Avoiding unplanned downtime: from simple checklists to high-tech sensors

A breakdown in your production? It always comes at the worst possible time. Fortunately, with the advent of Industry 4.0 technology, we’ve moved a step closer to a world without unplanned downtime. However, not every production line or component has the same requirements. That’s why AMR’s drive specialists offer their customers bespoke predictive maintenance. From common sense and simple checklists to vibration analyses and high-tech sensors: the right approach for every component.

For years, maintenance has been carried out at fixed intervals. The manufacturer determines, based on the number of operating hours, when its components are best serviced or repaired. “So there is a lot to be saved – in terms of time, materials and frustration – if we shift the focus from preventive to predictive maintenance. Then we only need to service components when their condition requires it. Never too early, but never too late either, so that a company’s maintenance department can focus on more than just putting out fires. This frees up time to tackle larger strategic projects, such as achieving energy savings,” explain AMR managers Annelies and Michael Oosterlynck. 

Predictive maintenance using common sense

Anyone scouring the internet will find hundreds of sophisticated solutions and systems on offer. Lots of bells and whistles that not everyone – and not every process – needs. “That’s why we prefer to advocate predictive maintenance based on common sense,” laughs Michael. “There are plenty of budget-friendly ways to improve machine uptime.” For AMR, predictive maintenance therefore starts with a good discussion. “Together with the customer, we assess just how critical certain parts of the production line are. Could a single component bring your production to a complete standstill? If so, we can apply continuous condition monitoring to that component. But for many other issues, other analytical techniques are just as effective.”

First-line monitoring and regular analyses

AMR also involves the operators in this process. “Experienced hands who know the machines inside out are becoming increasingly rare. We therefore try to teach these basics to our client’s staff,” explains Annelies. “Using simple checklists, they learn to listen, look and feel to assess the condition of the machines.” AMR then gets to work on this first-line monitoring to identify the appropriate actions to take in the event of problems. A second key element in this process is the analysis of vibrations, ultrasonic sounds and oil samples. “That is specialist work, though. By carrying out these analyses at regular intervals, we map out changes in a machine fleet. Clear reports tell our clients what needs to be done to prevent breakdowns or reduce energy consumption.”

Continuous condition monitoring of critical components

If, however, the components in question are critical or located in hard-to-reach places, AMR offers Asystom’s predictive maintenance solution. Michael: “Every manufacturer has its own app or platform, but Asystom’s tool is universal and works with all brands and all types of components. Plant managers or maintenance managers can therefore see the health status of all their key assets at a glance. What’s more, Asystom’s solution excels in its simplicity. All you need is a single versatile, compact sensor to monitor and measure temperature, vibrations, ultrasonic sounds and even the status of valves for leaks. And this can be done anywhere in the production area, even in potentially explosive atmospheres. Are the batteries flat? Then you simply need to replace the battery, not the whole sensor.”

Root cause analysis

 The software, which processes the captured data via a secure LoRa network connection, also stands out for its ease of use. A clear and cyber-secure dashboard shows how well your installations are performing. Yet it is by no means a one-size-fits-all solution. “The analyses are always carried out according to the type of component: a motor, a pump or a compressor. The algorithms, which utilise artificial intelligence, do more than simply report on performance. They provide the most logical explanation for any drop in performance or failure. The root cause analysis takes your own accumulated historical data into account. That way, you can very quickly identify the right course of action to avoid that unplanned downtime,” concludes Annelies.