Improving Maintenance and Reducing Downtime:
The Benefits of Industrial Remote Monitoring
by Dillon Jensen
JASM Co-Founder
Introduction to Industrial Remote Monitoring
The Industrial Internet of Things (IIoT) is a network of interconnected equipment, sensors, and software that allows for the collecting and analyzing of operational data in real-time. This type of technology is also referred to as Industry 4.0, often called “intelligent automation”. Remote monitoring is an essential component of IIoT, providing businesses with a complete view of their operations from anywhere in the world.
Each piece of equipment on a factory floor is generating operational data 24/7. Some of this data is obvious, such as sensor data displayed on an HMI, the state of a relay, or motor speed. Some data generated on the factory floor is only noticed under more creative consideration though: what about equipment power usage, vibration, or sound? All of this machine data together tells a story, regardless of whether or not anyone is listening.
The real transition to Industry 4.0 happens when you systematically start collecting data, and begin deriving insights from it. Just a decade ago, it was an optimistic view of the future of manufacturing. Today, it’s becoming the standard.
Reduced Downtime via Preventative Maintenance
Benjamin Franklin had a famous saying:
“An ounce of prevention is worth a pound of cure”
- Benjamin Franklin
Shockingly, Mr. Franklin was not referring to advanced IIoT-driven equipment maintenance when he said this, yet it is still an excellent policy for original equipment manufacturers (OEMs), even in 2024.
Preventative maintenance is a crucial strategy to reduce machine downtime. By regularly performing maintenance tasks at an interval, such as: inspection, fluid checks, cleaning and lubrication; you can identify potential issues before they cause a breakdown. It is the change from reactive to proactive. This approach helps to extend the lifespan of the machine, reduce repair costs, and ensure optimal performance. It is also easier for maintenance managers to plan, since most of the work performed is routine and more predictable both in frequency & expertise required. Think about it: Do you wait to change your car battery until after you have already been left stranded?
Additionally, scheduling maintenance during planned downtime, such as during holidays or weekends, can minimize the impact on production. By implementing a preventative maintenance program, you can significantly reduce unexpected downtime and increase the overall productivity of your industrial operations.
Advanced Remote Diagnostics
Though preventative maintenance is a forward-looking strategy and will improve the overall reliability of a business, the world is not perfect, and machines can still break down from user error or a sudden part failure.
Diagnosing why a system has broken down can be difficult, especially when the breakdown was completely unexpected. Every minute the problem stays unresolved, is lost productivity for the business, which can greatly effect the bottom line.
However, with remote monitoring, the maintenance team can gain & act upon invaluable information. Every minute leading up to the breakdown, and even after, the machine data is painting a detailed picture of its operational health. This data provides a previously-hidden breakdown context, which allows the diagnosis to be obtained much quicker than ever before. This translates to faster planning and implementation of the fix, minimizing downtime and getting you back to full production quicker.
Another benefit of this advanced diagnosis is that it can be done fully remotely. You don’t need your diagnostic technician to connect their computer to the PLC via a cable, or even be in the same time zone. All of the machine data, and wider operational context, is accessible anywhere, from the “cloud”. In the case for a niche machine requiring a specialized technician, the technician can use the data to determine the appropriate corrective action remotely, giving way to a faster fix when needed, and avoiding unnecessary on-site visits, incurring more cost & downtime.
A tool for business, not just machines
The insights obtained & operational efficiency gained for a single machine through remote monitoring, is a notable improvement. However, to realize the full potential of IIoT, all machines/relevant equipment must be monitored and analyzed within the context of the business.
Keeping machine productivity higher than ever before is a serious advantage, but being able to correlate poor customer experiences or operational losses with low performance from a specific machine, and being confident that the corrective action taken will fix the underlying problem, is peace of mind for the business leaders, not just the floor manager.
With remote monitoring, you are not just investing in the health of your machines, you are investing in the future of your business.
Conclusion
In conclusion, industrial remote monitoring (aka Industry 4.0) is a game-changing technology that enables companies to gain and maintain a competitive edge in today’s quickly-evolving landscape. Implementing remote monitoring allows businesses to streamline their operations, reduce costs, and increase productivity. With the increasing demand for efficiency, sustainability, and safety in industrial operations, remote monitoring software is becoming a must-have technology for any business looking to grow in 2024 and beyond.
If you’re looking for the easiest way to get started on your IIoT journey, reach out to us for a free discussion about monitoring applications within your unique business.
At JAS Monitoring, we offer intuitive monitoring software & lightweight hardware, striving to create the easiest way for OEMs to make the leap to Industry 4.0. Forget risky investment & unpredictable timelines: whether it is simple text alerts or a turnkey white-label monitoring service for your product, we look forward to working with you.
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