IoT: The Key Benefits of Predictive Maintenance with IoT

Statista reports that in 2018, $646 billion was spent on IoT globally. In 2019, it rose to $686 billion. It was $749 billion in 2020; by 2023, $1100 billion is expected. This staggering amount of money is being used by almost all segments of the economy, including industries.

We also have the manufacturing industry that uses IoT and related technologies to improve their work environment. This and other benefits have prompted more than 80% of manufacturing units to adopt IoT-based systems in their manufacturing and processing plants.

Predictive maintenance is one of the main benefits of IoT for manufacturing. Manufacturing can increase their productivity, decrease downtime and reduce costs by using predictive maintenance. We will be discussing how IoT-based, predictive maintenance can benefit manufacturing units in the sections that follow.

What’s Predictive Maintenance?

Predictive maintenance refers to a technique or system that uses data, special tools, and firmware to detect anomalies in machines or systems. We can fix faults that have yet to be discovered and avoid major obstacles.

This system uses sensors and actuators to continuously monitor the machine’s performance. It monitors the machine’s capabilities and refers to the threshold limit before it stops working or breaks down abruptly.

This information is sent to a computer interface and the managers and supervisors are notified about the anomaly. They can then initiate the corrective action. This reduces the downtime and ensures product quality and productivity doesn’t suffer.

IoT predictive maintenance uses condition monitoring to continuously evaluate the equipment’s performance. With the help of actuators and sensors, the IoT technology continuously records data about the equipment’s performance.

The computer firmware will suggest the timeframe and send warnings to start predictive maintenance.

Benefits of IoT Predictive Maintenance

Modern asset management is easier thanks to data analytics and other technologies such as IoT, Machine Learning, and others. They allow managers to move from manual and visible inspection to an automated monitoring platform. The latter makes decision-making easier and more efficient.

We are seeing a maturer predictive maintenance system with the advancement of technology. The industries are moving towards the predictive maintenance 4.0 era, which is consistent with the Industrial Revolution 4.0.

• Management and Cost Reduction

There are two types of costs associated with every asset within an organization. One is the purchasing cost and the second is the operational cost. The second cost is the regular one. An unexpected failure can result in sudden expenses.

Companies can avoid sudden equipment failure costs by using a predictive maintenance program. This system is very useful in a manufacturing plant where many machines work day and night to produce the same product.

IoT systems can accurately predict an asset’s health and workability by taking into account its past performance, health, and potential for failure. This information can be used to schedule maintenance and inspections. Predictive maintenance can reduce costs by as much as 12%

• Time-Saving

Predicting asset failures can help you save time and money. Knowing the asset’s health beforehand can save time and prevent unplanned maintenance.

We can therefore correct potential problems before they occur during routine breaks or holidays.

• Higher Productivity

To increase productivity, it is possible to forecast the machine’s and assets’ ability to perform and function. This is due to the fact we can start a timely maintenance program.

As long as the assets are maintained and issues are prevented from manifesting, productivity will not decrease. The same process can be used with all assets connected to the IoT network. This will allow for productivity to continue increasing over time.

• Higher Customer Satisfaction

Customer satisfaction is a primary goal for any organization. Companies can achieve this goal through predictive maintenance. This involves setting realistic expectations and ensuring product quality.

Predictive maintenance ensures that assets, equipment, machines, and other machinery will always work well. This allows you to deliver the services promised.

• Increases Asset Utilization

IoT allows for predictive maintenance that helps to maintain assets and machines. This can increase asset utilization if they are well maintained and there aren’t any sudden issues that could cause a breakdown.

IoT Predictive Maintenance can help identify the root cause of a failure. This will solve the problem at the root and ensure that your machine or asset performs at its best.

• Assets last longer

We monitor, maintain, and correct assets in a timely manner to ensure they give their best performance. Effective action is possible when a supervisor or manager can monitor the performance in real-time and predict potential breakdowns.

This is in addition, to the fact the broken or underperforming parts can be replaced without affecting other parts of an asset.

• Better Safety and Compliance

To ensure that employees are safe at work, every organization must be governed by law. This is particularly important in manufacturing industries, where workers are often working on large machines.

Predictive maintenance provides advance notice for any anomalies so that corrective actions can take place before an incident occurs. Any potential errors that could impact the workplace environment can be identified by sensors and data.

• Reducing Downtime and Tackle Unplanned downtime

Predictive maintenance and IoT represent key performance-enhancing technology for the assets and machines in an organization. Predictive analytics is useful for identifying potential problems, as some assets are available 24 hours a day.

Supervisors and managers are able to initiate corrective actions promptly. This results in a reduction of planned and unplanned downtime.

These are just a few of the many benefits IoT-enabled maintenance and predictive analytics can bring to organizations. They will experience increased productivity, lower costs, and better customer service.

Integration of IoT into Predictive Maintenance

Multi-technology and system integration is what allow us to accurately predict problems with machinery and assets. The Internet of Things, one of the most important technologies, allows companies to identify all issues and take necessary actions.

Many technologies, systems, and equipment can be used within the IoT network to create a predictive maintenance program. These include:

• Data communications: As sensors gather data and actuators translate that data, it is transmitted to central storage with the necessary data communication tools. An organization can either set up an internal storage system or use a public cloud storage system.
• Sensors: Sensors are available in many sizes and shapes. They can be used to collect data. They are placed at certain locations, points, and positions within assets.
• Predictive maintenance software: These are the software that analyses the data. It is responsible for generating reports from the data provided. It can notify users about machine usage, including warning them if the asset exceeds the limits set by the user.
• Data Storage: This can be either cloud storage or a server where all data is stored for further analysis. These data can be extracted by predictive analytics systems for interpretation and conversion into readable information.
• Predictive Analytics: Powered by machine learning and predictive analytics systems, predictive analysis systems allow for actionable insights once the data has been understood.

Conclusion

IoT, predictive analytics, and maintenance systems are transforming organizations’ work practices. They provide the efficiency and accuracy that businesses require to achieve the highest performance in all areas. Predictive maintenance is a tool that can be used by manufacturers to increase their productivity using existing assets and workers.