Freddie Coertze wants to make a distinction between predictive maintenance and condition monitoring.
“If I were to summarise the key differences, it would be to say that condition monitoring is a reactive approach to maintenance management that focuses on identifying problems as they occur. Predictive maintenance is a proactive approach that uses data analysis to predict when maintenance will be needed,” says the National IoT Business Manager for ifm Australia. “Both approaches can be valuable, but predictive maintenance is defined by the word ‘predict’. It has the potential to provide greater benefits by reducing downtime and minimising maintenance costs.”
According to Coertze, three components can ensure the success of a predictive maintenance program. It includes an Internet of Things (IoT) platform, condition-monitoring hardware and predictive formulas provided by artificial intelligence.
“Importantly, to have visibility of assets, you need the connectivity and integration that digitalisation provides,” Coertze remarks. “To help our customers simplify this integration, ifm created moneo – a self-service software platform that acts as a middleware to existing systems such as SCADA.”
The moneo solution has an inbuilt DataScience Toolbox that enables operators and engineers to leverage their knowledge of equipment with the benefits of AI-assisted predictive analytics and machine learning.
“Successful predictive maintenance is about detecting anomalies to machine performance early and automating the actions surrounding that deviation. It means that notifications are sent, and actions are prescribed to fix the issue,” explains Coertze. “It’s having full integration from the shop floor to the top floor.”
Why predictive maintenance and condition monitoring need the right data
Coertze says that while condition monitoring is widely used, there is a disconnect between the data collected by sensors and the workflow.
“Many industrial businesses still rely on manual processes in terms of how their sensor data is analysed, and maintenance is performed. Many businesses still use a preventative or scheduled maintenance approach – they might consider vibration on componentry. Still, it won’t give them the insight or ability to solve real equipment issues in advance,” he explains. “I believe that this type of condition monitoring provides information too late to make a significant difference.”
The moneo solution supports successful predictive maintenance by providing the platform, the sensor hardware, and the software that supports AI-assisted predictive formulas.
“We would first connect the sensors to the equipment to explain how it works. Then we would collect data from the sensors. The moneo software will identify baselines and set parameters and limits for how the assets should perform,” he says. “If the system detects an anomaly, a ticket will be sent to staff to investigate with a prescribed action to check and rectify the problem. This same predictive maintenance workflow is applied to everything within the operation or plant.”
Many benefits come with implementing successful predictive maintenance. They include better longevity of equipment, improved onsite productivity, and improved efficiency, particularly in energy use. As Coertze concludes, predictive maintenance will do more than prevent downtime. It will help keep equipment running optimally at all times.
“Condition monitoring with vibration analysis is simply not enough. When vibration starts, it’s often too late to intervene and save the machine. To protect your assets, you need to predict. That’s why having a predictive maintenance program is important, and moneo can ensure this program is implemented successfully.”
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