[go: up one dir, main page]

0% found this document useful (0 votes)
121 views12 pages

Power of Predictive Maintenance

This white paper discusses how predictive maintenance using online monitoring and AI can help manufacturers minimize downtime and lower costs. Four use cases are provided: 1) Electric motor condition monitoring using current sensors to detect worn components and eliminate unplanned downtime for a beverage company. 2) Recirculating pump condition monitoring using vibration sensors to remotely monitor pump health and schedule maintenance for a semiconductor manufacturer without disrupting production. 3) Hydraulic system condition monitoring to detect abnormalities before failures for an automotive manufacturer. 4) Power supply monitoring using onboard sensors to predict failures and reduce maintenance costs for an electronics manufacturer.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
121 views12 pages

Power of Predictive Maintenance

This white paper discusses how predictive maintenance using online monitoring and AI can help manufacturers minimize downtime and lower costs. Four use cases are provided: 1) Electric motor condition monitoring using current sensors to detect worn components and eliminate unplanned downtime for a beverage company. 2) Recirculating pump condition monitoring using vibration sensors to remotely monitor pump health and schedule maintenance for a semiconductor manufacturer without disrupting production. 3) Hydraulic system condition monitoring to detect abnormalities before failures for an automotive manufacturer. 4) Power supply monitoring using onboard sensors to predict failures and reduce maintenance costs for an electronics manufacturer.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 12

The power

What’s driving
of predictive
automotive
traceability today?
maintenance
Four use cases
An expert guidedemonstrate how real-
to the underpinnings
time insightschanging
of a rapidly into legacyindustry
assets minimize
downtime and lower costs

White paper | October 2020


August 2018
omron247.com
automation.omron.com
The power of predictive maintenance

Introduction

Unplanned machine downtime is a huge headache for the business sector. In 2016, the Aberdeen Group found
that these events cost companies an average of $260,000 per hour – a 60% increase over its 2014 survey. While
Aberdeen hasn’t published any further updates, it seems likely that ongoing problems – including pain points
like aging infrastructure, skilled worker shortage, and recent societal disruptions – are continuing to drive up
operational costs by reducing equipment availability.
In manufacturing, plant operators are tackling unplanned machine downtime by migrating from preventive
maintenance to predictive maintenance. Unlike preventive maintenance, which is performed according to
a schedule that reflects historical events, predictive maintenance monitors asset condition in real time and
prompts interventions before failures disrupt production. Advances in sensors, analytics, and communication
technologies are making predictive maintenance increasingly practical and affordable for small, medium, and
large manufacturing companies.
This white paper discusses the ways in which a solid predictive maintenance strategy backed by state-of-the-
art technologies can help manufacturers stay ahead of equipment problems and minimize downtime. Four use
cases are provided to help guide decision makers and define work efforts and budgets.

2
Contents

Using online monitoring and artificial intelligence to


optimize efficiency.........................................................................4

Developing a plan that delivers significant results in


less time................................................................................................5

Use case 1: Electric motor condition monitoring........6

Use case 2: Recirculating pump condition


monitoring..........................................................................................7

Use case 3: Hydraulic system condition


monitoring..........................................................................................8

Use case 4: Power supply with onboard


monitoring..........................................................................................9

Summary...........................................................................................10
The power of predictive maintenance

Using online monitoring and artificial intelligence to


optimize efficiency
While predictive maintenance may seem unfamiliar,
the strategy actually employs well-understood
methodologies to replicate the analyses of skilled
maintenance engineers. Once these analyses are Preventive
entered into an algorithm, predictive maintenance
solutions use artificial intelligence (AI) software to
maintenance vs.
monitor assets and generate alerts when unusual predictive maintenance
conditions, such as abnormal vibrations or high
temperatures, are detected.
Manufacturers that employ traditional
Adding sensors to key assets and accumulating
data on how they perform provide both immediate
preventive maintenance strategies
and long-term benefits. Plant operators are able often finding themselves either
to eliminate time-consuming maintenance and missing key signs of failure that
inspection activities, minimize quality defects, occur in between inspections or
and strengthen safety and security measures. prematurely replacing equipment to
Ultimately, any insights derived from the data will avoid these potential failures. These
allow manufacturers to correlate machine behavior
issues are two sides of the same coin,
with events on the factory floor. This analysis helps
which is the lack of 24/7 monitoring
companies maximize efficiency in an increasingly
competitive marketplace. of critical equipment.
By migrating to a predictive
maintenance strategy, manufacturers
can rest assured that their equipment
is being monitored around the clock
and that real-time data analysis will
reveal any potential issues well in
advance of an actual failure. This
minimizes downtime while also
dramatically cutting costs overall.

4
Developing a plan that delivers significant results in
less time
If there is an obstacle to implementing predictive Retrofit programs typically begin with prioritizing
maintenance, it is equipment connectivity. As a the installed base. Prioritization enables
recent survey notes, up to 92% of legacy machines manufacturers to focus initially on the assets that
are not designed for connectivity. require the most frequent maintenance and have
the biggest impact on production output. After
Manufacturers are understandably reluctant to
critical assets are identified, implementing the
abandon these investments, which is why they
predictive maintenance solution is straightforward.
are turning to retrofitted solutions as a way to
Key steps include replicating engineer knowledge
modernize while keeping costs affordable. Industry
for the targeted asset, establish a baseline of
providers have already brought several technology
acceptable conditions, retrofitting one or more
solutions to market for upgrading legacy assets with
sensors to the asset, and setting warning and
little or no equipment modification.
alarm thresholds.

