In the fast-paced world of manufacturing, the integration of production automation has become a transformative force, reshaping industries, and redefining the way businesses operate. One of the key areas where automation demonstrates its prowess is in enhancing reliability and maintenance processes. By leveraging advanced technologies, artificial intelligence, and smart systems, production automation is ushering in a new era of efficiency, cost-effectiveness, and minimized downtime.
Predictive Maintenance:
One of the most significant contributions of production automation to reliability is the advent of predictive maintenance. Traditionally, maintenance was often reactive, with equipment being repaired or replaced after a failure occurred. However, automation introduces predictive maintenance models that utilize data analytics, machine learning, AI, and sensors to forecast potential issues before they escalate into costly breakdowns and loss in production time.
Automated systems continuously monitor equipment performance, collecting real-time data on factors such as temperature, vibration, and wear. This data is then analyzed to predict when maintenance is needed, allowing for planned, proactive interventions. This not only reduces the frequency of unexpected breakdowns but also extends the lifespan of machinery and equipment.
Condition Monitoring:
Production automation facilitates comprehensive condition monitoring, enabling continuous surveillance of machinery health. Through sensors and IoT devices, the system can monitor various parameters and detect deviations from normal operating conditions. When anomalies are identified, automated alerts are triggered, prompting maintenance teams to investigate and address the issue promptly.
Condition monitoring, when integrated into an automated system, provides a real-time understanding of equipment health, allowing for timely adjustments and replacements. This proactive approach minimizes the risk of sudden failures, enhances overall reliability, and optimizes equipment performance.
Reduced Downtime:
Automation significantly reduces downtime associated with maintenance activities. With predictive maintenance and condition monitoring, maintenance tasks are scheduled during planned production pauses, preventing unexpected and lengthy disruptions. This strategic approach to maintenance ensures that machinery is in optimal condition when needed, maximizing production efficiency.
Additionally, automation streamlines the maintenance process itself. Automated robotic systems can perform routine maintenance tasks more quickly and accurately than their human counterparts, minimizing the time required for inspections, adjustments, and repairs. This results in increased overall equipment effectiveness (OEE) and improved reliability.
Data-Driven Decision-Making:
Production automation generates vast amounts of data, and the key lies in harnessing this information for informed decision-making. Through advanced analytics and machine learning algorithms, businesses can derive insights into equipment performance, failure patterns, and optimal maintenance schedules. These data-driven decisions lead to more effective maintenance strategies, reducing costs and improving overall reliability.
Types of Solutions available in the marketplace:
Condition Monitoring Sensors:
Vibration Sensors: Devices such as accelerometers and vibration sensors detect irregularities in machinery vibrations, aiding in identifying potential faults in rotating equipment.
Temperature Sensors: Monitoring temperature variations in machinery can indicate overheating issues or abnormalities in the operating conditions.
IoT Devices:
Smart Sensors and Actuators: Internet of Things (IoT) devices equipped with sensors and actuators provide real-time data on equipment conditions, creating a connected and monitored industrial environment via Ethernet or Ether CAT.
Predictive Analytics Software:
Leveraging predictive analytics, machine learning, and AI to forecast equipment failures and optimize maintenance schedules.
Machine Learning Platforms:
Using machine learning tools to analyze historical data and forecast potential equipment failures.
Asset Performance Management (APM) Solutions:
Incorporating data analytics with machine learning to predict equipment failures, optimize maintenance strategies, and improve overall asset performance.
Enterprise Asset Management (EAM) Systems:
EAM systems with predictive maintenance features for analyzing asset data, predicting failures, and scheduling proactive maintenance.
Remote Monitoring Services:
Cloud-based services that offer real-time monitoring and predictive analytics to improve asset reliability and performance.
Augmented Reality (AR) for Maintenance:
AR solutions that provide remote assistance and maintenance support, allowing technicians to visualize equipment data and instructions in real-time.
Check out Rockwell Automation’s software and hardware solutions for preventive maintenance and condition monitoring.
Businesses often adopt a combination of these products and services to create a comprehensive predictive maintenance strategy tailored to their specific needs and industry requirements. Integrating these technologies can lead to more efficient maintenance practices, reduced downtime, and increased overall asset reliability.
