repairs, replacements, or upgrades should be executed – thereby optimizing system performance in real-time.


Predictive Maintenance Improves Equipment Efficiency

Operators can see how current conditions affect equipment resources (i.e., water, oil, gas). This increases plant efficiency by producing fewer defects. Operators can also better predict and forecast repair requirements, which not only helps to provide the right equipment for a specific job, it can also reduce potentially expensive unplanned downtime. For example, predictive maintenance can be used to inspect and manage equipment health from outside or inside the plant site.


Predictive Maintenance Improves Equipment Operation

Predictive tools help with preventive and predictive maintenance in order to improve maintenance planning and improve product stability. A common feature of most successful predictive maintenance systems is that they are capable of making decision in real time. Both conditions and statistics of the production system are continuously monitored. With exception-based predictive maintenance, the system can react immediately if in a critical situation.

The system is constantly looking for relationships between certain conditions and their effects on the process and equipment performance. The acquired knowledge is then used to predict future events based on current data in order to improve maintenance planning and production stability. More importantly, the operators are able to foresee any potential faults or failures based on real-time data analysis from “smart” sensors that assess equipment performance.


Predictive Maintenance Reduces Spare Parts Inventory

The management of spare parts by an automated system can be costly and inefficient. One current trend is the use of predictive maintenance to manage the inventory of spare parts for complex machinery. Effective use of predictive maintenance software can help in identifying inefficiencies in the use of existing parts and equipment, especially on manufacturing lines where there is a high volume of fast-moving machinery.


Predictive Maintenance Improves Plant Safety

Predictive maintenance can be used to improve the quality of plant safety. It can be used to detect potential dangers and prevent accidents at a plant. The traditional approach to preventive maintenance is reactive, meaning that the equipment is checked only after it has failed. With predictive maintenance, there is a move toward proactive, real-time methods by putting an early warning on equipment that may not have failed yet.


Predictive Maintenance Improves Environment and Sustainability

Predictive maintenance can help to prioritize and eliminate activities that have a negative impact on the environment. For example, predictive maintenance can show where some parts of the plant are most inefficient with regard to their energy use, which may be due to poorly insulated equipment or hot spots in a plant. Similarly, predictive maintenance can monitor the amount of water used by plant machinery and detect leaks that can pollute the environment.


Predictive Maintenance Can Improve Security

Predictive maintenance may also be used to predict a security threat. For example, in many oil and gas facilities, equipment is guarded by guards at all times. If a predictive maintenance system is able to predict the potential failure of an alarm system, it can be used to deactivate this system before an attack occurs.


It’s time to move on from Paper based inspection to CLOUD based HVI APP !



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