Equipment monitoring Abnormality Alarm On-site maintenance


Digitization Remote Monitoring Maintain as necessary

5
The power of predictive maintenance

Use case 1: Electric motor condition monitoring

Worn components is a leading cause of three- analysis in real time, detect abnormalities, and
phase electric motor failure. Omron recently analyze the failure mode. With this insight, the
helped a beverage company find an effective company has been able to eliminate time-
solution for reducing these failure events. Prior consuming inspections and rely on alerts that
to the solution’s implementation, the company signaled a service requirement. The transition to
manually inspected its bottling line motors at three- a predictive maintenance solution has proven to
and six-month intervals and overhauled motors reduce costs and streamline maintenance work
once a year. With this preventive maintenance while also improving product quality by detecting
strategy, workers replaced parts frequently, but this rubber gasket failures before foreign matter can
approach was expensive and failed to eliminate contaminate products. The company is planning to
unplanned downtime. deploy the solution to other facilities and change
some existing maintenance practices.
Retrofitting the motor with a current transformer
allowed a monitoring AI to run a distortion

6
Use case 2: Recirculating pump condition monitoring

Industrial recirculating pumps run almost continuously. One semiconductor manufacturer used manual
inspections to check a motor in its water treatment plant, but conducting accurate inspections was difficult
without shutting down the pump. Scheduling maintenance was always challenging because of ongoing
production needs. This meant that service might be performed too early (wasting time and materials) or too late
(after an unexpected failure impacted production).

Retrofitting the recirculating pump with a vibration sensor allowed the monitoring AI to measure high-frequency
vibrations, detect abnormalities, and analyze the failure mode. Alerts permit maintenance engineers to monitor
pump health remotely, judge the potential impact of abnormalities, and solve problems without being onsite.
This use case shows how a predictive maintenance solution can streamline maintenance work while also
supporting semiconductor production by preventing unplanned downtime.

Omron’s advanced predictive maintenance products


Omron makes it easy for manufacturers to keep tabs on their equipment 24/7 with
high-performing technologies.

S8VK-X K6CM K6PM


Power supply Motor condition monitor Thermal condition monitor
The S8VK-X keeps track of DC The K6CM monitors vibration, The K6PM remotely tracks the
output voltage, current, peak temperature and current and temperature of high-voltage
current and runtime on a remote insulation resistance monitoring control panels and other
basis to quickly identify any to predict motor failures equipment to eliminate manual
DC circuit abnormalities and and eliminate the need for inspections and ensure a faster
maximize longevity. manual inspections. response to overheating.

7
The power of predictive maintenance

Use case 3: Hydraulic system condition monitoring

Hydraulic valves are essential to the normal valve temperature, detect abnormalities, and analyze
operation of many industrial machines, and the failure mode. Increases in surface temperature
temperature increases often suggest debris generate automatic alerts that allow maintenance
contamination in the hydraulic fluid flowing through staff to take immediate action if necessary. This
the valves. When a leading auto manufacturer was predictive maintenance solution reduced overall
relying on manual thermal inspections to monitor maintenance needs and improved machine
the condition of valves on its body panel hydraulic availability. Furthermore, since the company no
presses, unplanned downtime lasting days or longer needed to move production to other
weeks sometimes occurred. This was due to the hydraulic presses, efficiency also improved and costs
fact that maintenance engineers were unable to like overtime pay went down.
continuously monitor valve temperature.

Retrofitting presses with thermal image sensors


allows the monitoring AI to continuously measure

8
Use case 4: Power supply with onboard monitoring

Large production environments often house floor. With temperature, voltage, and power sensors,
hundreds of control panels. Temperature increases each power supply is able to calculate its own
in control panel power supply often indicates that remaining service and send a real-time health-
these components are degrading. Maintenance grade to a built-in display. Onboard networking
engineers for one automotive manufacturer also supports remotely monitoring multiple power
were using digital voltmeters to check power supplies from a central location. Using intelligent
supplies for out-of-spec conditions. These manual devices as part of a predictive maintenance
inspections were time-consuming and imprecise solution provides a framework for building an IoT
since components sometimes degraded between environment. It allows intensive monitoring without
inspections. To limit downtime, these workers relied hands-on inspections, improving efficiency and
on preventive schedules to replace power supplies equipment availability while lowering costs.
regardless of device health.

Retrofitting control panels with intelligent power


supplies has brought AI functionality to the factory

9
The power of predictive maintenance

Summary

The benefits of preventive maintenance only go Throughout the automotive, semiconductor,


so far. At some point, manufacturers are bound to commodities and other manufacturing
start missing signs of equipment degradation or industries, predictive maintenance solutions
driving costs up by replacing perfectly functional can streamline maintenance work while also
equipment on a “just in case” basis. A round-the- supporting production.
clock monitoring strategy is the only way to truly
keep track of equipment and minimize downtime.

10
References
1. Arsenault, Ryan for Aberdeen. (2016). “Stat of the Week: The (Rising!) Cost of Downtime”. Retrieved Friday, October 2, 2020 from
https://www.aberdeen.com/techpro-essentials/stat-of-the-week-the-rising-cost-of-downtime/.
2. Blyler, John. (2018). “Microservices Connect Legacy Assets to the IIoT”. Retrieved October 2, 2020 from https://www.insight.tech/
industry/microservices-connect-legacy-assets-to-the-iiot.

11
Omron Automation | 800.556.6766 | automation.omron.com

U129I-E-01 © 2020 Omron. All Rights Reserved. Sensing | Control | Safety | Vision | Motion | Robotics

You might also like