New-age technologies like Artificial Intelligence (AI), Machine Learning (ML), Internet of things (IoT), and predictive analytics are automating processes and augmenting human capabilities. Together, they set the stage for innovations in different sectors. Manufacturing is leveraging Predictive Maintenance (PdM) that takes preventive maintenance several notches higher.
What is Predictive Maintenance?
PdM changes the approach from reactive to proactive maintenance, empowering enterprises to anticipate changes in the system and preemptively manage them. In other words, it helps enterprises predict and avoid machine failure and resultant downtimes. These analytics-led predictions optimize maintenance efforts and facilitate frictionless interdependence.
According to Deloitte, PdM increases equipment uptime by 10-20% and reduces overall maintenance costs and maintenance planning time by 5-10% and 20-50% respectively. With a CAGR of 25.2%, the global predictive maintenance market is set to grow from USD 4.0 billion in 2020 to 12.3 billion by 2025. The growth is fueled by the continued demand for reducing maintenance costs and downtime.
In the current Industry 5.0 environment, the role of maintenance has evolved from merely preventing downtimes of individual assets to predicting failures and creating synchrony between people, processes, and technologies. Predictive maintenance plays its part well, though it does bring along certain challenges that necessitate human intervention.
Benefits of predictive maintenance in manufacturing
As mentioned earlier, predictive maintenance helps eliminate unplanned downtime and related costs. In an IoT-driven world where sensors, devices, systems, etc. are connected, McKinsey believes that the linking of physical and digital worlds could generate up to $11.1 trillion annually in economic value by 2025.
Maximized runtime also means better profits, happier customers, and greater trust. Predictive maintenance can ease logistics by choosing maintenance time slots outside of production hours or at a time when the maintenance personnel is available. It contributes to supply chain resilience, material costs savings, and increased machine lifespan.
However, PdM is only as good as the data it relies upon. Due to IoT technology, data comes from different sources and needs to be duly analyzed before it can be harnessed to make predictions. Hence the importance of IoT Predictive Maintenance
Limitations of predictive maintenance
We need to consider several elements to translate the information PdM provides into positive outcomes. For instance, depending on usage and maintenance history, it may advise you to replace a certain part or component. But this information can lead to further questions. You may need help in deciding which brand and vendor to consider, whether replacement of the component is a good option, or would it make better sense to replace the equipment entirely.
The forecast is often prescriptive and based on statistical models. While optimizing the operational efficiency of a particular line of business, PdM often fails to consider how it impacts other lines. For instance, when it suggests particular equipment is due for maintenance, it may not be able to offer advice as to where the production/processing needs to be shifted when it’s down. The value it offers will therefore be shaped by how decision-makers respond to predictive data.
Data quality and coverage are critical to make predictive maintenance work for the organization. For data to be suitably collected, integrated, interpreted, and transformed, we need dashboards, notification systems, and a bunch of other things to get started. This requires considerable research and planning to go into its implementation for it to start providing the insights we need.
Predictive maintenance use cases in manufacturing – The key lies in the way you respond
Decision-makers typically respond to predictive data with either hypothesis-driven or data-driven responses. The former stems from past business experiences and determines the plan based on a limited scope of response actions. Data-driven responses, on the other hand, aim to find solutions based on real-time business realities and consider several optimization scenarios to determine the way forward.
In contrast to hypothesis-driven decision-making, optimization ensures that all possible paths are explored and evaluated, relevant constraints are taken into consideration, and cross-functional interdependencies are looked into. A workable scenario based on business realities is thus created with no scope for purely intuitive responses.
Despite the analytics-driven insights, predictive maintenance is incomplete without human judgment. Smart decisions come from the ability to visualize the physical and financial outcomes before enforcing them. High-risk situations might arise, and thus they are best left to human discretion.
A predictive maintenance model for Industry 5.0
Manufacturers need clarity on several variables to understand the implications of failure. A false alarm triggered due to inaccurate predictions can result in a lot of unwarranted chaos and anxiety. However, a missed detection might often prove to be a costly error, sometimes resulting in loss of humans and property. Therefore, while understanding variables, they need to first know how often the variable behaviors occur on the factory floor. Strong domain knowledge along with solid data based on previous failures and scenarios is the key to understanding a machine.
Prediction accuracy will improve if we have adequate data on the behavior of machines when they are very close to failure. Only skilled personnel can determine this; some data sets, despite being important, are harder to collect and yet very critical for decision-making.
If we need data on a machine that breaks just once in a year or two, we need to work closely with machine makers who already possess a large pool of relevant data. Alternatively, we may choose to create a digital or a simulation model to create relevant data sets. The most expensive failures are usually the ones we never expect and hence relevant testing for different scenarios should also be considered.
The future of predictive maintenance
The way forward into Industry 5.0 is to create a predictive model that uses analytics, machine learning, and Artificial Intelligence (AI) in conjunction with human insights.
Manufacturers are now relying on predictive models to facilitate smart manufacturing as they struggle with quality issues more often than machine failures. Unusual temperatures, random vibrations, are all telltale signs that a machine may be in dire need of maintenance. Simple data sets can be a good starting point as we scale up with the right predictive maintenance solution. But, in the end, it’s the human insight that can give predictive maintenance its winning streak.
Predict business success with Trigent
At Trigent, we are helping organizations benefit from Industry 5.0 We help them build value with predictive analytics and rise above maintenance challenges. With the right guidance, we help them foster the man-machine symbiosis to harness new levels of operational efficiencies.