IoT in Predictive Maintenance: The 2024 Game-Changer

Updated by Nazanin Ghodsian, 08/20/2024

 

Using state-of-the-art technology, predictive maintenance monitors machinery in real time, seeing possible problems or faults before they become serious. Predictive maintenance uses ongoing data collecting to anticipate and prevent problems, in contrast to proactive maintenance, which concentrates on fixing equipment defects after they happen.

Predictive maintenance aims to identify any issues before they happen, as opposed to traditional preventative maintenance, which normally evaluates equipment according to its installation order—often giving older machinery priority. When equipment is maintained by a predetermined schedule, preventative maintenance might result in needless repairs and the use of spare parts, which raises operating costs and decreases equipment uptime.

Businesses may overcome the constraints of time-based maintenance schedules, save operating expenses, reduce spare part inventories, and increase team productivity by implementing IoT in predictive maintenance.

Conversely, IoT in predictive maintenance provides an unbiased perspective of a facility’s machinery. The truth is that no piece of machinery can function at its best continuously. Knowing when maintenance is required allows machines to be selectively brought offline to minimize the impact on overall production. Similarly, in the event of a breakdown, teams can promptly and effectively address the problem with the help of root-cause analysis, made possible by historical and real-time data.

This strategy gives maintenance departments the ability to order spare parts optimally, prioritize equipment repair as needed, maximize the impact of team members, and maintain equipment in its optimal condition—operational. The Industrial Internet of Things (IIoT) is the best place to turn if you’re interested in learning more about the technology underlying predictive maintenance.

 

What is IoT in Predictive Maintenance in Buildings?

IoT in predictive maintenance is a maintenance approach that collects and analyzes data on assets, machinery, or equipment via the Internet of Things. Data regarding the condition of the equipment is gathered by sensors and other devices to identify any problems that might need to be fixed to avoid future failures and needless downtime.

You might be wondering what the Internet of Things is, so let’s clarify before we go into how IoT in predictive maintenance operates. The Internet of Things, also known by its acronym “IoT,” is a collection of different hardware, apps, and software that are all linked to one another over the Internet. Then, these “Things” can communicate useful information with one another to build an extensive and cohesive network of potent data.

The Internet of Things is frequently used in IoT in predictive maintenance to monitor various variables that may point to possible equipment problems. These sensors and monitors are either mounted on or integrated inside equipment. These devices collect and send asset data to other networked “Things,” such as CMMS, predictive maintenance, or other smart manufacturing systems.

Other IoT technologies can do predictive maintenance analytics to find any possible problems that could lead to equipment failure by collecting and transmitting real-time data about the performance of the equipment. By using this process, companies may more accurately forecast the likelihood of outages or other disruptions and proactively plan maintenance.

 

Key Components of IoT in Predictive Maintenance

The maintenance of equipment is greatly impacted by the Internet of Things. To fully utilize this technology, however, you should get familiar with the following key elements of IoT in predictive maintenance solutions:

 

1. IoT Sensor and Devices

The fundamental components of IoT-powered predictive maintenance are IoT sensors and devices. They are embedded in machinery and equipment and gather data on a range of factors. These devices monitor vibration, temperature, pressure, humidity, and other parameters to give real-time information about the performance and state of the machinery.

 

2. Data Collection and Processing

Massive volumes of data are generated by IoT sensors and devices; these datasets need to be appropriately gathered and handled. Predictive maintenance systems therefore need reliable storage. Cloud-based platforms are the ideal option in this regard due to their flexibility and nearly infinite storage capacity. Edge computing, which allows data processing closer to the data source, is an additional component.

 

3. Connectivity

IoT in predictive maintenance solutions depends on smooth communication between sensors and equipment. The devices cannot share data over networks without connectivity. In this regard, communication protocols such as MQTT, CoAP, or Zigbee are essential.

