The internet of things (IoT) has provided manufacturers with a digital lean, which has resulted in higher automation and enhanced efficiency for them. While the Internet of Things (IoT technology) supports many areas in manufacturing, such as inventory management and monitoring production cycles, that help to improve efficiency, it is IoT-based predictive maintenance in manufacturing (also known as IoT predictive maintenance) that helps to save a significant amount of money in unexpected costs.
In contrast to reactive maintenance, the primary goal of predictive maintenance is to enable preemptive planning in order to avoid unexpected equipment breakdowns. For example, if you know when a specific machine needs to be serviced, it is easier to plan resources (such as personnel, spare parts, and other resources) for the maintenance work. The Internet of Things (IoT technology) contributes significantly to improving the accuracy of predictive maintenance.
Machine operating conditions are analyzed in real-time by the Internet of Things predictive maintenance systems, which anticipate when and how a machine may break down. It entails the use of sensors to gather data from equipment, as well as software to evaluate and provide reports based on the data acquired.
In this article, you will learn about the function that the Internet of Things (IoT) plays in predictive maintenance at a manufacturing facility. The advantages of IoT predictive maintenance manufacturing will also be discussed, as well as how to get the process started in your company.
What is meant by Internet of Things (IoT)?
IoT refers to a network of physical items (or “things”) that have been implanted with sensors, software, and other technologies for the purpose of connecting to and sharing data with other devices and systems across a network such as an internet.
What is an IoT system?
In computing, the internet of things, also known as IoT, is a networked system of interconnected computing devices such as mechanical and digital machines, objects, animals, and people that are all assigned unique identifiers (UIDs) and have the ability to transfer data over a network without the need for direct human or human-to-computer interaction.
All comprehensive Internet of Things systems, on the other hand, are the same in that they reflect the integration of four unique components: sensors/devices, connection, data processing, and a UI (Interface).
There are a number of high-quality gadgets available on the market. Smart mobile phones, digital refrigerators, smartwatches, smart fire alarms, smart door locks, smart bicycles, medical sensors, fitness trackers, smart security systems, and other IoT goods are just a few examples of IoT items available today.
Predictive maintenance meaning
It is a method that uses condition-monitoring instruments and procedures to continuously monitor the performance of a structure or piece of equipment while it is in operation.
Predictive maintenance ensures compliance with safety regulations, allows for proactive remedial measures and extends the life of assets. Taking a proactive approach and anticipating potential failures, pre-emptive investigations, maintenance schedule changes, and repairs may be carried out prior to the asset experiencing a breakdown or failing altogether.
IoT technology overview
|Components||Technologies and equipment that have been proposed||Features|
|Application||Java, XML, and JSON are programming languages used in application development.||Programming languages|
|Middleware||Request and response adapter protocol (RRAP), Fi-Ware||Responsible for dealing with issues such as registration services, service requests, and failures to provide services.|
|CommunicationsIEEE 802.15.4, Xbee, TCP / IP Architecture RFID, IEEE 802.15.4, Z_Wave, LTE, LoRa, NFC, UWB, M2M, 6loWPAN, NGN, WSN, Zigbee, Wavenis, Wireless Mbus, Wifi, Wmaz, PLC, GSM , GPRS, SCADA systems, IP networks, PSTN, XDLS, PAN, LAN, MAN, CDMA, WCDMA, CDMA, HSPA, Bluetooth, RF, Microwave, Infrared, among othersThey are low-energy consumers, are compatible with Arduino and other platforms, and are separated into two layers, one for physical access control and another for medium access control, respectively. Data transport is accomplished via the use of this protocol. Using wireless and wired networks as a foundation|
|Dispositive||Oracle Sun SPOT, MEMSIC Iris, Arduino UNO, RFID Readers, M2M Terminals, SCALA Meters, NFIC, QR Codes, BIDI Codes, People Mobile, Environmental Devices, Furniture, Buildings, Piping and Piping Systems, Weather Stations, Micro electro-mechanical Systems (MEMS) and nano electro-mechanical (NEMS)||Devices that are capable of participating in HTTP communications, mote modules with a variety of characteristics that increase the overall functioning of wireless sensor networks, and low-cost boards that are used for detection and actuation are all examples of what is available.|
What are the applications of Internet of Things?
- The human – devices that monitor and maintain health and wellbeing in humans; illness management, greater fitness, higher productivity are all possible with wearables and ingestibles.
- Home – Home controllers and security systems for the family home
- Retail environments – Retailers, banking, restaurants, theatres, and everywhere else where customers assess and purchase; self-checkout, in-store offers, and inventory optimization are all examples of retail environments.
