Maintenance is a vital part of every industry. Therefore architects and engineers are constantly finding ways to make it a cost-effective and efficient process. Proper maintenance not only impacts corporate profitability but also improves the life of machines.
During the early days, maintenance used to be reactive to breakdown, which means we perform maintenance only after the occurrence of failures. But today, maintenance is more predictive, thanks to the availability of advanced IoT sensors and predictive maintenance tools!
What is IoT-based Predictive Maintenance?
In simple terms, IoT-based predictive maintenance involves maintaining a system by identifying a fault before it happens. Many industries use this technique to save costs and avoid the sudden breakdown of machines.
IoT predictive maintenance mainly has five major components;
Sensors:- Installing different types of sensors on the machines to monitor their real-time performance.
Data Communication:- A system continuously transmits data from sensors to the centralised data hub.
Centralized Data Storage:- It is usually cloud storage where all the data from different IT systems, including the sensors, are stored.
Predictive Maintenance Software:- The software streams all data to maintenance teams and triggers alerts even when a small percentage of data falls outside standard ranges.
Predictive Analysis:- Generates actionable insights from data by applying predefined machine language algorithms. By analyzing the results, the system can predict when the machine needs maintenance, how long the machine can run without maintenance, etc.
Preventive And Predictive Maintenance using IoT - Understanding the Differences
Even though IoT preventive and predictive maintenance are two sides of a coin, they aren't the same! However, preventive and predictive maintenance have a few differences and similarities.
IoT preventive maintenance is a maintenance process performed by industries regularly to prevent the failure of a machine or equipment. A well-designed preventive maintenance schedule helps industries avoid equipment failure and machine downtime and increases asset lifespan. Preventive maintenance can be performed weekly, monthly, or yearly with the help of IoT devices.
IoT-based predictive maintenance technique tracks the performance of machines in real-time, detects faults and allows you to fix them before the machine breaks down. This method aims to detect possible defects early to avoid more maintenance activities. IoT predictive maintenance is performed on machines only when it is required. It helps you reduce the costs of spare parts and supplies and improve workspace safety.
Implementing IoT-based Predictive Maintenance: Step-by-step Guide
Follow these simple steps to implement IoT predictive maintenance in your industry.
Identification of Assets
If you still need to learn, all machines in your industry don't require IoT predictive maintenance. So initially, you must identify the impact of minimal downtime of a particular machine in your industry. If there's a significant amount of business loss due to the downtime of a machine, it requires predictive maintenance. Similarly, you can do the same with all machines and identify the critical assets which require predictive maintenance.
Choosing the Right Software
Since thousands of IoT-based predictive maintenance software and sensors are available, choosing the right one takes work. Moreover, the type of sensors depends on various factors like budget, type of machines, etc. It would help if you also considered the pricing, time to set up, security, etc., while choosing the service provider.
Talk with Service Provider
It is always advised to schedule a call with the service provider before choosing their solutions. Then, you can discuss the budget and see whether the features offered by the service provider meet your business needs. A good IoT-based predictive maintenance software provider recommends the best systems for you.