5 ways IIoT can transform your maintenance strategy

There are many reasons why organizations may not have plans to implement connected devices into their maintenance strategies. However, it’s becoming more and more evident that teams need to start planning for a future built on Industry 4.0 technology – including Industrial Internet of Things (IIoT) sensors and software.

But what is Industry 4.0, and why does it matter? And what is IIoT?

Industry 4.0 refers to the fourth industrial revolution. It encompasses the idea that industries should be interconnected, highly automated, and capable of self-monitoring. IIoT devices make it possible for teams to collect continuous data on machines so that information on asset conditions is available in real time. Maintenance professionals will then use that information to improve maintenance programs by timing repairs and replacements exactly when they are needed. The result is less downtime and a seamless, connected workflow that saves money and keeps machines running.

Companies that employ IIoT see a variety of benefits that assist their manufacturing teams and preserve their bottom line. Here are the top 5 ways IIoT can transform your maintenance strategy:

1. Connecting People to Data and Systems

IIoT isn’t about replacing maintenance and reliability (M&R) professionals but rather augmenting their capabilities to better meet the needs of organizations. Providing workers with the data they need to do their jobs effectively is vital for an Industry 4.0 maintenance program.

With IIoT systems in place, M&R personnel have the flexibility to collect asset and system measurements in a variety of ways. Handheld meters, wireless sensors, and SCADA systems can all integrate with modern cloud-based software.. That way, information can be shared across the organization to eliminate data siloes.

When they have the right data on hand and access to operational systems in a unified view, maintenance professionals are better able to make data-driven, results-oriented decisions. Connecting people, data, and systems is the cornerstone of Industry 4.0 reliability and empowers people to make the right choices at the right time.

2. Automate Data Collection for Safety

Removing interaction between people and hazardous places — called hazard controls or engineering controls — is a common way to improve safety in facilities. But when teams fail to monitor these assets regularly, they risk missing the first signs of asset failure and potentially subjecting maintenance personnel to lengthy repairs in dangerous conditions.

That’s where IIoT sensors can help. Fans near ceilings, motors in areas with excessive heat or noise, pumps under grating, and other inaccessible assets are ripe for remote monitoring sensor installation to reduce manual routes. These sensors transmit a steady stream of information to monitoring software via the cloud. As a result, maintenance personnel can complete critical repairs before an asset even fails, minimizing the need to work in dangerous environments. Keeping people out of harm’s way not only improves efficiency but increases workplace morale, too.

3. Improve Asset Lifespan

Repairing equipment on a rote schedule often wastes resources. Lubricants or components may not have reached the end of their lifecycle by the time scheduled maintenance comes around. Condition-based maintenance (CBM), which is enabled with remote monitoring, allows teams to extend the amount of time between repairs, improving asset uptime and availability.

Condition-based maintenance works hand-in-hand with continuous improvement programs, such as Lean, Sigma-6, 5S, and more. When assets are repaired before they get to the point of critical failure, they’re less likely to cause serious safety concerns. By keeping total breakdowns to a minimum, you reduce the likelihood of further equipment damage, which often increases equipment lifespan.

4. Keep Workforces Connected On the Go

IIoT tech also means keeping workers connected to asset information when they are on-the-go. After measurement devices and mobile apps upload data to the cloud, IIoT software allows access to data and systems via smart devices.

Software like a computerized maintenance management system (CMMS) or enterprise asset management (EAM)system can integrate multiple sources of data to enable reliability teams to make faster and better maintenance decisions. Most come with mobile apps that workers can use to view and log data when working in the field. Or, in the case of emergency technicians on-call, these software programs can automatically send alerts when live data shows that a machine needs repairs.

When temperature, pressure, or electrical measurements exceed user-set thresholds, the software generates an alert and sends it to maintenance teams’ mobile devices. Whether teams are on the shop floor or offsite, they’ll have instant notification of asset problems. This helps teams keep assets from ever facing critical failure in the first place, which improves uptime and workplace safety.

5. Future-Proof Maintenance Programs

Maintenance isn’t just something that has to be done; it can be a business value engine. Proper maintenance keeps companies in regulatory compliance, keeps them producing effectively, keeps their workers happier, and improves the organization’s bottom line. Using IIoT sensors and software gives your M&R team a more streamlined workflow to better meet the demands of facilities today and in the future.

To get the most from your Industry 4.0-based maintenance strategy, follow this chart: