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Predictive maintenance – impact and value to manufacturing

Technological innovation, such as the development of industrial IoT (Internet of Things) has made it possible to use machine data to improve operational performance and process efficiency. The availability of IoT has made it possible to optimise the remote monitoring and maintenance capabilities it offers to minimise the costs and consequences of both planned and unplanned downtime. This is a process commonly referred to as predictive maintenance. But even with these benefits, some manufacturers have yet to adopt it. PWE reports.

Maintec is back

Maintec, the dedicated UK maintenance and reliability event returns to the NEC in October. PWE takes a closer look.

Software strategies

How much do you know about CMMS (Computerised Maintenance Management Software) or EAM (Enterprise Asset Management)? Maybe you have an existing system which nobody likes or possibly you are working with spreadsheets and paper and feel there must be a better way to manage maintenance within your company. Whatever your situation, you are likely to be working in one of the many maintenance departments that doesn’t have a clear picture of how to ensure CMMS/EAM software use is deployed and developed to maximise its potential benefit. Phil Taylor, associate consultant, MCP Consulting Group, reports.

Ultrasound monitoring

Airborne and structure-borne ultrasound is a technology that has been around for more than 50 years. In the technology’s early days, the main application was compressed air leak detection. Even today, that is still the most widely used application for airborne ultrasound. Advancements in leak detection using ultrasound have come by way of reporting and documenting the air leaks that are found. The reports quantify the air leaks by showing the cost and CFM loss related with the air leak. UE Systems’ Adrian Messer, CMRP, reports.

How manufacturers can prepare for 5G

Heiko Noll, product manager devices at industrial communication solutions provider INSYS icom, explores what manufacturers should do to prepare their machines and plants for the 5G roll out.

Ash conveyor chain life doubles thanks to bespoke solution

A waste to energy incineration plant in the Netherlands has seen the working life of the chains on its bottom ash conveyor double, thanks to bespoke chains developed by Tsubaki. PWE reports.

Is 5G ready for manufacturing?

5G has been in the news recently for all the wrong reasons. But beyond the media controversy, the technology has the potential to bring about a fundamental change in the way manufacturers operate. Jonathan Wilkins, marketing director at EU Automation, explains how 5G can benefit manufacturers.

Digitalisation and brownfield facilities – can these fit together?

Today's plant automation systems provide transparent monitoring of system status, plus tools such as condition monitoring or predictive maintenance – all help to reduce unscheduled downtime. However, what about brownfield installations with legacy equipment? Hartmut Pütz* and Thomas Lantermann** report.

CMMS installed to improve maintenance processes

Spidex Software has announced that IMI Truflo Marine has selected Mainsaver CMMS to support improved maintenance management processes at its factory in Birmingham, UK. PWE reports.

Take digital maturity seriously

Clare Darlison, director of Idhammar Systems explains why manufacturers must take digital maturity seriously and how they can work towards achieving it.

Cracked steam turbine rotor solution

When a damaged steam turbine rotor needed to be repaired, a power generation plant in Indonesia turned to Sulzer. Rather than wait for at least a year for a new rotor from the original equipment manufacturer (OEM), the plant opted for a repair that took only sixteen weeks. This quick and effective repair also managed to achieve an 8% improvement in efficiency.

Maintenance in the digital world

Richard Chamberlain of Bosch Rexroth discusses, taking a proactive approach to maintenance is key to maximising uptime – something that can be supported by digital solutions in today’s Industry 4.0 landscape.

Free App provides convenient monitoring

Mitsubishi Electric has introduced a new app for iOS tablets and smartphones that provides convenient commissioning, maintenance, troubleshooting, parameterisation and monitoring support for the company’s FR-F800E and FR-A800E inverters. Available from the Apple App Store, the Inverter StartApp addresses modern requirements to glean more information from manufacturing processes, with easier accessibility, and to be able to act on that information in a timely and convenient manner.

Shaping modern asset management

Thomas Boswell, ERIKS’ reliability engineering manager, examines how digital industrialisation is transforming MRO and underpinning proactive asset management strategies.