 

4. Predictive Analytics

Predictive analytics is needed by an IoT in predictive maintenance system to gain insights into the maintenance of the machinery. It entails using sophisticated algorithms and frequent machine learning models to analyze sensors’ data. Businesses may replace or repair equipment parts before interruptions happen by using IoT analytics services.

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Benefits of IoT in Predictive Maintenance

Using IoT technology, IoT in predictive maintenance analyzes a manufacturing system in real time to predict when and how a component (s) may malfunction.

 

1. Reduce Maintenance Construction Cost

Every asset has several related expenses. The costs associated with an unplanned failure will also be added, thus increasing the overall cost of asset ownership. Therefore, by anticipating and averting equipment failure, businesses can save money. Enhancing maintenance planning can result in significant cost savings in industries with a high asset concentration.

IoT in predictive maintenance forecasts asset health, equipment utilization, and potential future problems using historical data from a variety of sources, including sensors and IoT devices. Based on this information, you can make decisions about when to schedule preventive maintenance or carry out routine inspections.

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2. Enhance Asset Utilization

Every firm is afraid of unscheduled downtime brought on by equipment failure, costly upkeep and repairs, and expenses resulting from delayed output. Fortunately, IoT in predictive maintenance makes it possible to use resources more effectively.

Technology aids in locating internal and external sources of delays as well as in establishing procedures to deal with problem areas. IoT in predictive maintenance finds problems with an asset’s functioning before it completely breaks down and provides early warnings, enhancing asset performance and reliability.

 

3. Extended Equipment Life

With the help of IoT in predictive maintenance, you can keep an eye on, care for, and maximize your assets’ performance, availability, and utilization. Real-time monitoring can provide you with more clarity on the performance of your equipment.

Anticipate machine breakdown and determine which parts require replacement. Plan maintenance and repairs in advance of problems that arise and receive real-time alerts to get started quickly before a big issue arises and interferes with daily operations.

 

4. Optimize Field Crew Efficiency

With the help of IoT in predictive maintenance, you can keep an eye on, care for, and maximize your assets’ performance, availability, and utilization. Real-time monitoring can provide you with more clarity on the performance of your equipment.

Anticipate machine breakdown and determine which parts require replacement. Plan maintenance and repairs in advance of problems that arise and receive real-time alerts to get started quickly before a big issue arises and interferes with daily operations.

 

5. Better Safety and Compliance

IoT in predictive maintenance assists businesses in identifying and mitigating potential safety concerns as well as estimating prospective problems before they hurt employees. By analyzing data from many sources and the information produced by sensors and actuators, they can move swiftly to lower safety concerns.

You can identify potentially dangerous situations and gauge how they might affect regular operations by looking at data collected over the largest periods. Proper IoT in predictive maintenance solutions always complies with laws by sending out commands to reallocate resources and maintain exposure levels below threshold values.

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6. Effective Production Lines

Constantly monitoring equipment performance helps prevent unplanned downtime and boost the overall throughput of operations. This improves production quality and maintains the health of the machines.

 

Implementation Steps & Best Practices of IoT in Predictive Maintenance

Now that you are fully informed about the use cases, practical applications, and difficulties associated with IoT in predictive maintenance, let’s look at how to put one of these systems into place in your company. The following five actions are necessary:

 

1. Determine Assets and Processes for Maintenance

At this point, you should determine which services and equipment in your organization need predictive maintenance. It would be ideal to discuss these assignments:

• To determine which assets are most important, undertake equipment audits and performance analyses.
• Examine past data to identify trends in equipment failure.
• Assess the risks related to performance and safety and how they affect your company’s operational effectiveness and customer happiness.
• Make a list of the equipment that needs to be maintained.

 

2. Choose the Right Sensors and Devices

Work together with engineers and IoT device development experts to select the right sensors for the monitoring needs of each asset. Here are some pointers to think about at this point:

• Establish the parameters (temperature, pressure, vibration, etc.) for data collection based on the nature and function of the asset.
• Check the accuracy and dependability of the sensor.
• Make sure that the sensors are installed and calibrated according to the manufacturer’s recommendations.

