APPLICATION OF IOT

IN
MAINTENANCE MANAGEMENT
By: Abhishek Kumar, Niharika Sharma and Shuchita Awasthi
 INTRODUCTION
◦ The internet of things is the interconnection of everyday devices to the internet. The
concept of the IoT is so big that it has been described as the fourth industrial revolution
after steam, mass production and the internet.
◦ Today, you can control your heating system via your phone or tablet so your house is at
the right temperature when you get home. In the future, technicians will be able to see
equipment failure codes on their Google glass in real time as the breakdown is happening.
◦ In the coming years, the IoT will be fundamental in improving productivity and efficiency
everywhere. It will lead to more efficient power management at plants and factories by
automatically adjusting environment control systems to reduce energy consumption when
it is not needed.
 APPLICATIONS
◦ Following are seven ways the IoT can improve the way assets are managed, but undoubtedly
there are many more.
1. Greater Adoption of Predictive Maintenance
2. Real-Time Data Analysis
3. Accurate Performance Metrics
4. Automatic Software Upgrades
5. Recommended Repair Actions
6. Tighter Parts and Inventory Control
7. Remote Assets
 GREATER ADOPTION OF PREDICTIVE
MAINTENANCE
◦ Rather than performing routine calendar-based inspections and component replacement,
predictive techniques monitor equipment for pending failures and notify you when a part
replacement is required.
◦ Sensors embedded in equipment check for abnormal conditions and trigger work orders when
safe operating limits are breeched.
◦ When a predictive maintenance strategy is working effectively, maintenance is only performed
on machines when it is required, thus reducing the parts and labour costs associated with
replacements.
◦ With more and more systems shipping with internet connectivity, the concept of predictive
maintenance is likely to expand exponentially in the internet of things
 DATA ANALYSIS IN REAL TIME
◦ Machine-to-machine (M2M) is defined as the technologies that allow
machines to communicate with each other. The internet of things takes
M2M to the next level by including a third element: data.
◦ The availability of all machine data in one virtual network gives original
equipment manufacturers (OEMs) the ability to aggregate and analyse the
data to generate better predictive analytic models.
◦ Rather than waiting for a system to fail, manufacturers are able to
accurately predict failure because sensors start reporting back when
operating conditions trend out of specification.
◦ By accurately mapping user behaviour, identifying failure patterns and
quickly recognizing recurring issues, OEMs will be able to design out
failures, improve their product and guarantee uptime. This should result in
increased customer satisfaction and fewer warranty claims.
 ACCURATE PERFORMANCE METRICS
◦ Availability, reliability and other key performance metrics such as mean time between failures
(MTBF) and mean time to repair (MTTR) can be calculated automatically by the system and fed
to reporting dashboards.
◦ This removes the human element in capturing all downtime, ensuring the data is as accurate as
possible. In addition, reliability metrics from different customer sites can be analysed to identify
best practice for implementation around the world.
 AUTOMATIC SOFTWARE UPGRADES
◦ Software changes can improve equipment performance or eliminate technical issues.
◦ Internet-connected machines make the software upgrade process easier and more efficient.
◦ When software fixes or patches are needed, the OEM vendor can push the upgrades to all
systems in the fleet at the same time without customer assistance.
 RECOMMENDED REPAIR ACTIONS
◦ When equipment goes down, failure data from various sources can be gathered,
aggregated and analyzed in real time within the cloud.
◦ Repair options can be taken automatically by the system, and actions can be
recommended to the technician if necessary.
◦ All possible failure data will be used to direct the repair, including system operating
conditions at the time of failure, previous repair data from the computerized
maintenance management system (CMMS), wear patterns and operating data from
the equipment fleet.
◦ In effect, the technician will be presented with all the information needed for more
effective decision-making and the fastest route to resolution.
 TIGHTERS AND INVENTORY CONTROL
◦ Effective inventory control can have a significant impact on limiting equipment
downtime and controlling maintenance budgets.
◦ Connected stockrooms that proactively monitor inventory movements and stock on
hand to ensure the site is only holding what is needed will become commonplace in
facilities everywhere.
◦ Through predictive maintenance and data analysis, OEMs will be able to optimize the
recommended spare parts lists, freeing up much needed capital and increasing
customer satisfaction.
 REMOTE ASSETS
◦ When it comes to unplanned breakdown maintenance, the IoT will make repairing
geographically dispersed assets a breeze.
◦ As mentioned above, it will reduce unnecessary service visits to remote or
geographically dispersed assets through predictive maintenance.
◦ Imagine connected assets such as wind farms, substations and pumps generating their
own work orders in the CMMS with a proposed list of action items and recommended
list of spares to complete the job.
◦ This will reduce the mean time to repair, which will in turn reduce the costs associated
with those emergency repairs
 CONCLUSION
◦ The true value of the internet of things can only be fully realized when you take a
holistic view of asset management.
◦ Powerful virtual cloud networks will continually collect, aggregate and model data to
then accurately predict failures and put contingencies in place to limit their impact on
system availability.
◦ Although it may take time for your company to become an IoT data-driven
organization, the change is coming, and you should be prepared for it.
 BIBLIOGRAPHY
◦ https://www.betterbuys.com/cmms/iot-applications-in-maintenance/
◦ https://www.reliableplant.com/Read/29962/internet-of-things
◦ https://www.bing.com/images/search?view=detailV2&ccid=3wJWyNEm&id=A32A2249
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