Case study for a Distillery Machines maintenance Application. IOT
Having a detailed, thorough maintenance program is important for any company dealing with heavy and intricate machinery. After all, proper maintenance can help you:
- Maximize reliability
- Minimize repair costs
- Avoid costly downtime
- Increase safety
- Improve quality
- Enhance productivity
But isn’t maintenance costly in and of itself? Sure, there are costs associated with maintenance. However, the combined cost of any maintenance plan — especially one that includes preventive AND predictive maintenance — is much more affordable than any catastrophe that will undoubtedly happen if your equipment is not properly monitored and maintained.
We have two ways of maintenance methods ie: preventive and predictive maintenance
So let’s start by getting a better understanding of what preventive and predictive maintenance are as well as the benefits of each.
1) Preventive Maintenance
Preventive maintenance includes the precautions you take to prevent anything from happening to a piece of machinery. For example, in the auto industry, some preventive maintenance actions include changing your oil at the interval required by your vehicle’s manufacturer, changing your air filter when it starts getting dirty, and rotating or balancing your tires regularly — or as soon as you detect the need to.
These are fairly simple actions that require a little planning and a bit of an investment, but if not done, they could cause much larger system-wide problems that will be much more expensive, time-consuming, and frustrating.
The same mindset applies to our industry. Preventive maintenance is designed to ensure equipment reliability by replacing worn — or about to be worn — components before they fail. These actions are usually performed during planned equipment downtime. Preventive maintenance includes those regularly scheduled, time-based actions (such as lubrication, calibration, adjustments, part replacements, etc.) you take to keep your machinery running smoothly while avoiding issues down the road.
2) Predictive Maintenance
Predictive maintenance is all about analysis. It’s about knowing the condition of your machinery at all times so that you can ensure maximum output and longer life. Some of the best techniques for performing ongoing predictive maintenance use technology associated with vibration and oil analysis, infrared imaging, ultrasonic monitoring, electrostatic, motor current, crack detection and trending practices.
By using this technology, you will be able to predict the future trend of your equipment’s condition and make corrections along the way. Predictive maintenance is all about knowing your systems. After all, the more you know about your system and how it’s running, the quicker you’ll be able to catch any anomalies, make adjustments to improve output and efficiency, and avoid a costly breakdown.
Nothing about predictive maintenance happens at a previously scheduled time. Further, it rarely occurs during any downtime. Rather, predictive maintenance is ongoing and usually happens while your machinery is up and working. It’s all about analyzing and monitoring all of the aspects of your machine’s functions and identifying when they are showing signs of failure.
What is Industry 4.0?
Industry 4.0 is a concept widely adopted as a driver in the digital industry and is based on the “Industry 4.0” project developed by the German government. This project was announced at the Hanover International Fair in 2011 and according to Industry 4.0 theory, the digital industry is based on customizable products, developed in a flexible manufacturing environment. [1]
The value of smart products will not only lie in their physical capabilities but also in the enhanced customer and supply partners’ experience. From the earliest stages of engineering and design, every aspect is integrated with high-quality services in a new category of hybrid products.
The new manufacturing concept developed by the Industry 4.0 initiative incorporates machines, processes, software, sensors, processors, and communication technologies. All these systems have a computing component, as well as physical interaction with the real world, thus providing a meaningful interface between the two.
User Persona
Wireframes
Application
Industry 4.0 enables a product-centric approach to service equipment; by using artificial intelligence models to predict machine downtime, schedule proactive maintenance and predict time to action for equipment requiring replenishment/replacement, manufacturers can
- Identify impending faults early and reduce costly emergency repairs
- Predict when a component will fail and proactively schedule maintenance plans
- Identify failure of an asset with longer lead time to improve reliability and performance
Design
Thank you