- Offices – Improved energy management and security in office buildings, as well as increased productivity, particularly for mobile workers
- Efficiencies in factories – such as maximising equipment utilisation and inventory management, are important in places with repeated work patterns, such as hospitals and farmland.
- Workplaces – Coal miners, oil and gas, and construction – are concerned with operational efficiency, predictive maintenance, and employee health and safety.
- Vehicles – Vehicles such as automobiles, trucks, ships, aeroplanes, and trains; condition-based maintenance, usage-based design, and presales analytics are all examples of what is covered.
- Cities – Public spaces and infrastructure in urban environments; adaptive traffic control, smart metres, environmental monitoring, and resource management are all examples of what is covered.
- Real-time navigation on train lines, autonomous cars, and aircraft; real-time routing, networked navigation, and cargo tracking are all examples of real-time navigation.
Predictive maintenance in automotive industry
Vehicles nowadays are far more intelligent than they were only a few years ago. Cars have gotten safer, more autonomous, more data-driven as a result of modern technologies such as the Internet of Things, Big Data, Data Analytics, artificial intelligence, and cloud computing. Automobiles are capable of connecting to everything: they can readily communicate with their surroundings, which may include other cars and people, as well as electronics, infrastructure, the power system, and smart houses.
In light of all of this, standard auto maintenance is no longer sufficient for contemporary cars, which contain millions of lines of code and are fitted with a variety of sensors and other electronic equipment. As a result, automobile manufacturers are progressively shifting their focus away from preventative maintenance and toward predictive maintenance.
Preventive maintenance has a wide range of uses in the automobile sector, including:
- Oil changing on a regular basis
- Inspection of the transmission
- Change of belts
- Inspection of the brakes and tyres
- Replacement of the cooling fluid
- Engine air filter and cabin filter replacement, among other things.
Predictive maintenance use cases in food and beverage industry
While the food and beverage business does not pose a danger to the environment, it may have a negative influence on the health of those who work in the sector. Food and drink must be stored and protected in an atmosphere that is entirely regulated and stable in order to avoid the health hazards associated with them.
The food and beverage business must deal with a variety of maintenance difficulties, ranging from complicated equipment to stringent regulatory requirements.
Damaged equipment might result in serious health consequences down the track. Not only may it damage an organization’s image, but in the worst-case situation, equipment malfunctions can result in the deteriorating of meals, which may then be mixed with fresh items when they are distributed to customers and clients.
This is where the concept of predictive maintenance comes into play. It is very concerned about the influence that it will have on operational efficiency and functional performance.
It might be difficult to adhere to the most strict and severe food and beverage regulations. However, with adequate monitoring of essential equipment, the likelihood of anything unexpected occurring is greatly reduced. This is especially true when you combine predictive technology with computerised maintenance management software and preventive maintenance practices.
Predictive maintenance oil and gas
The oil and gas sector, which was one of the early adopters of predictive maintenance, has a primary focus on minimizing the cost of maintenance while also reducing the potential of environmental catastrophes.
One of the factors that make predictive maintenance so successful in this industry is the capacity that firms now have to monitor the state of their assets remotely, which decreases inspection costs while still providing them with enough data to avert severe equipment breakdowns.
This is owing to the fact that sensors may now be integrated into and mounted on machines. These sensors provide data to specifically created prediction algorithms, which may alert them to the possibility of a system breakdown in real-time.
Sensors and IoT
Sensors are a critical component of the Internet of Things’ success, but they are not the typical varieties that simply transform physical variables into electrical impulses as they are often thought. They have had to grow into something more complex in order to play a technically and commercially feasible role in the Internet of Things environment, and they have done so.
It will become clear that sensor intelligence, in addition to supporting the Internet of Things connection, also generates a slew of other advantages, like predictive maintenance, more flexible manufacturing, and increased production output.
Sensors must have the following characteristics in order to function as the Internet of Things components:
- Because of their low cost, they may be deployed in huge numbers at a reasonable cost.
- The ability to “disappear” unobtrusively into any surroundings due to its modest physical size
- Because a wired connection is often not feasible, wireless connections are used instead.
- Self-identification and self-validation are important component of social development.
- It consumes very little power, allowing it to operate for years without the need for a battery replacement or it may function with energy harvesting.
- Robust, in order to reduce or eliminate the need for maintenance.
- Self-diagnosis and self-healing are essential.
- A self-calibrating device that also receives calibration orders through a wireless connection
- Pre-processing of data in order to lessen the strain on gateways, PLCs, and cloud computing resources
IoT sensor data
As the Internet of Things (IoT) market continues to develop, so do the prospects for sensors to be used in many applications. In a variety of applications, sensors are used in tiny packages, multisensor modules, ultra-low power designs, and packages designed for severe environments, among other configurations. Sensors that are reliable and precise provide the groundwork for engineers to comprehend the unique qualities of a wide range of applications, from motor bearings to patients receiving home care.
