How Isabelle transforms her maintenance process with predictive maintenance ?

If you are a maintenance manager, like Isabelle, you surely dream of implementing predictive maintenance for your critical equipment. Right now, your work is endless because it’s hard for you to know when a breakdown will occur and where it will occur. A sinking engine, an out-of-control boiler that breaks down or a crank that jams despite long days spent on inspection tours or overseeing repairs can frustrate many of you.

Industrial Object Internet systems offer the possibility to integrate new models of machine condition monitoring. They are great tools for reducing the risk of downtime and the duration of downtime. There is a wide variety of sensors used to monitor the health of machines in real time: temperature, vibration, amperage, etc.. Choosing the right device to meet performance and cost constraints requires an understanding of how new technologies are integrated into the Industry 4.0 as a whole. So here are seven good questions to ask yourself to take your first steps in the Internet of Industrial Objects and especially in the continuous predictive maintenance of your equipment. You will then see how Isabelle has integrated this exercise into a continuous improvement 4.0 project.

The 7 good questions to ask you !

Before you start setting up an Internet-based system of Objects for Predictive Maintenance, here are the right questions to ask yourself to choose the sensors for data collection and the system to analyze the data and provide you with quick feedback on the actions to take (before a break!) :

    Performance: What is the range of metrics required? A data to the second? A data to the hour ?

    Isabelle is maintenance manager for an injection molding SME located in Lévis, near Quebec City. Currently, her team of maintenance guys periodically inspects the equipment in accordance with the work order requests generated by the CMMS (Computerized Maintenance Management System). Isabelle has asked the IT department to develop a condition-based maintenance system in-house. However, the IT department is overwhelmed by other projects. Having decided to present a 4.0 improvement project to her plant manager, let’s see how Isabelle is preparing to build her condition monitoring system.

    1. Assets: Which equipment to monitor and how to use the data ?

    Isabelle knows that the best way to sell a project to its plant manager is to propose a pilot project of the quick win type with a good ROI (return on investment). She therefore targets equipment which is both essential to operations, which currently has a low level of visibility for operators but which is very expensive in terms of production loss and non-quality if this equipment stops in emergency.

    Moulding press

    So Isabelle chooses to start with 2 water tanks and 2 gas tanks. Ensuring that the fluid in the water tanks is at the right temperature is vital for the cooling stage of the mould making process. The gas tanks store nitrogen gas, which plays an essential role as a propellant during the injection moulding process.

    Isabelle wants her team members to receive SMS alerts when the temperature and temperature values are too low.