Predictive Maintenance as a Service: A game-changer for Manufacturing

Manufacturing encompasses a diverse and wide array of processes, industries, and raw materials. Yet all manufacturers everywhere share a common enemy: Unplanned Downtime, which harms productivity, asset health, brand reputation & dotted line.

Every year, top fortune 500 manufacturing enterprises lose almost 1 trillion to unplanned downtime, nearly 8% of their annual revenue. Here is how the introduction of Predictive Maintenance as a Service can be a gamechanger in the world of manufacturing & asset maintenance to curb unplanned downtime.

But to understand why Predictive Maintenance as a service is so revolutionary, let’s understand how asset maintenance was performed until a few years ago:

What are the types of Asset Maintenance practices in Manufacturing?

Reactive Maintenance: Reactive Maintenance means letting your machines run unchecked till they fail. Maintenance here is post-failure, as a reactive approach after the anomaly. While it saves you unnecessary downtime & maintenance costs for parts that don’t require servicing, it also means you risk machine failure anytime by being blind about your machine health.

Planned Maintenance or Preventive Maintenance: After the reactive maintenance approach resulted in constant fire-fighting for the plant manager, maintenance became a time-based activity, i.e., annual, bi-annual, based on their own and peer’s experiences. But often, it was noted that a planned downtime, although revealing nothing wrong with the asset, would still result in loss of productivity & profits. And sometimes, the machines would fail even before the planned period, so the problem persisted.

With the failure of both of these approaches to curb machine failure and thereby unplanned downtime in time, the industry looked forward to solutions like IoT & AI to power up maintenance with real-time insights. And that is what predictive maintenance as a service is all about.

Predictive Maintenance as a Service: Predictive Maintenance (PdM) relies on real-time monitoring of machine health using smart technologies like edge-computing, IIoT, data science, and analytics. Once an anomaly (w.r.t vibration, temperature, or acoustics) is detected, it is flagged off to the relevant plant supervisor for the next immediate action. A maintenance activity can thus be scheduled if something goes wrong while the maintenance expert can also decode the exact ‘something’. PdM enables the maintenance teams with necessary controls to extend equipment lifecycle, optimize the cost of maintenance, maximize machine uptime and amplify factory performance.

What Industries can Predictive Maintenance as a Service make the most impact on?

While any manufacturing plant- whether discrete or process-based can deliver a clear impact with Predictive Maintenance as a Service measures, the process-based manufacturing plants can truly thrive because of their unique workflow of interconnected processes.

Since the output of the process manufacturing plant depends on the previous steps completed in tandem, the stoppage of even a single machine can halt the entire production process. This is where predictive maintenance as a service can help by ensuring that the machine health issues are taken care of before they become serious.

With real-time insights from interconnected assets being monitored and analysed instantly, predictive maintenance as a service provides massive power to the manufacturers without any drawbacks of a conventional maintenance solution. And that is when the true digital transformation will happen when data and insights combine to provide value.

Infinite Uptime offers responsively designed machine diagnostics, remote condition monitoring, and predictive maintenance solutions in diverse industries such as Cement, Steel, Mining and Metals, Tire, Paper, Automotive, Chemicals, FMCG, Oil and Gas, and more. To understand how predictive maintenance applies to your process plant and can help in achieving plant reliability, explore the comprehensive solutions of Infinite Uptime.

To Know more about Predictive Maintenance as a Service: https://www.infinite-uptime.com/predictive-maintenance-as-a-service-a-game-changer-for-manufacturing/