As well as condition monitoring, analysis of smart sensor
data directly allows for two powerful abilities, continuous
improvement loops and predictive maintenance. Manufacturers
can perform data analysis that creates an overview of a plant, by
comparing old, new and hypothetical production cycles. Using
this overview can improve plant efficiency by fine-tuning the
system as it works, creating a constant improvement loop.
For example, an annealing process requires metal rods to
be heated in a furnace to a specific temperature. This is done
by putting the metal on a conveyor belt that travels through the
furnace. Placing a smart sensor on the conveyor belt motor lets
the system compare the speed of the conveyor belt to the heat of
the rods. In this way, the motor can fine-tune itself as it works,
making sure that the metal rods are able to reach the correct
temperature.
Over time, gathering this data allows for the creation of
accurate machinery lifecycles. Comparing the current status
of machinery to overall lifecycle models can predict when
a component is likely to break down. Known as predictive
maintenance, this is a cutting-edge method that streamlines
maintenance and reduces downtime.
Accurately predicting what part of a machine is about to fail
means that manufacturers can order parts when they need them.
For example, if the furnace’s conveyor belt motor was operating
at an unexpected speed, the smart sensor could notify the
manufacturer that it was about to fail so that it could be replaced
before a breakage. As such, having an industrial parts supplier
that bases itself on providing fast and reliable delivery prevents
extended downtime and cuts costs.When to retrofit
New pieces of machinery may come with a smart sensor
included. However, machines that are moving towards the latter
part of their lifecycle can still benefit from having smart sensors
retrofitted. The sensor will be able to provide the information
required to inform predictive maintenance, which can drastically
reduce failure rates and can even prolong the life of the machine.
Retrofitting smart sensors to legacy equipment can bring
great benefits to manufacturers because of the insights they can
gain on their equipment. With the prediction of over half of IoT
devices being shipped to the Asia-Pacific region by 2026, it is a
trend that will drastically alter the manufacturing landscape in
the region.
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