Overcome Predictive Maintenance Challenges and Choose the Right Solution Providers

Overcome Predictive Maintenance Challenges and Choose the Right Solution Providers

Justify Initial Investment

Implementing a predictive maintenance (PdM) strategy in a factory with conventional and existing equipment can be challenging due to the high initial investment required. The primary factors contributing to this cost are the predictive maintenance devices needed to capture data from each asset, regardless of the age of the equipment. Additionally, a significant amount of time is required to integrate these devices into either a new or existing network. This process involves programming and setup, which can be time-consuming, especially if the factory has devices from different manufacturers. Once the initial investment is made and the devices are properly set up, the ongoing costs are minimal, and the benefits of predictive maintenance can be fully realized.

Automation solution providers can help reduce the costs of implementing predictive maintenance by guiding manufacturers to the most effective solutions. Often, companies might focus on monitoring variables like vibration, current, or temperature without fully understanding if these are the right parameters for their specific issues. An experienced provider can help identify the root causes of problems and recommend the most appropriate devices. For example, if a motor's issue is likely due to bearings, monitoring vibration would be the right choice. By suggesting devices that are easy to configure and integrate into the existing network, providers can ensure that the investment is both cost-effective and useful.

Simplify Data Integration and Management

One of the biggest challenges in integrating data from diverse sources into a unified system is ensuring that all devices and systems can communicate effectively. For example, you might have one device using Ethernet IP, another using RS485, and yet another using Profibus, while your PLC supports Profibus and Ethernet IP. This requires a communication converter to translate between these different protocols.

Additionally, it's crucial to identify and use only the relevant data parameters for your specific application. You might only need a handful of variables out of the many available, and integrating these specific parameters into a unified system ensures that the output is meaningful and actionable. Built-in algorithms can help filter and process data, ensuring that you are monitoring the right information and that it is useful for your system.

Automation tools simplify the integration process by not only gathering data but also analyzing it to provide filtered, actionable insights. For instance, a motor condition monitoring product sends a green light if everything is okay or a red light if there's an issue, and it can transmit this alarm through widely used protocols like Ethernet IP.

Overcome Limited Technical Expertise

Companies often lack the foresight and vision necessary to implement a true predictive maintenance strategy. Without a clear understanding of PdM, they might confuse it with merely collecting data, as in a preventative maintenance approach. Successful PdM requires long-term data analysis and decision-making based on real-time factory floor data. Another critical skill gap is the ability to interpret the data accurately. Raw numbers from sensors need to be translated into actionable insights by skilled workers who understand what specific readings mean for different machinery. Integrating both IT and OT systems is also a significant challenge, as PdM relies on collecting data from the factory floor and transmitting it to a centralized database or management system. This integration ensures that even inexperienced workers can make informed decisions based on the data, enhancing overall maintenance efficiency.

A solution provider can address these skill gaps by making data easy to understand and interpret. This involves providing user-friendly interfaces for data analytics, intuitive built-in tools, and robust integration platforms that seamlessly connect the factory floor with centralized data management systems. Comprehensive training programs are also essential, as they can teach workers how to interpret data and make informed decisions, thereby bridging the skill gaps effectively.

Equipment Compatibility Solutions

Legacy equipment often lacks modern communication ports like Ethernet IP, making it difficult to integrate with current data gathering and analysis systems. For example, the OMRON K6CM motor condition monitoring product can send alerts through Ethernet IP, but older systems may only provide raw, uninterpretable data. If a legacy system does have Ethernet IP, it can more easily support modern technology.

To integrate predictive maintenance systems with older equipment, it's crucial to assess the efficiency and limitations of the legacy systems. Providers can serve as business consultants, offering guidance on whether upgrading equipment would be beneficial based on potential returns. By analyzing the current performance and potential gains, they help you make informed decisions that maximize your investment and enhance overall system performance.

Choosing a Solution Provider

When selecting a PdM solution provider, it's crucial to consider a comprehensive portfolio of capabilities. A provider that specializes solely in vibration monitoring might excel in that area, but if they can't integrate that data into a broader control system or provide actionable insights, they are only offering a partial solution. The expertise and support from the provider's representatives, consultants, salespeople, and technical staff are also vital. The key is not just receiving raw data but having it presented in a way that is easy to understand and interpret and ensuring seamless integration with other devices and systems.

OMRON as a leading automation solution provider helped a global baked goods manufacturer upgrade to an automated system, enhancing data tracking with EtherNet/IP and automating data logging. Initially, they struggled with manual processes that led to unstable data tracking, increased downtime, and safety risks. With OMRON solutions, the company not only synchronized their processes and eradicated errors but also set the stage for the next step: implementing predictive maintenance. This tailored approach has significantly improved their production efficiency and safety, while also boosting product availability.