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How Predictive Maintenance and IoT Save Manufacturers Money

Wouldn’t it be nice to see into the future? We aren’t there yet, but we’re getting close. Digital transformation is a step in the right direction, which utilizes artificial intelligence and machine learning, smart sensors, and interconnected devices to analyze data in real time.

Predictive maintenance uses all of the above technologies to reduce downtime and lower costs associated with equipment failure. In this article, we’ll explain what predictive maintenance is and how you can implement this technology to grow your manufacturing business.


What Is Predictive Maintenance?

Predictive maintenance means addressing equipment and machinery failures before they happen. A part of Industry 4.0, predictive maintenance uses smart devices like sensors to collect and analyze data related to the performance of equipment to predict when a machine is most likely to fail so it can be repaired just in time.

As opposed to reactive maintenance, in which manufacturers wait for a machine to fail before repairing it, or scheduled maintenance, in which machinery is repaired regularly whether it needs to be repaired or not, predictive maintenance identifies possible points of failure while the machinery is still functioning.


How Does Predictive Maintenance Work for Manufacturers?

Predictive maintenance uses smart devices that are part of the Industrial Internet of Things (IIoT) to measure machine performance and transmit that data to an IoT platform like ProphecyIoT. Your IoT platform then analyzes the data automatically and updates stakeholders by generating alerts when critical components of equipment are worsening in performance.

Here’s what it looks like step-by-step:

  1. IIoT devices are integrated into machinery
  2. The devices collect data using sensors that monitor variables like temperature, speed, vibration, etc.
  3. The devices transmit that data to your central IoT software
  4. The IoT software analyzes that data
  5. If the data doesn’t fall into set parameters of optimal performance, it generates an alert
  6. The alert is sent to maintenance teams who investigate and rectify the problem


Benefits of Predictive Maintenance

The benefits of predictive maintenance may seem obvious, but let’s make sure we have the whole picture before moving forward.

  • Lower Costs – Costs are lowered directly and indirectly by predictive maintenance. Directly, you no longer have to pay for maintenance if the machine doesn’t need it. It also solves for unplanned downtime and associated costs. Indirectly, predictive maintenance gives your team the ability to assess machine and product quality in real-time, reducing defects and returns while helping you retain customers. Finally, well-maintained equipment tends to last longer, saving you money on high-dollar assets.
  • Safety – Equipment that operates properly is safer than equipment that breaks and malfunctions. This means you can expect fewer accidents and injuries in your factory.
  • Less Downtime – Downtime isn’t only a burden for you; it disrupts the whole supply chain. Predictive maintenance reduces downtime, keeping your production and sales objectives on track.
  • Resource Allocation – Predictive maintenance allows you to focus on machines that need attention first, optimizing the maintenance process. You can use the money and labor you save where it will make the biggest impact.
  • Better Performance – Quality management teams love predictive maintenance as it ensures products are created to your business’s standards consistently.


How to Leverage IoT Devices for Predictive Maintenance

Your team can leverage IoT platforms for predictive maintenance in many ways. Best of all, IoT software automates resource-consuming tasks so you can spend more time and money where it counts. Here’s what you can do.

Smart Sensors

Installing sensors and other smart monitoring devices on equipment and machinery allows you to continuously collect data in real time on almost any critical parameter, like temperature, humidity, pressure, vibration, and more.

Data Collection, Transmission & Analysis

IoT platforms allow the devices to collect and transmit data on equipment performance to a central location for easy access. Most manufacturers opt for cloud-based platforms so you can get alerts on the go. You can also configure the platform to process and analyze data collected by sensors to recognize patterns, anomalies, and trends that point to potential equipment failure.

Failure Prediction

Your IT team or IoT consultant can develop predictive maintenance models that use the analyzed data to alert your team when equipment is likely to fail. Models are based on factors like degradation patterns, historical failure data, and even operating conditions.


We mentioned that you can configure your IoT system to generate alerts and send them to your maintenance team, but you can also offer machine operators alerts in real time to protect them from on-the-job injuries.

Preventive Steps

Predictive maintenance devices allow your team to take preventive steps before small issues become big, costly problems. For example, historical failure data allows you to create a data-informed maintenance schedule. Take corrective actions based on statistical probability.


Predictive Maintenance Is ProphecyIoT

When your IoT platform tells you equipment is about to fail, believe it. It’s not magic; it’s ProphecyIoT. Our manufacturing IoT experts want to hear your story, your pain points, and your vision. Contact us today to learn how ProphecyIoT can launch your business into a profitable future.


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