Maintenance 4.0

Introducing Maintenance 4.0

Accelerate your digital transformation to compete more efficiently, generating higher productivity, improved asset uptime, increased safety, and lower costs. 

Below you can explore the what, why and how of Maintenance 4.0.  Think your ready to digitize your Predictive Maintenance approach? We have you covered with our popular Wi-care as a Service solution.

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What Is Maintenance 4.0

In the world of Industry 4.0, many industrial manufacturers have or plan on implementing a digital transformation strategy that involves augmented machines with wireless connectivity and sensors, connected to a system that can visualize the entire production line, control, and make decisions on its own. This digital transformation describes the trend towards automation and data exchange in manufacturing technologies and processes.

At the epicenter of this transformation is Maintenance 4.0, a method of preventing asset failure by analyzing production and maintenance data to identify patterns and predict issues before they happen.  

Why It Matters

Over the decades, maintaining a competitive edge across asset-intensive industries required companies to adopt powerful efficiency tools and methodologies like Lean Six-Sigma and Total Quality Management. However, with the advancements in digital technologies and big data, many industry leaders are turning to ways to accelerate automation and data exchange to make better decisions.

Predictive Maintenance (PdM) is an essential part of many industrial companies’ 4.0 strategies. As a method of preventing unplanned downtime, by analyzing production and maintenance data, an organization can identify patterns and predict failure before it occurs. At the highest level of PdM maturity, companies are utilizing a combination of condition monitoring and process data for better detectability of hard to detect failure modes. 

The “data silos” of condition monitoring data (e.g. vibration, ultrasound) and process data (e.g. flow, pressure, temperature) can be combined to obtain better detectability of hard to detect failure modes, which leads to earlier and better alarming. By embracing “the future of predictive maintenance” it’s possible to better support the decision-making process and predict previously unpredictable failures.

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How We Can Help

Our Maintenance 4.0 roadmap helps our customers get a sense of where to go and the efforts required to achieve success. We connect stakeholders across all functions, solve their traditional business challenges across their organization and create new opportunities through the use of technology to achieve operational excellence.

When launching a 4.0 initiative in Predictive Maintenance, the project success rate is dependent on elements such as:

  • What data sources are already collected? 

  • What is the openness to change? 

  • How well are the fundamentals of maintenance and reliability implemented and yielding results? 

I-care helps its customers in the preparation to align these new innovative technologies with their strategic business goals.

 

Maintenance 4.0 Roadmap

No matter where you are on your 4.0 journey, I-care can support you in any of the steps to bolster your innovation initiatives:

Assess

Better understand your current 4.0 maturity, highlighting your actual strengths and areas of improvement. Aligning your 4.0 strategic goals.

Identify

Use the right data to target the most valuable areas to improve your business.

Generate and Collect

Generate data from the right data sources. Instrumenting your assets with condition monitoring and process sensors to improve detectability.

Analyze your data

Develop diagnostic and/or prognostic models that increase the detectability of failure events or optimize your production.

Visualize your data

Visualize your data with transparent dashboards for better decision-making.

Act

Act to valorize the insights from your data. Improve the performance of your maintenance interventions to obtain world-class maintenance.

Assess

Better understand your current 4.0 maturity, highlighting your actual strengths and areas of improvement. Aligning your 4.0 strategic goals.

Identify

Use the right data to target the most valuable areas to improve your business.

Generate and Collect

Generate data from the right data sources. Instrumenting your assets with condition monitoring and process sensors to improve detectability.

Analyze your data

Develop diagnostic and/or prognostic models that increase the detectability of failure events or optimize your production.

Visualize your data

Visualize your data with transparent dashboards for better decision-making.

Act

Act to valorize the insights from your data. Improve the performance of your maintenance interventions to obtain world-class maintenance.

Key Benefits/Outcomes

No matter what your current maturity, together we can take the right steps to pave the way to higher performance and deliver:

  • Improved uptime 

  • Increased asset lifetime

  • Satisfied customers because you can deliver on time

  • Cost reduction as a result of avoided failures and secondary effects of these failures on other parts of production lines

  • Detection of any failure mode before the equipment downtime undermines your operational performance 

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Contact us today to learn more about accelerating your Maintenance 4.0 journey.

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