Predictive maintenance is focused on predicting tomorrow’s condition based on today’s data in order to avoid unplanned maintenance and reduce overall maintenance costs.
At its core, it measures asset health through integrated technology applications for the early detection of component failures.
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At I-care, our proven predictive maintenance technologies, services, and diverse asset management solutions ensure industrial machines around the world are more productive, safer, and environmentally friendly.
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Accelerate your digital transformation to compete more efficiently, resulting in, increased productivity, improved asset uptime, increased safety, and reduced costs.
Below you can explore the what, why and how of Maintenance 4.0. Once you’re ready to digitize your Predictive Maintenance approach, we have you covered with our popular Wi-care as a Service solution.
In the world of Industry 4.0, many industrial manufacturers have already adopted or are considering a digital transformation strategy that encompasses augmented machines with added functionalities such as wireless connectivity and sensors. These machines are connected to a system that is capable of visualizing the entire production line, exercising control and making independent decisions. This digital transformation is part of a trend toward 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.
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 analysis, ultrasound analysis) and process data (e.g., flow, pressure, temperature) can be combined to obtain better detectability of hard-to-uncover 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.
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 through years of experience and innovative processes like Wi-care.
Better understand your current 4.0 maturity, highlighting your actual strengths and areas of improvement. Aligning your 4.0 strategic goals.
Choose appropriate data to target and enhance the most valuable areas of your business.
Generate data from the right data sources. Instrumenting your assets with condition monitoring and process sensors to improve detectability.
Develop diagnostic and/or prognostic models that increase the detectability of failure events or optimize your production.
Visualize your data with transparent dashboards for better decision-making.
Assign value to the insights from your data and schedule maintenance interventions. Record improved asset reliability and machine health per
Regardless of your current Maintenance 4.0 maturity level, together we can take the right steps to implement the measures that lead to enhanced performance, resulting in:
Improved equipment uptime
Increased asset lifetime
Satisfied customers due to expedited deliver rates
Cost reduction as a result of avoided failures and secondary effects of these failures on other parts of production lines
Reduced costs by preventing failures and mitigating their effects on other components of the production line
Avoided equipment downtime and improved operational efficiency with early detection of potential failure modes
Watch this short video as one of our 4.0 experts, Olivier Dengis, highlights the key steps to implementing Maintenance 4.0 into your Predictive Maintenance Strategy.
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