Conclusion: Revolutionizing Reliability and Maintenance through Production Automation
Production automation has ushered in a new era for reliability and maintenance in manufacturing. By embracing predictive maintenance, condition monitoring, and data-driven decision-making, businesses can optimize their operations, reduce downtime, and enhance overall reliability. As technology continues to evolve, the marriage of automation and maintenance will undoubtedly play a pivotal role in shaping the future of manufacturing, ensuring that industries remain competitive and resilient in the face of dynamic challenges.
Kristi Perkins, a dynamic professional wielding an MBA from Eastern Washington University. At the forefront of Rockwell Automation's triumph, Kristi specializes in revolutionizing the semiconductor industry. With a keen focus on empowering clients to elevate their production and automation prowess. Kristi is also a proud member of the International Society of Automation – Smart Manufacturing Group, amplifying her influence in cutting-edge advancements.
In August 2002 I spent a week in Japan at the chemical plant of an internationally renowned chemical manufacturer. While there I asked them about how they do their maintenance. They told me about their maintenance philosophy. And I want to pass on to you what I learnt about the Japanese way of doing maintenance on that trip.
In August 2002 I spent a week in Japan at the chemical plant of an internationally renowned chemical manufacturer. While there I asked them about how they do their maintenance. They told me about their maintenance philosophy. And I want to pass on to you what I learnt about the Japanese way of doing maintenance on that trip.
In my consulting and educating roles at Noria, I’m often asked what effective plant reliability management looks like. How does one recognize it when he or she sees it? While there are plenty of details, I’ve boiled it down to the following 12 dimensional elements.
In my consulting and educating roles at Noria, I’m often asked what effective plant reliability management looks like. How does one recognize it when he or she sees it? While there are plenty of details, I’ve boiled it down to the following 12 dimensional elements.
The cost of maintaining the status quo is enormous. The status quo affects each and every one of us every hour of every day, at work and at home. We have come to accept doing nothing as a safe and acceptable alternative. We even make it the default solution. Doing nothing is the management equivalent of a baby’s soother. It makes us feel safe and comfortable. But there is a cost to doing nothing.
The cost of maintaining the status quo is enormous. The status quo affects each and every one of us every hour of every day, at work and at home. We have come to accept doing nothing as a safe and acceptable alternative. We even make it the default solution. Doing nothing is the management equivalent of a baby’s soother. It makes us feel safe and comfortable. But there is a cost to doing nothing.
Results-oriented organizations focus first on the quality and volume of production throughput, followed closely by the cost to produce the required quality and volume. This approach will improve reliability performance, which will drive manufacturing costs down.
Results-oriented organizations focus first on the quality and volume of production throughput, followed closely by the cost to produce the required quality and volume. This approach will improve reliability performance, which will drive manufacturing costs down.
It never ceases to amaze me that no matter what industry you are in or how big or small of a company you work for, success is dependent on the ability to find, attract, hire, manage, develop and retain the right people. I continue to see companies disproportionately dedicate more focus and investment into non-people issues such as technology or equipment than focusing on getting “the right people on the bus.” I haven’t quite figured out why, but I believe it could boil down to one of three reasons:
It never ceases to amaze me that no matter what industry you are in or how big or small of a company you work for, success is dependent on the ability to find, attract, hire, manage, develop and retain the right people. I continue to see companies disproportionately dedicate more focus and investment into non-people issues such as technology or equipment than focusing on getting “the right people on the bus.” I haven’t quite figured out why, but I believe it could boil down to one of three reasons:
The concept of Best Practice is easy to describe and discuss – the more difficult part is determining your path towards reliability and maintenance Best Practice and more importantly, sustaining standards and developing a continuous improvement culture.
The concept of Best Practice is easy to describe and discuss – the more difficult part is determining your path towards reliability and maintenance Best Practice and more importantly, sustaining standards and developing a continuous improvement culture.
Christer Idhammar of IDCON INC presents the implementation steps you need to take if you want to be successful in improving reliability and maintenance, sustain that improvement, and continue to improve after that.
Christer Idhammar of IDCON INC presents the implementation steps you need to take if you want to be successful in improving reliability and maintenance, sustain that improvement, and continue to improve after that.
