Predictive maintenance showcase a new pavilion at Hannover Messe

The integration of predictive maintenance (PdM) and the data generated through the Industrial Internet of Things (IIoT) is expected to pinpoint impending outages before they occur, speed up overhaul processes and avoid production outages.

02/29/2016


In today's evolving manufacturing environment, machines and components are digitally integrated and able to "talk" to one another. This enables factory operators to continuously capture data on machine states, combine it with information from other systems (such as ERP or CRM software), analyze it and predict the optimal point in time at which to initiate maintenance.

The integration of predictive maintenance (PdM) and the data generated through the Industrial Internet of Things (IIoT) is expected to pinpoint impending outages before they occur, speed up overhaul processes and avoid production outages.

A recent study by the World Economic Forum and the consulting firm Accenture lends substance to the high hopes currently riding on PdM. According to the study, PdM can reduce the cost of planned repairs by 12%, cut maintenance costs by almost 30% and reduce unscheduled downtime by 70%.

"Predictive maintenance is currently the most talked-about and closely watched maintenance, repair and overhaul strategy out there," said Peter-Michael Synek, the Deputy General Manager of Germany's VDMA Fluid Power Association.

It's one reason that the "Predictive Maintenance 4.0 Showcase" will debut at Hannover Messe in Germany on April 25-29. "Predictive maintenance is now so important that we have decided to feature it as a new dedicated showcase," said Marc Siemering, Deutsche Messe's senior vice president in charge of Hannover Messe. "The showcase will include a group pavilion and will be located in the northern section of Hall 17, just across from the North 1 entrance. It will present real-life examples of predictive maintenance applications."

The displays and live demonstrations at the Predictive Maintenance Showcase will be supported by guided tours that will take participants to the display stands of selected providers at various locations throughout Hannover Messe. Tour participants will witness continuous machine data capture, processing and analysis in action and learn how it can give factory operators real, useable information on the condition of their systems, machines and machine components.

Synek sees predictive maintenance as "the next evolutionary stage from conventional maintenance strategies" and a development that delivers major benefits to plant operators. "The ability to reduce or even eliminate unforeseen downtime and associated production bottlenecks flows through into greater productivity. Maintenance and servicing costs go down, and production quality and planning reliability go up," he said.

Synek's views are backed by a study by market research firm IDC which identifies the three primary benefits of predictive maintenance as improved production planning, longer machine up-times and a reduction in unscheduled plant shutdowns. Conducted in 2014, the study revealed that 25% of the manufacturing companies surveyed at that time were already using some form of predictive maintenance based on real-time data, whether in pilot projects or at full scale.

A further 25% indicated PdM implementation plans for 2015. The IDC market researchers also note that manufacturers of industrial plant, machinery and equipment are gearing up for a massive expansion of their predictive maintenance offering. The researchers therefore anticipate a "dynamic market for predictive maintenance solutions based on real-time data."

Not that this anticipated multi-billion-dollar market is the exclusive domain of automation hardware providers. Major international IT providers, such as SAS, SAP, IBM and Bosch Software Innovation, are currently also investing extensively in their capacity to service the growing demand for PdM solutions.



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
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.
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
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 Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
Maintenance & Safety
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me