After the upsurge of the pandemic, the global manufacturing industry experienced a setback due to factory shutdown and equipment stoppage. The manufacturers were unsure about the operational efficiency of the equipment that was non-functional for a considerable period. Though Diagnostic services deliver the instantaneous health of the equipment, strengthen the production goals, and ensure reduction in maintenance expenses.
Let’s take a look at a few misconceptions that deprive professionals of its adoption.
Here are a few misunderstandings around industrial machine health monitoring and diagnostic services the industry should be aware of:
- Diagnostic Services are expensive – Equipment maintenance is an infinite process. Maintenance activities imply 24 X 7 availability of Maintenance workforce, access to required inventory, and observing the government regulations. Diagnostic services streamline maintenance efforts, predicts the failure before the impact, provide repair time, avail the procurement of spares, thus substantiating the long-term cost. A minor ignorance of anomaly in equipment data in a process plant can lead to catastrophic failure, but timely diagnostics can prevent it. Diagnostic services deliver ROI within months compared to the loss of production saved per prediction rather than the cost of the machine being monitored.
- Diagnostic Services are hard to implement – Smartphone configured sensors sense the equipment, detect the variance in performance, and AI-driven algorithms diagnose the root cause, suggesting measures to prevent the downtime and improve its reliability. A primary diagnosis in a steel plant can ensure the completion of the production cycle and guide the plant authorities with a remedial measure. Rapid deployment of such sensors across equipment is possible, and the implementation of a digital reliability program is now possible within days.
- Diagnostic Services are to be delivered by a CBM Expert – Systematically and timely planned analysis of the equipment data with easily executable actions suggested based on data-driven programs alleviate the need for a CBM Expert in every unit. The effectively executable disciplinary actions compensate with the time required to share the equipment analysis report and obtain directives. The number of equipment monitored by a single CBM expert can be exponentially increased using such technology.
- Diagnostic Services are implemented only for critical equipment – Diagnostic services are independent of the criticality of the equipment. The criticality of the equipment in a plant depends on its function, cost, downtime, etc. However, the purpose of each component is significant and may affect the life cycle of the entire assembly. The underperformance of semi-critical equipment in FMCG can adversely affect the production line. With improved diagnostic services using IoT and digital technologies, it is now possible to digitize all equipment in a plant rather than a few super-critical ones like only the turbines and high-speed compressors.
- Diagnostic Services are Applicable Only for Expensive Equipment – High capital investment in equipment cannot compensate for the unplanned downtime. Diagnostic Services can lead counsels to discourage unforeseen shutdowns. The plant authorities can rely on the tips to replace the existing equipment with a standby (if available). Just like a simple lube oil pump failure can stop an expensive and critical compressor in a refinery, many rotating assets should be digitized and monitored remotely irrespective of the size and cost of the equipment, but instead based on the impact of the failure of such equipment.
- Diagnostic Services are Not Necessary for Equipment Under Warranty – Diagnostic services for warranty equipment improve its lifespan and ensure higher efficiency. A competent overview of equipment performance and operation confirms the optimum energy consumption. The services justify warranty claims for an OEM and help him to plan after-sales services. A failure within the warranty may get a free replacement/repair from the OEM, but the plant operations still penalize the cost of downtime and production loss.
- The remote diagnostics technology of today is not reliable – The advanced technology promotes diagnostic analysis supported with AI-driven algorithms, history of the equipment, an in-depth study of the equipment, and consequently increases the reliability of the equipment. Most MEMS-based IoT devices for rotating asset monitoring can now deliver similar or better results than traditional portable piezo-electric transducers, allowing for scalable deployment of such technology over many assets with the same reliability of data and analytics as a portable analyzer.
- Diagnostic Services are difficult to integrate into Automation Systems – Diagnostic services focus on accuracy in observations, precision in diagnosis, and favorable recommendations to prevent unplanned breakdown. The data-view comprising various parameters monitored for the equipment is readily available for integration through APIs or Modbus interfaces. With the advancement of API integration, interoperability of multiple solutions is now possible, and plants can opt for fully integrated solutions that communicate with each other and are not data silos.
- Diagnostic Services intend a change in the infrastructure – The evolution to Industry 4.0 implies most engineering and processing industries are equipped with Wi-fi connectivity/ Ethernet, toolsets like long switches, sophisticated routers, etc. Diagnostic offerings conditioned to streamlined data monitoring systems adapt to the existing infrastructure and do not indicate an increase or change in infrastructure.
- Diagnostic Services are a replacement to CBM – One of the biggest challenges faced by the CBM team is transforming their activities into monetary gains. Diagnostics encourages the CBM team to evaluate maintenance operations with a profound and streamlined equipment health status. A historical record of all the maintenance activities to prevent downtime transforms their efforts into value-addition to the plant. Diagnostic services do not undermine a CBM expert but instead enhance a CBM expert to deliver more excellent value over a more significant number of assets than previously possible.
Industrial Diagnostic Services offered by Infinite Uptime supplemented with a patented Vibration Monitoring System ensures correct maintenance, protects the equipment, collateral damages in the plant, and reduces the maintenance costs. The innovative service caters to screening the data, analyzing the root cause of equipment misbehavior, and proposing corrective measures to avoid an unplanned shutdown.