Boosting the scope of shrink fits with engineering adhesives

Bonded shrink fit assemblies not only enhance the service life of an assembly but pave the way for new design concepts and cost savings. Higher load transmission can be obtained from existing designs and geometries and there’s the potential for equal performance with relaxed tolerances and the reduction in size and weight of the assembly. Bob Orme, senior technology specialist, reports.

MTC aids big productivity gains

A family owned precision engineering company in Coventry has achieved a 10% increase in its forward order book and has made double-digit productivity gains with the help of experts from the Manufacturing Technology Centre (MTC).

Achieving best clamp load retention performance in extreme conditions

Threaded assemblies are the most important detachable parts used in machinery construction, installation and repair. Relaxation of tension and self-loosening is common for any machine but when it is operating in harsh environments, the need to minimise this deterioration with effective thread locking is even more important. Various methods are available but what are their respective strengths and failings?

Three-way monitoring

Standard components specialist norelem has launched a new range of oil level gauges that can help engineers and manufacturers steer clear of dangerous situations involving oil.

Predicting the future of maintenance

Gernut van Laak, group automation solutions leader of ABB's Food and Beverage Programme, explains how plant managers can budget for maintenance and ensure optimum efficiency for all processes.

Drives help meet rubber mill safety standards

Ensuring rubber compounder mills capable of operating with bulk weighing up to three tons could stop within 1/6th of a revolution and reverse to meet European EN safety standards was going to be a challenge for materials specialist Clwyd Compounders.

Inverters that look after themselves

PWE provides some insight into how preventative and actual maintenance is done with smart VSDs.

Pulp mill ensures availability of drying machine with online monitoring for Industry 4.0

At Swedish pulp mill Södra Cell Värö, condition monitoring has long been a well-integrated and successful part of preventive maintenance. The mill is now making further investments in condition monitoring and has chosen the high-performance and highly flexible online system Intellinova Parallel EN to maximize the availability of the pulp drying machine.

The evolving role of the CISCO

It's a simple fact that data makes the modern economy turn. Being the first business to act on insights gained from pivotal pieces of information gives businesses a distinct competitive advantage. However, it's also quickly becoming a fact that the same data is being targeted by skilled cybercriminals intent on causing damage to infrastructure. Robin Whitehead (pictured), managing director of systems integrator Boulting Technology, explains how this is impacting the role of the chief information security officer (CISO) and resulting in the need for end-to-end digitalisation.

Mitigating standby generation failure

Companies have become increasingly reliant on the security and continuity of their power supply. Simone Bruckner, managing director of power resistor and load bank manufacturer Cressall Resistors, explains why regular load bank testing should be a crucial part of any company’s standby strategy.

Smart CM protects production process

Muntons Malt, one of the UK’s largest producers of malted barley has chosen the Smart Condition Monitoring (SCM) system from Mitsubishi Electric to protect fans and motors vital to its large-scale and sensitive production process. PWE reports.

Delivering the thrills without the spills

Zip World turned to Turck Banner for its system requirements. The company’s range of products, designed to last in harsh environments, matched its client’s needs where safety is paramount.

Optimising plant performance through digitalisation

Industrial plant operators are increasingly supporting better decision-making by using the digitalisation capabilities available through instrumentation and plant management systems. Saverio Barbero Lodigiani and David Lincoln for ABB Measurement and Analytics in the UK, explain how these capabilities can help to boost plant and process performance by providing the data needed for smarter operation and maintenance.

Augmented reality in the manufacturing space

Nick Boughton, digital lead at leading systems integrator Boulting Technology, examines how AR can be used across the manufacturing industry.

Condition monitoring solution prevents unscheduled stoppages

A steel producer has installed a condition monitoring solution from Schaeffler to help prevent unscheduled stoppages to its critical furnace deflection rolls. PWE reports.

Visualising the future of plant maintenance

Nick Boughton (pictured), digital lead at Boulting Technology, explains how AR and VR are re-defining plant maintenance.