 

3. Enable Connectivity and Data Transmission

At this stage, to guarantee smooth communication between devices and sensors, you might wish to consult with IoT specialists. Here, the duties to perform consist of:

• Choose a network technology that works for you (Wi-Fi, cellular, LPWAN, etc.).
• Use the communication protocols that your system requires.
• Encryption, authentication techniques, and other safeguards for safe data transfer.
• Provide guidelines for data transmission between devices and a centralized platform for monitoring.

 

4. Develop Predictive Models

It’s better to work with ML engineers and data scientists at this point. These professionals will assist you in developing predictive models that meet your specific needs. The following are additional topics you should discuss:

• Collect past sensor data.
• Ascertain the precise maintenance requirements you have.
• For increased forecast accuracy, validate and improve the models regularly using fresh data.

 

5. Leverage Maintenance Insights

Creating actionable insights from the gathered, processed, and analyzed data is the final stage. You ought to think about how to incorporate these maintenance forecasts into the procedures that your business uses. Here are some helpful hints that might be useful:

• Create an alarm system that notifies maintenance personnel if any irregularities in the equipment are found.
• Establish precise guidelines for handling notifications.
• Assign maintenance duties by anticipated failure timelines.

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5 Use Cases of IoT in Predictive Maintenance

Contrary to popular assumption, IoT in predictive maintenance is not limited to manufacturing facilities. Although this discovery has great promise for this industry, it may potentially have applications in other sectors. Now let’s examine the top five IoT-based predictive maintenance use cases.

 

1. IoT in Predictive Maintenance in Transportation and Logistics

The Internet of Things is redefining how transportation systems operate and revolutionizing global logistics. We’re here to demonstrate that. IoT sensors that are mounted on trucks, containers, ships, and automobiles continuously track the position, temperature, and humidity of the goods. In this instance, predictive maintenance enables companies to expedite delivery times, avoid freight damage, and optimize routes.

Apart from this, fleet management is usually handled via IoT in predictive maintenance solutions. They install Internet of Things (IoT) sensors on cars to collect information on fuel efficiency, tire pressure, and engine performance. Through the application of predictive maintenance algorithms to analyze the gathered datasets, they can proactively schedule maintenance and maintain their fleet at the lowest possible cost.

Air travel is another application for this breakthrough. Airlines can schedule maintenance services using the data they collect on engine performance, system health, and general aircraft health.

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2. IoT in Predictive Maintenance for Manufacturing Equipment

The industrial sector is one of the additional use cases for IoT in predictive maintenance. Businesses utilize Internet of Things (IoT) sensors to track the health of their gear and equipment and identify deviations in temperature, vibration, and other vital indicators. In turn, the predictive maintenance system notifies maintenance crews of potential problems before they result in malfunctions. This lowers downtime and optimizes manufacturing operations.

 

3. IoT in Predictive Maintenance for Energy Infrastructure and Utilities

Another excellent market for IoT in predictive maintenance is the energy sector. When it comes to the real-time monitoring of turbines, transformers, and generators—all crucial parts of power plants, grids, and utility systems—IoT sensors are invaluable. These tiny devices monitor a wide range of characteristics, including temperature, vibration, and electrical currents as well as water purity. They enable businesses to spot indicators of deteriorating equipment and stop mishaps.

 

4. IoT in Predictive Maintenance for Healthcare

Patient care and medical equipment management are changing as a result of IoT in predictive maintenance. IoT sensors are used by hospital units to keep an eye on vital medical equipment, such as ventilators and MRI machines. It lowers expensive downtime and contributes to patient safety.

IoT in predictive maintenance goes beyond equipment and includes wearable devices tracking data like heart rate and sleep patterns for health monitoring. Healthcare professionals can enhance patient outcomes and avoid unforeseen health issues by assessing those criteria.