The current economic climate dictates that cost management is a critical activity for many companies and their managers. Maintenance is very often seen as an area where cost cutting targets can be easily and quickly achieved. Many maintenance managers take the view that this type of philosophy always ends up with increased costs in the future. This is not true in many cases. 15 years of analysis and review of maintenance programs by the author shows that most maintenance departments are more reactive than they should be and because of this, they over spend and underperform.
The current economic climate dictates that cost management is a critical activity for many companies and their managers. Maintenance is very often seen as an area where cost cutting targets can be easily and quickly achieved. Many maintenance managers take the view that this type of philosophy always ends up with increased costs in the future. This is not true in many cases. 15 years of analysis and review of maintenance programs by the author shows that most maintenance departments are more reactive than they should be and because of this, they over spend and underperform.
The work process we call maintenance planning can almost always be improved in any given mill or plant. In fact in most plants we visit maintenance planners don’t plan. Planners do all kinds of tasks except work order planning.
The work process we call maintenance planning can almost always be improved in any given mill or plant. In fact in most plants we visit maintenance planners don’t plan. Planners do all kinds of tasks except work order planning.
Maintenance practices and technologies have evolved to meet the needs of the changing industrial environment. The function has evolved from a community of reactive fixers, to dedicated craftsmen, to proactive professionals. The next generation of personnel could well be based on practitioners of Quality Management Systems (QMS).
Maintenance practices and technologies have evolved to meet the needs of the changing industrial environment. The function has evolved from a community of reactive fixers, to dedicated craftsmen, to proactive professionals. The next generation of personnel could well be based on practitioners of Quality Management Systems (QMS).
You can develop, document, and preach your improvement plans as much as you want, but if those plans do not result in better front line maintenance performance, you have just wasted money and time. Maintenance managers cannot produce expected results without the help of others, especially the frontline. Those organizations that have experimented with autonomous teams lacking front line leadership often fail to deliver sustainable results. If you believe this statement is wrong, I am very interested in hearing back from you.
You can develop, document, and preach your improvement plans as much as you want, but if those plans do not result in better front line maintenance performance, you have just wasted money and time. Maintenance managers cannot produce expected results without the help of others, especially the frontline. Those organizations that have experimented with autonomous teams lacking front line leadership often fail to deliver sustainable results. If you believe this statement is wrong, I am very interested in hearing back from you.
The goal of every lubrication program should be to ensure that all equipment receives and maintains the proper levels of lubrication such that no equipment fails due to inadequate or improper lubrication. In order for this to happen, we must follow the 5R's of lubrication - right lubricant, right condition, right location, right amount, right frequency.
The goal of every lubrication program should be to ensure that all equipment receives and maintains the proper levels of lubrication such that no equipment fails due to inadequate or improper lubrication. In order for this to happen, we must follow the 5R's of lubrication - right lubricant, right condition, right location, right amount, right frequency.
To compete in this adverse environment, companies switched mantras, from "do or die" to "do more with less or die." Every year, the bar of acceptable performance is raised. Employees are challenged to achieve these objectives with fewer resources. According to the U.S. Labor Department's Bureau of Labor Statistics, between 1981 and 1996, the total number of workers who lost jobs they held for three or more years because their plant or company closed or moved was nearly 18 million.
To compete in this adverse environment, companies switched mantras, from "do or die" to "do more with less or die." Every year, the bar of acceptable performance is raised. Employees are challenged to achieve these objectives with fewer resources. According to the U.S. Labor Department's Bureau of Labor Statistics, between 1981 and 1996, the total number of workers who lost jobs they held for three or more years because their plant or company closed or moved was nearly 18 million.
Information technologies (IT), in the context of this paper, include all computer systems and networks, plant automation systems such as distributed control systems and programmable logic controllers, design drawing databases, procedures databases, and diagnostic monitoring systems. The role of information technology is critical for maintenance optimization because it relies on the ability of the plant personnel to bring all data together in a coherent fashion for optimum analysis and decision-making.
Information technologies (IT), in the context of this paper, include all computer systems and networks, plant automation systems such as distributed control systems and programmable logic controllers, design drawing databases, procedures databases, and diagnostic monitoring systems. The role of information technology is critical for maintenance optimization because it relies on the ability of the plant personnel to bring all data together in a coherent fashion for optimum analysis and decision-making.
