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How can you use smart sensors to improve your maintenance program?

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Smart sensors are devices that can measure, process, and communicate physical or environmental data, such as temperature, vibration, pressure, or humidity. They are widely used in smart manufacturing applications to monitor and optimize the performance, quality, and safety of production processes and equipment. One of the main benefits of smart sensors is that they can help you improve your maintenance program, by enabling predictive and preventive strategies that reduce downtime, costs, and risks. In this article, we will explain how you can use smart sensors to enhance your maintenance program and what are some of the best practices and challenges to consider.

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1 What is a maintenance program?

A maintenance program is a set of activities and procedures that aim to keep your equipment and systems in good working condition, prevent failures, and extend their lifespan. A maintenance program can be classified into three types: reactive, preventive, and predictive. Reactive maintenance is when you fix something after it breaks down, which can be costly, inefficient, and unsafe. Preventive maintenance is when you schedule regular inspections and repairs based on time intervals or usage cycles, which can improve reliability and reduce breakdowns, but also waste resources and cause unnecessary interruptions. Predictive maintenance is when you use data and analytics to monitor the condition and performance of your equipment and systems, and perform maintenance only when needed, based on indicators of potential failures, which can optimize efficiency, quality, and safety.

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Gaurav Singh

Results-Driven Production Manager | 15 Years in Paper Manufacturing | Skilled in Process Optimization | Proven Leadership in Paper Manufacturing Operations |Enhancing Efficiency and Quality in Paper Manufacturing.
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Smart sensors enhance maintenance by providing real-time data for condition monitoring and predictive maintenance. They enable remote monitoring, data analytics, and energy efficiency, contributing to reduced downtime and optimized asset health management. Early issue detection leads to cost savings and seamless integration with CMMS streamlines maintenance workflows, promoting proactive strategies and extending equipment lifespan.

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2 How do smart sensors enable predictive maintenance?

Smart sensors enable predictive maintenance by collecting and transmitting real-time data on the status and behavior of your equipment and systems, such as temperature, vibration, pressure, or humidity. This data can be analyzed by software tools or algorithms to detect anomalies, trends, or patterns that indicate the need for maintenance, such as wear, corrosion, or misalignment. By using smart sensors, you can identify and address potential issues before they become critical, and avoid unnecessary or excessive maintenance actions. For example, you can use smart sensors to monitor the vibration of a motor, and detect any changes that could signal a bearing failure or a misalignment, and then schedule a repair or replacement before the motor fails or causes damage to other components.

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Er. Ram Teja Ganta

Senior QA/QC (Mech) Professional > Manufacturing | Metal Fabrication | Machinery | Farm Equipment | Energy
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By using sensors that predicts the operational count or count the run time on completion of given job, we can pre-schedule Time Based Maintenance that exactly needed to maximise the availability of critical equipments.

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3 What are the benefits of using smart sensors for maintenance?

Using smart sensors for maintenance can bring you many benefits, such as reducing downtime and improving productivity, reducing costs and increasing profitability, improving quality and customer satisfaction, and improving safety and compliance. Smart sensors can help prevent unexpected breakdowns and interruptions, optimize maintenance resources and expenditures, ensure equipment is operating at optimal conditions, and prevent accidents or hazards. This can help avoid losses in output and revenue, save on labor, materials, and energy costs, enhance reputation and customer loyalty, reduce risks and liabilities, and foster a culture of safety and responsibility.

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4 What are the best practices for using smart sensors for maintenance?

Using smart sensors for maintenance effectively requires following some best practices, such as defining maintenance goals and objectives, selecting the right sensors and locations, integrating the sensors and data sources, and analyzing the data to generate actionable insights. It's important to have a clear vision of what you want to achieve with your maintenance program and how you will measure and evaluate your results. You should also choose the sensors that are suitable for your equipment and systems, install them in the appropriate locations, connect them to your data network and platforms, and integrate their data with other sources. Finally, you should use software tools or algorithms to process and analyze the sensor data, identify patterns or anomalies that indicate the need for maintenance, and generate alerts, notifications, or reports.

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5 What are the challenges for using smart sensors for maintenance?

Using smart sensors for maintenance can also pose some challenges, such as managing the volume and complexity of data generated by multiple sensors and data sources. To ensure data quality and security, you may need to invest in data infrastructure and capabilities, such as cloud services, edge devices, or data analytics platforms. Additionally, smart sensors can require new skills and competencies for maintenance staff, such as data literacy, analytical thinking, or problem-solving. It is important to provide training and education for your staff to leverage the full potential of smart sensors for maintenance. Finally, you may need to adjust your maintenance schedules, procedures, and workflows to adapt to changing maintenance needs and expectations. Doing so can help optimize your maintenance outcomes and benefits while aligning them with your operational and business goals and strategies.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Jennifer Marvin, PE, ACC

Coach | Author | Senior Engineer at Boeing | Intellectual Property Expert | Leadership Educator | VP of Aerospace & Women Engineers at OLT | Keynote Speaker | DEIB Advocate | Board Director
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For every dollar spent in maintenance you can save at least ten fold that in capital equipment costs should you have to replace. Another cost guideline is if the cost to repair something is more than 85% of the cost to buy it new, buy it new. Thanks for asking! Coach Jen

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How can you use smart sensors to improve your maintenance program?

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3

4

5

6

1 What is a maintenance program?

2 How do smart sensors enable predictive maintenance?

3 What are the benefits of using smart sensors for maintenance?

4 What are the best practices for using smart sensors for maintenance?

5 What are the challenges for using smart sensors for maintenance?

6 Here’s what else to consider

Manufacturing

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How can you use smart sensors to improve your maintenance program?

1

2

3

4

5

6

1 What is a maintenance program?

2 How do smart sensors enable predictive maintenance?

3 What are the benefits of using smart sensors for maintenance?

4 What are the best practices for using smart sensors for maintenance?

5 What are the challenges for using smart sensors for maintenance?

6 Here’s what else to consider

Manufacturing

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