Various physical phenomena such as heat and pressure, as well as the five human senses (sight, hearing, touch, taste, and smell), may be detected and measured using Internet of Things (IoT) sensors, which can be found in a broad variety of designs.
Temperature and humidity sensors, acceleration sensors, gyro sensors, and a variety of other sensors are examples of sensors that measure physical qualities.
A few examples of sensors that detect the five senses of the human body include thermometers, sound pressure sensors, odor sensors, imaging sensors, and a variety of other types of sensors.
Wireless sensors for IoT
In this sort of sensor, Bluetooth® is the most often used wireless connection technology, although there are additional solutions based on 3G, 4G, and LPWA network communications available.
When using a Bluetooth®-enabled sensor, which is the most generally available wireless type sensor, data may be sent to a central terminal on a regular basis, allowing for more efficient processing. Sensors with 3G, 4G, and LPWA connectivity provide data to the cloud, where it may be processed.
Many wireless type sensors are equipped with button or coin cell batteries, which enable them to continue to collect data as long as the battery continues to provide power to the sensor. With the wireless connection capability included in these sensors, it is possible to transfer the information gathered to other devices wirelessly.
What is the function of the Internet of Things (IoT) in predictive maintenance for manufacturing?
Machine data (such as operational temperature, power supply voltage, current, and vibration) is gathered by sensors and wirelessly sent to a cloud-based centralized data storage platform in real-time, a process known as predictive maintenance in the Internet of Things (IoT).
Data from the centralized data storage system is then collected and analyzed by maintenance teams, who use predictive analytics programs and machine learning (ML) algorithms to generate actionable insights.
Specific components make it possible to conduct IoT-based predictive maintenance. The following are the five fundamental components you’ll need to do IoT-based predictive maintenance operations:
Predictive maintenance Machine Learning based on the Internet of Things has five components.
Installing them at specified spots in assets allows them to acquire all of the machine data they need.
2. Data transmission and storage:
A system that permits data from sensors to be sent to a centralized data repository.
3. Data storage in a centralised location
A centralized data storage place where all of the machine data, as well as business data originating from other IT systems, is kept.
4. Predictive maintenance software
All data is sent to maintenance teams, who are notified when the machine runs outside of the user-defined range. Additionally, it aids in the generation of reports.
5. Predictive analysis (or forecasting):
Incorporates data analytics programs or machine learning-based algorithms that are applied to data in order to provide meaningful insights.
Predictive maintenance Benefits with IoT technology
Manufacturers that use the Internet of Things-based predictive maintenance get a variety of advantages from the technology included inside. Let’s have a look at the advantages and try to comprehend them a bit better.
Maintenance expenditures are being reduced:
Maintaining a machine is a must, but an unexpected equipment breakdown may throw a wrench in your maintenance budget. Predictive maintenance based on the Internet of Things (IoT) allows you to prepare appropriate inspection and maintenance procedures to minimize unforeseen downtime.
Asset durability has been improved:
Due to unanticipated equipment breakdown, unplanned downtime leads to decreased machine utilization, which in turn results in lower profitability. Predictive maintenance based on the Internet of Things enables for more efficient use of machinery by allowing for the prediction and prevention of machine faults.
Machines have a longer service life as a result of this.
Because IoT-based predictive maintenance enables you to monitor equipment in real-time, you can identify components that need immediate repair with pinpoint accuracy. You will be able to arrange maintenance and repairs ahead of time, so prolonging the life of your equipment.
Improved worker safety and compliance with regulations:
It is possible to monitor operating parameters (such as temperature, RPM, or voltage) and identify potentially hazardous preparations that may pose a danger to employees if left unresolved using IoT-based predictive maintenance.
Steps to Launch IoT-based Predictive Maintenance
The Internet of Things (IoT)-based predictive maintenance has shown to be effective in extending the life of assets, reducing asset downtime, and reducing the need for an unexpected repair. You also understand the components that will be required for the development of an Internet of Things-based predictive maintenance system.
To implement Internet of Things-based predictive maintenance in your manufacturing organisation, follow these steps:
Identify the assets that need preventive maintenance activities, such as:
Recognize that not every piece of equipment would need preventative maintenance services. Consider the financial effect that zero or low downtime of a certain machine or piece of equipment might have on your bottom line. This will assist you in identifying the assets that are most appropriate for Internet of Things-based predictive maintenance. You may also score the discovered assets based on the number of downtime issues they have had in the past and the amount of business loss they have caused. This will assist you in kicking off IoT-based predictive maintenance with the most essential assets as soon as possible.
