Embracing IoT – At the Right Place and Right Time

Embracing IoT – At the Right Place and Right Time

Introduction

The current COVID-19 situation has made it obligatory for manufacturing industries to find new ways of operation and revenue streams. Machines that last long are not considered for the factor of getting obsolete and things are not planned considering the uncertainties. IoT can help these OEMs (Original Equipment Manufacturers) not only to improve their product quality but also will open new avenues to their businesses that were never available before.

Using Data to improve machine efficiency

The key obstacle in improving machine performance also commonly known as the OEE (Overall Equipment Effectiveness), is knowing its performance in history. The current practices of data logging lack the factor of real-time. These practices also involve risks like human error, latency, and manipulation of the data which cannot be avoided. If there is a system that provides real-time data with all the alerts and notifications, it becomes easier for the decision-makers to take quick and informed decisions about improving their machine performance.

Based on a real-life experience, one of our deeply experienced Industrialist says,

“The OEMs (Original Equipment Manufacturers) do not have data of their machines to analyze the frequency of the fault occurred, the upcoming oil change that is to be done, the idle time of the machine, and the machine operating time. Once there is an automated mechanism to address this problem, the OEMs (Original Equipment Manufacturers) can improve the quality of the product they are building. For example; If the data analytics gives alerts regarding improper vibrations, one can ascertain it could be due to improper torque on a bolt.”

A simple way to address this problem is to upgrade the existing system with an adequate feedback mechanism that provides real-time insights. This will improve the reliability of the machine and eventually upgrade the product quality. This always seems to be the “best deal” for any manufacturer which will be beneficial in the long run.

One-stop solution – Remote machine monitoring

Let’s say a machine has undergone a breakdown. Historically, it would require reckoning a service team, the travel time of the team, the time required to detect the fault and troubleshooting it and the time to get the machine operational again. The cost associated with this lost time is the main concern for any company. On the contrary, a remote Machine Monitoring Solution will provide real-time data that can be used to predict the future uncertainties and schedule the maintenance accordingly to avoid barriers in production and proactively initiating huge cost savings.

The management can detect any exceptions or abnormalities that are beyond the acceptable limits in the OEE (Overall Equipment Effectiveness), percentage of the machines so that they are serviced in time. Also, if a new person is recruited in the maintenance department the historical trend of the data will help the new person take less time understanding the patterns of the machine behavior.

Use of data in designing future machines

The data that is being analyzed can not only be used for predictive maintenance but also will be useful to design the machines to aid maximum production value and improved product quality. These modifications can be done with minimum infrastructure. This ensures the OEMs (Original Equipment Manufacturers) stay ahead of their competition.

Conclusion

Industry 4.0  not only is a disruptive technology that helps the user with data and knowledge but also it helps the user to have an edge over his competition and ensure customer satisfaction.