Controlling production means controlling revenue. But, what do you really mean by controlling production? Now, in a plant when you switch on the machines they generally perform their task until you switch them off and call it a day. During this time, you focus on the effectiveness of the staff presuming machines would perform at optimum capacity. Most often than not, it is the machine performance that hampers the production. This is when condition based maintenance comes into play.
The quantum leap from Industry 3.0 to 4.0 has completely changed the manufacturing scenario. The production can now work at full swing with the machines performing cohesively. When a machine suddenly comes to a halt, it heavily affects the production. Not only does the company incur the cost of the breakdown (of the unit) but also the huge cost of the halt of production, which in the end results in losses both in terms of physical output and revenues.
Machines are susceptible to damage but they show signs of breakage before the breakdown. Now, though these signs were not possible to read earlier, the application of IoT in the industrial space has made it so with real-time machine health monitoring. Just before the machines crash down completely, it initially starts to wear down, slowly hampering the output, a unit at a time. This is what most maintenance systems fail to register and what seems to be a small deterioration in the health of the machines, costs millions in huge plants.
Condition monitoring techniques are commonly used on rotating equipment, auxiliary systems and other types of machinery like compressors, pumps, electric motors, internal combustion engines, and presses.
Condition based monitoring are of different types:
Vibration analysis and diagnostics
Acoustic emission (airborne ultrasound)
Ultrasound testing (material thickness/flaw testing)
Machine Health Monitoring is therefore of utmost importance. Infinite Uptime’s predictive maintenance delivers condition based maintenance through a variety of parameters.
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Infinite Uptime is the first award-winning IoT enterprise that provides hardware enabled condition monitoring through a patented technology. The process of effectively observing the equipment’s health is quite seamless with IDE. The Industrial Data Enabler is a small plug-n-play device that is capable of measuring tri-axial high-frequency mechanical vibrations, temperature, and acoustics. It is a handheld device for productivity optimization and automated predictive maintenance in the industry.
It can detect anomalies and defects in real-time through visual LED indicators. Knowing beforehand that your machine may face a possible harm gives you enough time to tackle the problem. This is possible with Infinite’s condition based maintenance.
A machine may face any issue, any time of the year and hence you need a comprehensive condition based maintenance.
In a nutshell, here is why you should be having Condition Based Monitoring (CBM) today:
- Maintains the life of the machinery by providing time-to-time maintenance
- Reduces unnecessary downtime costs
- It is an ongoing process, so the analysis is simultaneously performed without having to stop the production.
- Tailored maintenance is possible when the exact cause or area of improvement is known.
- Increases performance
- Reduces the chances of the complete production halt