IoT, a springboard to predictive maintenance

One of the major objectives of effective maintenance is to minimize the downtime of machines. To this end, the use of the IoT for predictive maintenance is a considerable asset. 

IoT predictive maintenance

Anticipating outages before they occur enables the necessary maintenance interventions to be performed rapidly at the chosen date and time. This requires a 4.0 CMMS that integrates the IoT into its operation. 

The advances made by this technology seem almost infinite, and it is therefore important for industrial companies to have agile and scalable tools, constantly improving their productivity and competitiveness.

IoT and Maintenance

Industrial maintenance is far from being the only area covered by the IoT. However, it is one of the main sectors that benefits from it. 

IoT predictive maintenance

What is the IoT?

The Internet of Things (IoT), is the connection between the Internet and physical objects. In practice, it takes the form of objects connected to the Internet, whose physical existence is thus linked to a digital existence. The considerable amount of data collected on these objects helps to improve its functioning and effectiveness, but also leads to developing new knowledge. The IoT is generally considered the third evolution of the Internet.

For several years, the Internet of Things has become increasingly important in industrial production. This development was made possible by the spread of fiber optics, cloud computing, Big data or software in SaaS mode, but also by the emergence of more and more varied and less expensive sensors and, of course, by the explosion of the use of mobile devices.

The IoT thus improves productivity in a wide range of areas and is estimated to have, and will have even more in the future, a significant impact on the GDP of the countries in which it is used in the industrial sector.

How does the Internet of Things work in maintenance?

The IoT allows, through sensors, to continuously monitor the functioning of machines through certain key parameters of detection of malfunctions and failure. The vibrations of a machine are the most common parameter: the detection of abnormal vibrations usually stands for an impending failure.

The IoT also allows to track some of the following parameters: 

  • the temperature or pressure of a machine,
  • its energy consumption,
  • the speed of rotation of a pin.

Any unusual data transmitted by the sensors is collected and analyzed by the CMMS to which they are connected. If necessary, this can result in a maintenance operation, before the failure occurs.

Moving from preventive maintenance to predictive maintenance with IoT

The Internet of Things, combined with a next-gen CMMS, enables companies to adopt a predictive maintenance strategy, in order to optimize the productivity of their equipment.

IoT predictive maintenance

From preventive maintenance to predictive maintenance

Preventive maintenance consists of intervening on machines at specified intervals or according to prescribed criteria. It aims to reduce the probability of failure or degradation of equipment. This type of maintenance strategy is based on knowledge of similar machines and feedback.

Predictive maintenance, or forecasting maintenance, allows you to move to a different level of maintenance efficiency. According to the NF EN 13 306 X 60-319 standard, it consist of performing maintenance operations "following extrapolated forecasts of the analysis and evaluation of significant parameters of the degradation of the property, notably through connected sensors that have been installed on machines."

This makes it possible to predict the maintenance needs of each piece of equipment on the basis of its own data, not by extrapolating from the operation of similar machines nor by relying, with a certain margin of uncertainty, on experience. This avoids, for example, carrying out preventive maintenance interventions at regular intervals when they are not really necessary.

According to management consulting firm McKinsey, predictive maintenance, which has been booming in recent years, could reduce the costs of factory equipment by up to 40%, while reducing downtime by up to 50%.

4.0 CMMS solutions, the indispensable ally of the IoT

To be able to use IoT in industrial maintenance and thus to implement a predictive maintenance strategy, the adoption of a next-gen CMMS (4.0 CMMS) is essential. This, based on the numerous data transmitted by the sensors installed on each machine and using the Big Data (without which the data would be impossible to process), allows to predict with great precision the future malfunctions of the equipment.

IoT predictive maintenance

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In this way, machine and therefore production downtimes, spare parts requirements or maintenance team schedules can be organized more easily and with greater precision, and the negative impact of interventions on the plant's productivity can be greatly reduced.

Constantly improving technology 

The Internet of Things is constantly progressing, as the sensors used are more and more efficient and less and less expensive. So some companies are starting to design "smart" sensors, for example, through artificial intelligence.

But in order to take full advantage of this progress, it is necessary to be equipped with a CMMS that is also constantly evolving and adapting and that is in line with next-gen apps. These are regularly updated and perfected by their developer teams, based on the feedback from their users and the needs they express.

The IoT is thus a great tool for optimizing industrial maintenance, by adopting a predictive maintenance strategy. Backed by an agile 4.0 CMMS solution, it allows companies to extend the lifetime of machines while gaining productivity, now and in the future. In terms of maintenance, the joint use of the IoT and next-gen CMMS solutions offers companies, durable guarantees in terms of competitiveness.

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