Let's talk about MRO...

Jonathan Wilkins, marketing director at EU Automation, explains the technology that manufacturers can use to improve MRO in their facilities.

Question: How can I assess and monitor the condition of bearings that rotate at speeds of between 0.5 and 60 RPM?

The answer to this month’s trouble shooter is provided by MISTRAS Group Ltd.

New HMI software features improve operator efficiency

Rockwell Automation has updated its HMI software to equip industrial workers with better information to run and maintain their systems. New features in the FactoryTalk View software version 10.0 include greater access to information, new mobile device support and better cross-software integration to improve productivity.`

Learn the system

Dave Dyer, technical sales engineer at Global Heat Transfer, explains how a detailed understanding of a heat transfer system can help manufacturers maintain efficiency and prevent costly downtime.

Putting the AI into maintenance

Sean Robinson, service leader at industrial analytics platform supplier Novotek UK & Ireland, explains how plant managers can make proactive maintenance even more effective with machine learning.

Maintenance insights at Maintec

A host of senior engineering professionals will be taking part in the Insights keynote theatre at this year’s Maintec Exhibition in November to discuss and debate the latest challenges influencing maintenance engineering. PWE reports.

Taking control

It’s widely understood that improving the efficiency of equipment and processes will make a business more competitive and reduce operational costs. However, this is easier said than done, as identifying the areas that need improving can be challenging — especially in sugar plants, where many managers have grown accustomed to high energy usage and carbon emission levels. PWE reports.

Visualising the future of plant maintenance

Nick Boughton, sales manager at leading systems integrator Boulting Technology, explains how AR and VR are re-defining plant maintenance.

Smart condition monitoring

Muntons Malt, one of the UK’s largest producers of malted barley has chosen the Smart Condition Monitoring (SCM) system from Mitsubishi Electric to protect fans and motors vital to its large-scale and sensitive production process. PWE reports.

How do I capture better thermal images?

The answer to this month’s trouble shooter is supplied by FLIR Systems.

Retrospective digitalisation

Nick Boughton, digital lead at systems integrator Boulting Technology explains how plants with legacy equipment can retrospectively upgrade their facility to a smart factory.

Improving manufacturing with predictive analytics

Stefan Reuther, chief sales officer at COPA-DATA, explains how to leverage predictive analytics to reduce factory downtime and increase business competitiveness.

The answer to this month’s trouble shooter is provided by Henkel. Q: What are the options for stopping bearing spinout?

A:

Putting the AI into maintenance

Over the past five years, the industrial sector has begun to see the value in digitalisation and has invested more in adopting it. With this has come a cultural shift from reactive equipment maintenance to proactive maintenance that pre-empts problems. Sean Robinson, service leader at industrial analytics platform supplier Novotek UK & Ireland reports.

Smart instrumentation

Developments in smart instrumentation and asset management systems are offering a raft of new opportunities for industrial process operators. Providing real-time access to an expanded array of information, these developments can help to dramatically improve process performance. PWE looks at the key developments that have taken place and the benefits they can bring in a process environment.

Maintenance life blood

Phil Taylor Associate Consultant, MCP Consulting Group, looks at maintenance software strategies.

Highlighting the IoT possibilities in maintenance

Europe's biggest conference on maintenance & asset management returns to Antwerp, Belgium between September 24-27. PWE reports.

New flowmeter technology

Flowmeter technology has made some significant steps in the past few years. While the traditional mechanical systems have remained relatively unchanged, the development of ultrasonic, sonar and magnetic systems has progressed significantly.

On the road with IoT

As more companies move to a predictive model of equipment maintenance, they are looking for ways to use connected devices to improve field service. George Walker, managing director of field service management software provider Novotek UK and Ireland, explains how the Internet of Things (IoT) is changing field service.

Turning data into value

Marc Heggemann, head of group commercial digital solutions at Sulzer, says that the future lies in gaining insight from the available data, and ensuring we have the right information at the right place at the right time. PWE takes a look at the company’s BLUE BOX advanced remote analytics platform.