 

5. IoT in Predictive Maintenance for Smart Homes, Buildings, and Cities

Our living environments are included in IoT application cases, from smart houses to cities. Commonplace appliances like washing machines, refrigerators, and security systems are easily linked to the Internet of Things in smart homes. People can minimize inconvenient failures and optimize energy utilization thanks to this connectedness.

IoT’s influence extends to smart cities and goes beyond private residences. Building-integrated IoT sensors can monitor electricity distribution, security, ventilation, and air conditioning systems. On a bigger scale, this real-time data collection decreases disturbances.

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Challenges and Considerations of IoT in Predictive Maintenance

Even if the use cases for IoT in predictive maintenance are quite promising, you should be aware of any potential risks. Let’s examine the key ones:

 

1. Data Privacy and Security

The data from IoT systems is a two-edged sword. Although it facilitates real-time equipment maintenance updates, inadequate security might jeopardize and upset users. Take into account the following factors to steer clear of such awkward situations:

• Establish explicit consent processes and be transparent with users about how data is collected.
• Use access controls and encryption to ensure safe data storage.
• Clearly define your data ownership policies.
• Permissions for managing user data can be set.

 

2. Integration with Existing Systems

It’s important to take into account how precisely the new technology will function within your current system and equipment when installing the IoT in predictive maintenance. Make careful to address the following matters:

• Verify that the data works with a variety of devices and systems.
• Allow space for your predictive maintenance system to grow.
• If required, update your legacy systems.
• Inform your staff about the recently implemented solution.

 

3. Sensor Accuracy

Reliable sensors are essential for your IoT in predictive maintenance system to function properly. Some things to think about in this regard are as follows:

• Select sensors that work well with your workflow.
• Regularly calibrate and maintain your sensors.
• Make sure the environment is conducive to the operation of your sensors.
• Remove noise or inaccuracies from sensor data.

 

4. Complex Data Management

IoT in predictive maintenance solutions collects enormous volumes of data, as was previously indicated. Trying to keep track of them all could be too much. But do not worry; take into account these points:

• To facilitate management, standardize data formats.
• Select systems for scalable data storage.
• To obtain more precise insights, clean up the gathered datasets.

 

Conclusion

Using data analytics and machine learning algorithms, predictive maintenance is a proactive maintenance approach that foresees equipment problems or malfunctions before they happen.

With this strategy, businesses can plan maintenance at the right moment to prevent equipment breakdowns and save downtime. For industrial operations, predictive maintenance is critical because it helps minimize expensive repairs and equipment replacements while enhancing reliability and safety.

The cost of networking is rising daily along with the amount of traffic on the internet. To reduce the amount of data exchanged on the cloud, predictive maintenance systems evaluate the data on the premises in real time. This lowers the price of cloud storage as well. The Internet of Things (IoT) is revolutionizing the maintenance industry by making predictive maintenance approaches possible, which assist enterprises in maximizing equipment uptime, averting failures, and cutting down on operating expenses.

In the maintenance sector, IoT predictive maintenance is rapidly changing the game. Organizations may anticipate future equipment failures, minimize downtime, and improve maintenance schedules by utilizing IoT devices, predictive analytics, and machine learning algorithms.

IoT in predictive maintenance has certain risks and problems, but overall, the advantages are much more than the disadvantages. Organizations may successfully deploy IoT predictive maintenance and maintain a competitive edge with the right strategy and execution.

 

Which Industries can Benefit from IoT in Predictive Maintenance?

• Answer: By enhancing asset reliability and operational performance, IoT-driven predictive maintenance can greatly benefit industries like manufacturing, energy, transportation, and utilities.

What are the Challenges of Implementing IoT in Predictive Maintenance?

• Answer: Concerns about data security, integrating IoT devices with legacy systems, expensive startup expenses, and the requirement for qualified staff to handle IoT systems are among the difficulties.

 

Resources:

Intuz | SmartMakers | SoftwareAdvice | WebbyLab | PixelCrayons | AspenTech | Parsec | SoftwareAG

For all the pictures: Freepik