Applications of IOT in

Maintenance

Subbmitted by: Priyal Kaka

Tejaswini Kavya
Nisha Hemnani
What is maintenance management ?
• The goal of maintenance
management is to control the
resources, time and costs of a
company to ensure the efficiency
and adequacy of the maintenance
operations and to avoid waste of
resources or periods of downtime
due to faulty equipment.
What is Internet of Things (IOT)?
• The Internet of Things (IoT) is
a system of interrelated
computing devices,
mechanical and digital
machines, objects, animals or
people that are provided with
unique identifiers and the
ability to transfer data over a
network without requiring
human-to-human or human-
to-computer interaction.
IOT in maintenance management
• For maintenance implications, the IoT uses sensors and connected devices
across the industry to easily track key performance indicators (KPIs) and
control machines access to accurate, real-time data to make the smartest
maintenance decisions.
• The IoT has the power to completely transform the industry through
proactive maintenance strategies. For instance, with the help of IoT sensors
and data gathering, maintenance managers are able to better predict when
a breakdown will occur based on historic records and past service requests.
• A more proactive maintenance strategy means less equipment downtime,
fewer emergency work order requests and better budget planning.
Predictive maintenance management
strategies
Oil and gas companies
Oil & gas companies particularly benefit from applying predictive maintenance
solutions. Physical inspection of oil & gas production equipment requires
personnel to go into hazardous environment to examine the equipment, which
in some cases is not feasible. IoT-based predictive maintenance allows oil & gas
companies to identify potential failures and increase the production of highly
critical assets.
Railways
Railway companies apply IoT-based predictive maintenance to ensure
the rails and the rolling stock are in proper condition. For
example, BNSF railway deployed force detectors, vision cameras,
infrared and acoustic sensors to identify defects in freight-car braking
capabilities, excessive friction in wheels and bearings, rail curves and
straightaways damages. Data gathered by sensors is relayed to the
cloud for analysis and run through ML algorithms to reveal unhealthy
data patterns that lead to breakages. The solution helps to improve
safety, reliability and velocity of the rolling stock, as well as reduce train
delays caused by equipment malfunctions.
Discrete manufacturing

Major discrete manufacturers are using predictive maintenance based

on IoT to monitor, for example, the health of spindles in milling
machines. They are prone to breaking, while their repair is expensive.
An IoT-based predictive maintenance solution can help to predict
potential damage by collecting data from ultrasonic and vibration
sensors attached to the spindle. Analyzing the collected data helps to
identify fragile spindles before they break.
Equipment Maintenance
Critical Machine Operating data like RPM, Vibrations, Operating hours,
temperature can be synced to cloud data in real time. This can trigger
conditional Maintenance as well as preventive maintenance for
machines.
Process manufacturing
• In process manufacturing, pulp processing and paper manufacturing
companies leverage IoT to monitor the state of paper-making
machines. Scheduling maintenance for a press roll based on a cover
failure prediction
• Steel plants have multiple furnaces that use water cooling panels to
control temperature. Leakages in the panels may cause safety issues
and production losses. An IoT-based predictive maintenance solution
can help detect anomalies and carry out a root cause analysis,
preventing production delays and equipment failures.
In garment industry
• The garment manufacturing industry requires several heavy duty
machines as part of their production processes. Maintaining these and
ensuring that each piece of equipment works effectively is a key part of
ensuring their productivity.
• While many of these machines see usage over several years, and
processes are in place to monitor the health and performance of these
machines across their lifetime, advances in technology like IoT and
connected machines are changing the landscape today.
• Advanced analytics helps monitor the performance of the machines
• Insights are used to improve lifetime and productivity of the equipment
reducing maintenance cost by 38%
• This also resulted in an efficiency increase of 54%
Automatic repair recommendations

• When equipment breaks down, failure data can be gathered from

various different sources, accumulated and analyzed in real time
within the cloud. Options for repairs can be done automatically by the
system, even actions to take can be recommended to the technician if
necessary. Failure data can be used to address the repair, including
system operating conditions at the time of breakdown together with
previous repair data from the Enterprise Asset management (EAM).
Accordingly, the technician or mechanic will be given all the
information he needs for more effective decision-making. Deploying
EAM or Maintenance management software with an application
programming interface (API) that integrates with IoT devices will be
essential for ensuring accurate and usable information.
Improved Inventory Management

• Using the IoT, maintenance managers can connect their stockrooms to

track orders, incoming shipments or low stock.
• For instance, the maintenance team has the ability to collect data remotely
via sensors that tracks when certain inventory may be low. From there,
they’re able to connect this sort of data collection to a software device to
produce alerts when certain stock may be close to out.
• If you depend on the power of a computerized maintenance management
system (CMMS), connect your stockroom with your tool to automate
reorders, generate inventory reports and track costs to avoid shortages and
improve budget. This results in fewer emergency inventory orders and less
downtime due to out-of-stock inventory to fulfill a work order.
Remote Assets

• When it comes to unplanned failure maintenance, the IoT enabled

devices can make it easier and more efficient to maintain assets in
remote locations. As it was mentioned before, IoT reduces
unnecessary visits to remote locations where you need to inspect
assets through predictive maintenance. For example connecting
assets through IoT like wind farms or pumps would make assets
generate work orders based on their condition. By using EAM and
mobile solutions, technicians would get exact location of the object
that needs maintenance, described problem and list of spare parts
needed to fix the asset. That would extremely reduce time and costs
associated with emergency repairs in Asset Intensive Industries.
Data analysis in real time

• Machine-to-machine, or M2M, is a term that can be used to describe

technology that enables other connected devices to exchange information
and execute actions without the manual assistance of humans. The
internet of things takes M2M even further by including additional element:
data. Having access to all data from machinery in one network gives
manufacturers the ability to accumulate and analyze the data and
transform it to better predictive maintenance. Instead of waiting for a
failure, manufacturers can accurately predict breakdown because IoT
devices reports when operating conditions are out of specification. By
identifying failure patterns and quickly recognizing issues, manufacturers
are able to improve their production and significantly reduce downtime.
That leads to increased customer satisfaction and less warranty claims.
.
Performance Metrics

By using IoT devices, key performance indicators (KPI's) like mean time
between failures (MTBF) or mean time to repair (MTTR) can be
calculated automatically by the system and send back to reporting
dashboards. This then excludes the manual human work of capturing
downtime and ensuring accuracy and availability of data.
Conclusion
• For years, manufacturers have been practicing a time-based approach
to the equipment maintenance. They used to take the age of
machinery as the factor for planning the maintenance routine. The
older the equipment the more frequent maintenance procedures
need to be carried out,however, that worldwide, only 18% of
equipment has failed due to its age, while 82% of failures occur
randomly. It proves that a time-based approach is not cost-
effective – a piece of equipment gets maintained irrespective of the
actual need.
• To avoid ineffective maintenance routine and costs that accompany
it, manufacturers can leverage Industrial IoT and data science