In this article, we discuss equipment maintenance challenges and identify opportunities for minimizing downtime with the use of predictive and prescriptive maintenance and the Internet of Things.
Most industries have moved away from the traditional corrective maintenance model of running equipment until it fails, to a proactive model where maintenance is planned in defined intervals to optimize asset performance and prevent failure. In the last two decades, advances in information and communication technology (ICT) and computer science (especially in the areas of artificial intelligence [AI] and machine learning [ML] technology), have paved the way to a predictive maintenance (PdM) and prescriptive maintenance (RxM) model (1, 2, 3).
Predictive maintenance uses the Internet of Things (IoT) sensor devices and data to predict asset maintenance schedules to prevent failure (4, 5). Predictive maintenance utilizes AI and ML to assess equipment, operations, processes, services, or systems data to anticipate and address potential issues before failures occur. For example, ML algorithms use supervised learning analytical techniques including regression, decision trees, and neural networks to predict equipment failures. Prescriptive maintenance takes this one step further by providing solutions common to an error alert based on AI, ML, system diagnostics, and previous equipment failures (5).
Predictive and prescriptive maintenance is customized to each asset, process, organization, and industry. Organizations can expect to control operational risk by reducing equipment downtime and improving production uptime.
Maintenance challenges
Organizations employing traditional maintenance approaches often request urgent support when equipment fails without any notice, which leads to downtime (6, 7, 8, 9, 10, 11). Timely resolution of equipment failures have a variety of contributing factors, including service level agreements (SLAs) with vendors, ease of escalation and coordination of activities, time needed to order and receive parts in case of no local inventory, and time associated with repairs. The root cause of these failures and the resulting downtime, often originates from knowledge gap of operators and in-house teams, which can extend to proper equipment use, routine maintenance, and troubleshooting. Challenges associated with continuous training and employee turn-over further exacerbate the issue.
Impacts of downtime and process resolution
Unplanned downtime impacts business continuity and may result in significant revenue and profit losses. Non-financial implications in extreme cases can extend to patient outcomes. Consequences that are harder to measure in the short-term are related to human resources: pressure on the production floor due to the urgency caused by downtime and the resulting investigation can add additional stress to in-house teams, the cumulative effects of which are decreased staff morale and attrition.
Organizations can keep their processes running consistently with predictive and prescriptive maintenance, where downtime is proactively scheduled to avoid potential equipment failures. This type of maintenance offers a more cost-effective service with a limited duration of downtime, effective resolution of equipment issues, and rapid return to uptime.
Catalysts for change
Organizations considering a digital maintenance solution are looking for speed and scalability of deployment, ease of use, and accurate equipment warnings and predictions. Predictive and prescriptive maintenance service solutions offer a variety of advanced resources for organizations to reduce downtime. This maintenance approach educates in house teams on how system components contribute to production outcomes, and offers a more cost-effective resolution to stoppages through reduced lead time needed to repair equipment, utilizes on-hand spare parts, and schedules and performs preventive maintenance that maximizes equipment uptime.
Regardless of an organization’s needs, this type of maintenance can be customized to empower decision making that improves equipment performance, process continuity and budget predictability, and delivers a high return on business outcomes.
No matter where you are in your digital transformation, we offer a variety of proactive ways to keep your equipment and your production running smoothly. Discover how by contacting us here.
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