Digital twins, augmented reality and the Internet of Things are no longer science fiction terms. Each of these technologies is already changing business processes. Moreover, some of them are even becoming crucial for competitiveness. Learn more about what businesses should expect from the 4th Industrial Revolution and changes in equipment maintenance from Kyrylo Kostanetskyi, CableEAM Product Owner.
“Europe and the US are intimidated by China’s rapid development. They can’t compete with it in terms of human resources, so they’ve created Industry 4.0, which is about to reformat production. The minimum number of people will be producing the maximum amount of services and goods.
What I mean by Industry 4.0 technologies
The Industrial Internet of Things is the integration with equipment sensors and automatic transfer of information from them. This is what our company does.
Digital twins. Objects in the virtual world must duplicate their real prototypes by their key indicators. In this case, you need much fewer resources to compare them. We can show additional information by visualizing the data. Say, we can’t see how much the real machine has been working non-stop, but this becomes possible in the virtual world.
Using smart devices that quickly provide us with the necessary information. Such swift updates can guarantee additional safety in high-risk industrial facilities. For example, a smart bracelet may report that the concentration of gas in a mine has increased.
What SmartEAM offers in Industry 4.0
Businesses have changed their approach to equipment maintenance. Now we have to control such indicators as vibration, temperature, pressure, gaps, alignment, and the like. Thanks to this, we can predict when the equipment will run out of resources and when it should be stopped and serviced. With the indicators, we can predict failure weeks and even months in advance, order spare parts in time and not keep them in stock.
It is also essential to monitor the condition of the equipment by calculating its overall effectiveness (overall equipment effectiveness, or OEE), analysis of operating modes, control of operating time, and energy efficiency analysis. To fulfill these tasks, we use smart devices that are very easy to install and use.
Previously, planned maintenance (PM) was considered as the most effective one. According to this approach, equipment maintenance was carried out at regular intervals. Yet now there are very few companies that can afford such an approach, as it is expensive and far from being cost-effective.
PM was then replaced by new methodologies, such as risk-based maintenance (RBM). It suggests that we need to treat our equipment in different ways – depending on its importance for the production process – and weigh the consequences of its failure.
Another approach is reliability-centered maintenance (RCM), which first appeared in the aviation industry. We implement some of its elements for all our clients, and it gives positive results.”