The removal of operator risk is one obvious benefit, but this technology can also protect both the environment and the bottom line, says Frederic Thomas, Managing Director of AVT Reliability®.
The arrival in the marketplace of web hosted condition monitoring (CM) systems signalled a step change in industrial IoT, creating a culture of truly proactive asset maintenance for those companies which have embraced it.
The ability to collate a wide range of data on one platform and respond pre-emptively to impending problems has obvious benefits for asset reliability and operational efficiency. But the impact on workplace safety has also been significant.
The most advanced web hosted systems now offer the remote collection of data, via long range, low energy Bluetooth® routers, completely removing the need for manual collection of data.
Vibration sensors attached to assets routinely collect the data and automatically upload it to an online database, removing the risks inherent in having a maintenance engineer come into proximity with large operational assets, particularly those which are hard to access.
This has the obvious advantage for maintenance staff, whose safety is improved while their time is freed up for more productive tasks. But the potential benefits go way beyond the factory floor.
A web-based CM system allows the data collected from assets to be stored securely in the cloud, where it can be securely accessed by any authorised user, from any location in the world, via a standard web browser.
This means that not one shred of information gathered goes to waste, as is so often the case with traditional paper-based recording. Every piece of information collected can be used intelligently to identify ‘bad actors’, pre-empt potential problems and inform a proactive ongoing maintenance plan.
It also instantly closes any gap between plant and personnel. If a key team member is on the road, abroad for a conference, or working from home for any reason, it no longer means they must be absent from operational involvement.
The most advanced web hosted CM systems, like Machine Sentry®, are able to efficiently collate a wide range of information and measurements, such as vibration, thermal imaging, oil analysis, or simply pictures from visual inspection, all on one single interface. The end user will also automatically and instantly have access to the initial fault diagnostic findings from an Automated Diagnostic Assistant (ADA™).
Authorised personnel working from any location can simply log on to the system using their laptop or smart phone. Key data is automatically presented to them as an asset status summary on an easy to read dashboard. Additionally, if they want to focus on a specific aspect of the plant, they can drill down to view the data on any individual asset. Information encompassing anything from the latest monitoring readings to maintenance activity and operative comments is available within minutes of it being completed.
In a world where the marketplace is becoming increasingly global, access to the real-time condition of assets by senior decision-makers can be invaluable. Not only is it more effective, but it also helps reduce an employee’s carbon footprint by reducing unnecessary travel.
Responsible business leaders are also becoming increasingly conscious of the potential for extreme or unforeseen events to wreak significant disruption on industrial operations.
Having business critical information readily available, even when working remotely, can play a crucial role in enabling operational management decisions that can make the difference between uninterrupted production and costly downtime.
Time is money and, even when everybody is on site, the cost of management time spent searching through sheaves of paper for specific information can soon mount up, particularly if that information is not efficiently recorded or stored.
Upfront costs are also low, making digital CM technology accessible to companies of any size. Nothing more than a tablet or mobile phone is required and web based software means installation and setup does not demand any complex or costly IT input.
Cost and time savings, improved asset reliability and operational efficiency are good enough reasons to make the investment in a web-based CM system. But the ability to work remotely with instant access to vital information is an added benefit that the ‘pen and clipboard’ approach can only dream of delivering.
