Predictive maintenance is a proactive approach to maintenance that uses embedded systems and cutting-edge technologies, such as sensors and IoT devices, to predict machine and equipment failures and anomalies. The adoption of such technologies to monitor the working conditions and wear of equipment allows for a maintenance scheduled well in advance. In this way, immediate interventions help prevent more costly future failures. To optimize the maintenance plan, specific tools must be complemented by data analysis.
Why Implement Predictive Maintenance
Systems and technologies for predictive maintenance offer several advantages for Industry 4.0:
- Reduction of machinery and equipment failures. By continuously and in real-time monitoring the wear and tear of equipment, it becomes possible to take preventive action to address potential malfunctions before they turn into actual failures. Careful predictive maintenance can lead to an overall reduction in failures by up to 70%.
- Reduction of maintenance costs. The prediction and timely intervention on minor malfunctions allow for savings of up to 25% on the costs required for maintenance.
- Reduction of environmental impact. Safe and well-maintained machinery and equipments operate efficiently with appropriate energy consumption. On the other hand, failures and breakdowns lead to energy wastage, as well as the waste of materials and components. Furthermore, well-functioning machinery will not need to be replaced or discarded, minimizing the environmental impact of these practices
- Increase in productivity. Damage and malfunctions can delay, or even halt, production, causing significant delays and financial losses. Predictive maintenance and preventive intervention can ensure the continuous operation of production lines.
- Improvement of safety conditions. Machinery and equipments in optimal condition enhance safety conditions, including for the technicians working with them.
The use of predictive maintenance technologies can be a crucial factor from an industrial competitiveness perspective.
What CogniMade offers
- Vibration sensors for detecting mechanical anomalies in machines, fans, or motors;
- Infrared sensors that can detect temperature increases and overheating in motors, fans, and equipment;
- Customized sensors;
- Gateway/Dataloggers for Modbus RS485, EtherCAT, or wireless connections;
- Cloud platform for data collection and visualization, allowing the generation of configurable automatic reports and enabling the programming of alarms with varying severity thresholds, notified via email or SMS;
- Customized data analysis with machine learning algorithms, to identify variations from optimal performance based on the provided data.
For more details on CogniMade products, please visit the dedicated page.