Selecting the Proper Predictive Maintenance Software:
Searching for the most appropriate predictive maintenance software solutions may be a daunting task with hundreds of products available on the market today. Find an appropriate tool in our predictive maintenance and computerized maintenance management system (CMMS) markets. Also, read extensive user reviews of the software you are interested in to get a sense of what is excellent and what is not in those products before purchasing them.
How to improve productivity in manufacturing pdf? (Three ways to increase productivity by IoT Technology)
Technology advances with the passage of time, making the Internet of Things (IoT) devices less expensive and less complicated. Now, even small and medium-sized enterprises (SMBs) should be prepared to implement sensor-based real-time equipment monitoring.
Examples of important IoT advantages, such as improving product quality, maximizing equipment effectiveness, and allowing proactive maintenance, maybe discovered just as often in the implementation of a plan including linked assets as there are limitations and warnings against doing so.
Because of this, even while the majority of manufacturers see the need for an IoT strategy in manufacturing, many are hesitant to use the technology and lag behind more sophisticated rivals in the absence of a clearly defined roadmap.
Every IoT journey starts with a particular end goal in mind, and the metrics you’ll need to measure are drawn directly from the issue you’re trying to address. Three popular IoT use cases for manufacturers attempt to improve some of the most crucial manufacturing processes:
- The Cost of Poor Quality (CoPQ) is an important concept to understand and reduce. It represents the money that you would have earned if your manufacturing equipment was in excellent working order at all times.
- Increase the overall effectiveness of the equipment (OEE): Factors such as availability, performance, and quality are taken into consideration in order to assess how efficiently a manufacturer functions in comparison to its maximum potential.
- True Predictive Maintenance should be enabled: You may automatically send status data from your assets to your production and maintenance systems, alerting you when a problem is impending. Sensors are mounted to your equipment.
As suppliers and customers collaborate to develop proven use cases and integration best practices, the difficulty of integrating this technology has decreased dramatically in recent years. Sensors are inexpensive and can detect a broad variety of circumstances; they are all IP-based, so you don’t always need a gateway and can just position the sensor and link it to a cloud service, and they are easy to install.
Boosting Productivity at Work with the Internet of Things: A Four-Phase Roadmap
Keywords: How to increase work productivity, Boosting productivity in the workplace, Productivity boosting
Phase 1: Discovery
It is necessary to define your project in a variety of ways during this initial phase of the IoT roadmap in order to ensure that everyone involved knows the goal and can tackle difficulties from a complete viewpoint. Bring together your stakeholders and respond to the following questions:
- What is the exact difficulty or problem that you are trying to tackle using Internet of Things technology?
- What measures can you use to successfully monitor your progress toward achieving that goal?
- How many computers do you have to link together in order to get the information?
- Will you be using a wired or wireless connection to connect to the Internet?
- What sorts of sensors do you need in order to accurately assess the necessary conditions?
Smart Sensors in IoT Come in a Variety of Forms
1. An electric current sensor: In manufacturing, it measures the ‘current’ over time.
2. Detection of the presence of water sensor: Moisture and leaks in air conditioning systems or pipelines are detected.
3. Ultrasonic sensor: Identifies high-frequency sound in machinery and may be used to repair them.
4. Vibration sensor: Vibrations that occur outside of typical operating circumstances are detected.
5. Thermocouple temperature sensor: Internal temperature measurement or infrared temperature measurement
6. Pressure sensor: The pressure of liquid or air is recorded throughout time.
Phase 2: Setup and Configuration
At the end of this second stage, you will have created the network infrastructure, which will include the data structure (i.e., how the data will be structured as it is received) and any applications that will be required to meet the business case.
For example, you should design a dashboard that allows you to see the current status of your equipment at a glance, as well as alerts that notify maintenance technicians when sensors identify a problem.
Phase 3: Continuous Improvement
This is critical because it allows you to monitor progress over time and continually improve indicators that signal success for this specific project, such as higher quality or decreased downtime, as well as track and prevent errors.
Phase 4: Evaluation
Our objective and the prerequisites to get there were found in the first three stages of the IoT roadmap, and we put in place the connections and apps to collect data and create a strategy to measure progress in the subsequent phases.
The last phase requires manufacturers to analyze the outcomes of deploying data-driven solutions in order to understand their effect and make any necessary adjustments, all while keeping the primary goal in mind.
Thus this method contributes to the process of continuous improvement in the manufacturing sector.
There are no longer any reasons to delay implementing an IoT strategy in manufacturing. Smaller businesses can afford the IoT hardware and software, and the use cases and advantages are obvious. If you follow these steps, you will be on the road to success.