Maintenance a prime benefit for IIoT

Frost & Sullivan study finds maintenance improvement can drive greater profitability.


Image courtesy: CFE MediaThe emergence of Industrial Internet of Things (IIoT) as a plant strategy has focused on productivity and operational issues. One area of great potential, and one area that often gets overlooked, is maintenance. A recent study by global consultancy Frost & Sullivan talked about the relationship between IIoT and maintenance. The study found that service strategies will shift from corrective to preventive and predictive maintenance services over the next five years.

"Effective utilization of predictive analytics can optimize costs and eliminate unplanned downtime, which are highly attractive benefits for manufacturers," Frost & Sullivan officials reported. "Big data analytics is poised to change the maintenance services models across the manufacturing sector. The investments for establishment of robust maintenance and support service model by leveraging the big data analytic concepts is the critical factor for the high growth rate."

Report author Srikanth Shivaswamy, senior research analyst for industrial automation and process control for Frost & Sullivan, discussed the ways IIoT will impact the maintenance area.

CFE Media: One of the hottest topics around IIoT is the potential for better maintenance within plants. Has maintenance been overlooked by most plant managers? How will IIoT potentially change that?

Shivaswamy: Conventional maintenance systems followed pre-set approaches for maintenance and repairs; service activities were performed according to pre-design standard operating procedure. Maintenance and repair operations were initiated based on equipment or process flow breakdown.

Internet of Industrial things would see the emergence of scheduled and automatic maintenance and repairs activities generated by pre-programmed algorithms.

  • Dynamic maintenance schedules can be generated based on real-time data by sensors.
  • Ability to migrate to a completely different service model to adjust to a new process/ product /solution and improve the overall performance of the end-user.
  • Flexibility to scale up and down the services capabilities.

CFE: Will this increase in data also change the training and skill set needed for maintenance workers? What are the challenges and opportunities here?

Shivaswamy: The skill set of the maintenance workers need to be tuned to understand the dynamic service models. In most cases the maintenance workers needs to be trained to understand and operate the IIoT based platform.

Challenges and opportunities:

  • Development of smart and user-friendly platforms for data management
  • Asset and resource management modules
  • Standard service and maintenance models
  • Use of off the shelf mobile devices
  • Development of integrated cloud platforms to execute design, maintenance, and business services.

CFE: It appears that there will be more companies providing third-party services in both maintenance management and cyber-security. What do you see as the pros and cons to such an approach?

Shivaswamy: The increase in number niche companies can be attributed to the emergence of industries data services and cyber security services. The lack robust software platform in the industrial space has been seen as a lucrative opportunity by most of the niche companies.This would witness the upcoming of innovative platforms to increase the utilization of products, equipment and assets. Lack for standardization across software platforms has been the major concern for data cross-flow and integration.

CFE: What is the first thing plant managers should do to prepare for IIoT in their facilities?

Shivaswamy: Information technology and communication infrastructure in the most of the plants needs to be improved for complete implementation of IIoT modules.

The Top Plant program honors outstanding manufacturing facilities in North America. View the 2017 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
Welding ergonomics, 2017 Salary Survey, and surge protection
2017 Top Plant winner, Best practices, Plant Engineering at 70, Top 10 stories of 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Setting internal automation standards
Knowing how and when to use parallel generators
PID controllers, Solar-powered SCADA, Using 80 GHz radar sensors

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me