{"id":1421,"date":"2020-11-06T11:03:21","date_gmt":"2020-11-06T10:03:21","guid":{"rendered":"https:\/\/syram.eu\/?p=1421"},"modified":"2021-02-02T10:11:42","modified_gmt":"2021-02-02T09:11:42","slug":"maintenance-predictive-industrie","status":"publish","type":"post","link":"https:\/\/syram.eu\/en\/maintenance-predictive-industry\/","title":{"rendered":"Predictive maintenance: using IIoT and ML to prevent equipment failure"},"content":{"rendered":"
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Predictive maintenance in industry: using IIoT and ML to prevent equipment failure\n<\/h2>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Sooner or later, all machines break down, but with a wide range of consequences. A sudden failure of the coffee maker can ruin your mood and your morning. Consequently, an unexpected malfunction in a power plant has the potential to leave thousands of people in total darkness for hours, and cause a loss of several million Euros.<\/span><\/p>

For example, the average cost of unplanned downtime in the energy, manufacturing, transport and other sectors is \u20ac250,000 per hour, or \u20ac2 million per working day.\u00a0<\/span><\/p>

Indeed, to avoid costly breakdowns and mitigate the damage caused by breakdowns, companies need an effective maintenance policy. This article presents the strategies available, the advantages of the most advanced predictive approach and the resources required to implement it.<\/span><\/p><\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Maintenance strategy: corrective vs. preventive vs. predictive<\/h2>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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First of all, there are three main types of maintenance strategy to which a company can adhere: corrective, preventive and predictive. Each option has its advantages and disadvantages, so let's take a closer look.<\/span><\/p><\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Reactive maintenance: solve the problem when it happens<\/h3>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Major benefits:<\/strong> low maintenance costs, reduced permanent staff, minimal planning required<\/span><\/p>\n

Main disadvantages:<\/strong> high repair costs, safety risks, potentially greater damage to machines<\/span><\/p>\n

Thus, reactive maintenance, also known as corrective maintenance, from operation to failure, means that actions are taken when the equipment is already down. This approach saves time and money on planning and support services. It can be applied to redundant, easy-to-repair, non-critical assets. Let's say light bulbs are replaced only after they've burned out.<\/span><\/p>\n

While corrective maintenance requires no up-front costs, it proves very costly in the long term, taking into account overtime, reduced asset life, reputational damage and safety risks. According to Marshall Institute estimates, the reactive approach costs companies up to 5 times more than proactive types of maintenance.<\/span><\/p><\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Preventive maintenance: repair everything on schedule<\/h3>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Major benefits:<\/strong> increased efficiency and equipment lifecycle, reduced likelihood of breakdowns, cost savings<\/span><\/p>

Major drawbacks:<\/strong> no way to rule out catastrophic failures, increased work intensity and planned downtime, extra time on planning<\/span><\/p>

Thus, preventive maintenance triggers regular inspections of equipment to mitigate deterioration and reduce the likelihood of breakdowns. Planned activities such as lubrication or filter changes extend the useful life of assets and increase their efficiency. All this translates into savings. Studies show that average savings from planned maintenance amount to 12 to 18% compared with reactive maintenance.<\/span><\/p>

However, preventive measures cannot entirely exclude the possibility of catastrophic breakdowns. What's more, this practice requires additional planning and human resources. Often, the frequency of checks is higher or lower than necessary to guarantee reliability.<\/span><\/p><\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Predictive maintenance (PdM): don't fix what isn't about to break <\/h3>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Major benefits:<\/strong> reduced maintenance time and costs, longer asset life, reduced safety, environmental and quality risks<\/span><\/p>\n

Main disadvantages:<\/strong> the need for organizational changes, major investments in hardware, software, expertise and staff training<\/span><\/p>\n

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Indeed, predictive maintenance has become possible with the advent of Industry 4.0, the fourth industrial revolution driven by automation, machine learning, real-time data and interconnectivity. More or less similar to preventive maintenance, PdM is a proactive approach to machine maintenance. The difference is that a company plans activities based on constant condition monitoring. Once unhealthy trends have been identified, damaged parts are repaired or replaced to avoid more costly breakdowns.<\/span><\/p>\n

The benefits of PdM for companies include :<\/span><\/p>\n

-Reduced maintenance costs, <\/span><\/p>\n

-Extended equipment life, <\/span><\/p>\n

-Reduced downtime, <\/span><\/p>\n

-Increased production capacity and enhanced security. According to a Deloitte Insights report, \"PdM promises\".<\/span><\/p>\n

-Reduction in maintenance planning time from 20 to 50%,<\/span><\/p>\n

-Increase in equipment uptime and availability from 10 to 20%, and<\/span><\/p>\n

5-10% reduction in overall maintenance costs.<\/span><\/p>\n

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But these improvements require significant investment in IT infrastructure and expertise - namely, in industrial IoT (IIOT) sensors, analytics software with machine-learning capabilities; the services of data scientists and IT specialists, and staff training. A company needs to build an entire ecosystem to support prevention activities. <\/span><\/p>\n

In the following sections, we'll look at when these efforts make sense, and what exactly it takes to implement LOP.<\/span><\/p><\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Predictive maintenance use cases in industry and success factors<\/h2>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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In the first place, this cost- and technology-intensive strategy is justified by high-value, mission-critical equipment that must always be operational. Obviously, PdM is too expensive and inefficient for components that can be down for hours or even days without affecting the production cycle. Anything in between requires further deliberation to make the right choice.<\/span><\/p>\n

Currently, the most efficient PdM is used in the following industrial sectors:<\/span><\/p>\n

-manufacturing plants,<\/span><\/p>\n

–<\/span>power plants,<\/span><\/p>\n

-railroads,<\/span><\/p>\n

-aviation,<\/span><\/p>\n

-oil and gas industry, and<\/span><\/p>\n

-logistics and transport.<\/span><\/p><\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t

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Tasks you can solve with predictive maintenance<\/h2>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Whatever your industry, when you decide to implement it, you need to clearly understand that PdM only applies to tasks of a predictable nature. The PdM strategy can answer five main questions:<\/span><\/p>

\u00a0<\/p>